Chana M201 2014 Workshop Manual

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Summary of Contents for Chana M201 2014

Page 3 2.3.1 Brake System - Overview....2.3.1-1 3.2.2 Clutch..........3.2.2-1 2.3.2 Rear Drum Brake ......2.3.2-1 3.2.3 Manual Transmission ....3.2.3-1 2.3.3 Front Disc Brake ......2.3.3-1 3.2.4 Manual Transmission External 2.3.4 Parking Brake and Operation..2.3.4-1 Control .......... 3.2.4-1 2.3.5 Hydraulic Brake Control ....2.3.5-1 2.3.6 Power Brake .........2.3.6-1 M201 2014.01...
Page 4 5.1.5 Rearview Mirror ......5.1.5-1 5.1.6 Instrument Panel and Console ..5.1.6-1 5.1.7 Bumper......... 5.1.7-1 5.1.8 Handles, Locks and Latches ..5.1.8-1 5.1.9 Interior Trim Panel and Ornamentation....... 5.1.9-1 5.1.10 Exterior Trim ......5.1.10-1 5.2 Body Repairs 5.2.1 Body Repairs........ 5.2.1-1 M201 2014.01...
Page 5 GROUP Overview SECTION PAGE 1.1 Service Information 1.1.1 Overview ........................... 1.1.1-1 1.1.2 Identification Codes ......................1.1.2-1 1.1.3 Traction and Lifting......................1.1.3-1 1.1.4 Maintenance Interval......................1.1.4-1 1.1.5 Noise, Vibration and Harshness ..................1.1.5-1 M201 2014.01...
Page 7: Table Of Contents
Noise Type in Automotive Engineering..................1.1.5-1 Vibration Process Engineering ....................1.1.5-2 Noise and Vibration on Vehicle....................1.1.5-4 Noise and Vibration Caused By Intake and Exhaust Systems ..........1.1.5-4 Vehicle Body..........................1.1.5-5 Symptom Diagnosis and Testing...................... 1.1.5-6 Inspection and Verification......................1.1.5-6 M201 2014.01...
Page 8 Service Information How to Use Diagnosis Procedure Section ................1.1.5-6 Noise Diagnosis Procedure ......................1.1.5-7 M201 2014.01...
Page 9: Overview
The information in the specifications shall use the Manual metrics except the torque (imperial). As you read through this manual, you will come across WARNINGS and CAUTIONS. WARNING: Warnings are used to indicate that failure to follow a procedure correctly may result in personal injury. M201 2014.01...
Page 10: Health And Safety Precautions
• Do not use the mixed refrigerant, such as Before using any product the Materials Safety Freon R12 and R134a. Data Sheet supplied by the manufacturer or supplier should be consulted. M201 2014.01...
Page 11 Used in vehicle coolant systems, screenwash solutions. Many are irritant, sensitizing or harmful to the skin and respiratory tract. Some are eye The antifreeze will generate steam when heated. irritants. Skin and eye contact should be Avoid inhaling such gas. M201 2014.01...
Page 12 The safety and health data chemical materials. chemical table of the substance can be obtained materials, especially the solvent and fuel, from the manufacturer. will make the skin dry, and also irritate the skin to catch dermatitis, or some noxious M201 2014.01...
Page 13 Make sure that all electrical equipment is maintained in good condition and regularly tested. Faulty equipment should labeled preferably removed from the workstation. Make sure that wires, cables, plugs and sockets are not M201 2014.01...
Page 14 If effects persist, consult a doctor. If liquids are swallowed inadvertently, consult a doctor and give him the information on the container or label. Do not induce vomiting unless this action is indicated on the label. M201 2014.01...
Page 15 (mist may arise in dewaxing). Avoid skin and eye contact and make sure there is adequate ventilation. High Pressure Gas Cylinder Refer to: Fire Prevention. Gases such as oxygen, acetylene, argon and propane are normally stored in cylinders at M201 2014.01...
Page 16 2. Health Precautions: Refer to: Foam, Insulation Fiber. • Avoid long contact with oil, especially the engine oil. • Wear protective clothes, including gloves. • Do not put wiping cloth with oil stains in pocket. • Avoid oil polluting clothes. M201 2014.01...
Page 17 There is always a danger when loads are lifted or contamination by lead. Avoid ingestion of lead or suspended. Never work under an unsupported, inhalation of solder dust. suspended or raised load, for example a suspended engine. M201 2014.01...
Page 18 In extreme cases or confined spaces where adequate ventilation cannot be provided, respirators may be necessary. M201 2014.01...
Page 19 Refer to: Acid and Alkali Metals. vicinity unsupervised. M1101003 M1101006 4. Displaying the caution circle with a deleted White Spirit lighted match symbol, cautions against the use of naked light or flame within the Refer to: Solvent. M201 2014.01...
Page 20: Standard Workshop Practice
• Always make sure that the jumper cables are adequate for the task. Heavy duty cables must be used. M201 2014.01...
Page 21 (high) or the heated rear windshield, to reduce the Refer to: Solvents, Sealants and Adhesives. voltage peak when the cables are removed. M201 2014.01...
Page 22: Solvents, Sealants And Adhesives
Instead, those items particularly • That the ignition controlled warning lamps relevant to the system(s) being checked can be are illuminated. extracted. • That the engine temperature gauge registers a reading compatible with the engine temperature. M201 2014.01...
Page 23 (if equipped) register the correct readings and operate correctly. • That the switches and controls operate smoothly, warning and indicator lamps operate correctly direction M201 2014.01...
Page 25: Description And Operation
Meaning of VIN Item Description Item Description 1 ~ 3 Manufacturer identification code Driving type Vehicle brand Check digit Main vehicle parameter code Year of manufacture Engine type Manufacturing factory code Vehicle body type 12 ~ 17 Production serial number M201 2014.01...
Page 26: Nameplate
1.1.2-2 Identification Code 1.1.2-2 Nameplate VIN: LS5A3ASDXAAXXXXXX SC6406A JL473Q 1243mL 68KW 1730kg 2013/XX/XX M1102002 M201 2014.01...
Page 27: Description And Operation
CAUTION: It is prohibited to make the rear wheels on the ground in the traction. Otherwise, transmission damaged. CAUTION: The traction distance shall not exceed 80 km and the speed shall not exceed 50 km/h. M1103002 M201 2014.01...
Page 28: Lifting
Otherwise, the vehicle may be damaged or injury may be caused. CAUTION: When lifting the vehicle with a two-post lift, vehicle lift arm adapters must be used under the lifting points. M1103003 M201 2014.01...
Page 29: Maintenance Interval Description And Operation
11. Do not raise the temperature of electronic control unit to over 80 in the malfunction heating simulation or the maintenance that may increase the temperature of vehicle. M201 2014.01...
Page 30: Daily Maintenance Schedule
Remark: a) symbols in chart: J - Inspection T - Adjust; G - Replace; R - Replace when necessary; X - Tighten b) Service interval should be judged by odometer reading or months, whichever comes first. Service interval is shortened under severe conditions. M201 2014.01...
Page 31 J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G damage) 23. Tire (abnormal wear and J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G pressure) 24. Wheel and Wheel nut (damage, J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G tightness) M201 2014.01...
Page 32 (adjust accelerator pedal every 5000 km cable) COOL AIR *30. Refrigerant Amount Fill at any time *31. Refrigeration system J.T.G J.T.G J.T. J.T. *32. Compressor *33. Condenser Clean at any time *34. Evaporator *35. Dryer *36. Refrigerant pipe M201 2014.01...
Page 33 Bolt and nut in chassis 10000 km or 6 months Brake disc and lining (front) brake drum and J.T.G 10000 km or 6 months toe (rear) Suspension ball joint and BCDE J.T.G 10000 km or 6 months dust boot M201 2014.01...
Page 35: Description And Operation
(such alternator, drive belt). • Chatter sound can be heard when vehicle runs on rough road. The unstable noise is usually caused by the shock absorber, chassis components loose components inside the vehicle. M201 2014.01...
Page 36: Vibration Process Engineering
Damping vibration not only audible low frequency vibration but also the high frequency vibration that cannot be heard. • Generally, the low frequency vibration is visible. • The high-frequency vibration is palpable through the floor and the steering wheel. M201 2014.01...
Page 37 All sound insulation components such as door decorated board, carpet, ceiling, carrier and seat should be insulated with vehicle body. M1105004 • Then the sound wave will be reflected directly to reduce the occurrence of Hall Item Component Description Effect. Engine Engine installation M201 2014.01...
Page 38: Noise And Vibration On Vehicle
Air Intake System Air intake system can be regarded as the vehicle air and solid noise source. M1105009 M1105007 Item Component Description Exhaust system can be regarded as the vehicle Air filter air and solid noise source. Intake hose Canister M201 2014.01...
Page 39: Vehicle Body
The vehicle body not only causes air noise, but also causes solid noise. Muffler • The vehicle body must absorb vibration from all components, and try to ensure the vibration is not transmitted to the interior of the vehicle body. M201 2014.01...
Page 40: Symptom Diagnosis And Testing
Confirm condition, proceed to appropriate section and start correct diagnosis. When the condition is identified, the job is partly done. Follow the diagnosis procedure. Quick Checks are described in the Steps, while more involved M201 2014.01...
Page 41 • Damaged powertrain/drivetrain holders. emit roar or whine noise. • Excessively High Constant Velocity (CV) • Trim panels can also cause whistling or joint operating angles caused by incorrect whining noise. body height. Check body height, verify M201 2014.01...
Page 42 Remember, the road test quick checks following: may not tell where the concern is, but they • Worn, damaged or incorrectly installed will tell where it is not. front wheel bearing. M201 2014.01...
Page 43 After verifying that the condition has been corrected, make sure all components removed have been installed. M201 2014.01...
Page 45 2.3.3 Front Disc Brake ....................... 2.3.3-1 2.3.4 Parking Brake and Operation.................... 2.3.4-1 2.3.5 Hydraulic Brake Control ....................2.3.5-1 2.3.6 Power Brake ........................2.3.6-1 2.4 Steering System 2.4.1 Steering System - Overview....................2.4.1-1 2.4.2 Steering Gear........................2.4.2-1 2.4.3 Steering Column ....................... 2.4.3-1 M201 2014.01...
Page 47 Diagnosis Procedure for Excessive Noise................2.1.1-29 Diagnosis Procedure for Driving Vibration................2.1.1-32 Diagnosis Procedure for Abnormal or Excessive Wheel Wear ..........2.1.1-35 2.1.2 Front Suspension Specifications ........................... 2.1.2-1 Torque Specifications........................ 2.1.2-1 Description and Operation ....................... 2.1.2-2 System Overview........................2.1.2-2 M201 2014.01...
Page 48 Rear Shock Absorber Assembly ....................2.1.3-8 2.1.4 Wheel and Tire Specifications ...........................2.1.4-1 General Specifications ......................2.1.4-1 Torque Specifications........................2.1.4-1 Description and Operation........................2.1.4-2 Components Description......................2.1.4-2 Components Exploded View.....................2.1.4-3 General Inspection ...........................2.1.4-4 Removal/Installation and Charging of Tire ................2.1.4-4 Tire Rotation ..........................2.1.4-5 Inspection and Verification......................2.1.4-5 Tire Abrasion Diagnosis......................2.1.4-5 M201 2014.01...
Page 49 Suspension System Wheel Runout Inspection ......................2.1.4-6 Initial Inspection before Tire Alignment..................2.1.4-7 Tire Abrasion Inspection ......................2.1.4-7 Symptom Diagnosis and Testing....................2.1.4-10 Inspection and Verification...................... 2.1.4-10 Symptom Chart........................2.1.4-11 Removal and Installation........................ 2.1.4-13 Wheel and Tire ........................2.1.4-13 M201 2014.01...
Page 51: Suspension System - Overview
Front wheel toe-in 0 ± 1.5 mm Front camber angle 0.5° ~ 1.8° Front wheel alignment parameter Kingpin inclination angle 9.5° ± 2.5° Kingpin caster angle 4.1° ± 1° Rear wheel toe-in Rear wheel alignment parameter Rear camber angle M201 2014.01...
Page 52: Description And Operation
If vehicle positive camber angle is too large, it will lead outer tire shoulder wear. If vehicle negative camber angle is too large, it will lead inner tire shoulder wear. Camber angle cannot be adjusted. M201 2014.01...
Page 53: General Inspection
The front spring end is mounted on the body through rubber bushing. The rear spring end is connected with the body through internal and external plate. The rear axle moves up and down with the spring during vehicle running. M201 2014.01...
Page 54: Wheel Bearing Inspection
2. Hold the bottom and top of wheel and shake Replace the wheel hub assembly if any forcefully. Inspect if front wheel bearing is wrong is found. loose. 3. Inspect every wheel disc dents, deformation and cracks. It is necessary to replace the severely damaged wheel disc. M201 2014.01...
Page 55: Tie Rod Ball Joint Inspection
Inspect if the ball joint is worn or stuck with/ without abnormal noise. If there is failure or clearance due to serious wear, replace it. M2101006 M2101005 M201 2014.01...
Page 56: Suspension Device Inspection
Use long travel to compress shock tire. absorber quick possible. Every 3. Inspect the suspension equipment that can compressing action must stable be selected, such as the suspension of M201 2014.01...
Page 57: Rear Shock Absorber Inspection
Road test shall be carried out at flat road. In the case of vibration, note and record the following: • Vehicle speed at the time of vibration. • Type of vibration that occurs within each speed range. • Mechanical vibration or audible sound. M201 2014.01...
Page 58: Front Wheel Toe-In Inspection And Adjustment
After toe-in adjustment, the exposed thread length of the left and right tie rod adjusting nuts should be within 4 mm. 1. Turn the steering wheel to center position and lock it. M201 2014.01...
Page 59: Symptom Diagnosis And Testing
3. If an obvious cause for an observed or reported concern has been found, solve the fault before proceeding to the next step. 4. If the cause is not visually evident, verify the symptom by referring to the symptom chart. M201 2014.01...
Page 60: Symptom Chart
Vehicle driving shimmy • Front shaft swing arm bushing of front suspension loose and worn • Stabilizer bar bushing worn • Rear shock absorber and bushing worn or loose • Incorrect wheel alignment • Rear leaf spring bushing worn M201 2014.01...
Page 61 Assembly (2.1.2 Front Suspension, Removal and Installation). • Replace the rear suspension leaf spring or bushing. • Rear suspension leaf spring or Refer to: Rear Leaf Spring bushing worn or loose Assembly (2.1.3 Rear Suspension, Removal and Installation). M201 2014.01...
Page 62 Testing). • Vehicle overload Abnormal or excessive wheel wear • Tire rotation is not performed • Wheel bearing worn or loose • Wheel or tire swing • Insufficient tire pressure • Poor driving habit • Wheel distortion M201 2014.01...
Page 63 Replace the strut or fitting parts. Refer to: Front Strut Assembly • Shock absorber strut or fitting (2.1.2 Front Body shakes parts failure Suspension, Disassembly Assembly). • • Suspension assembly loose or Inspect the suspension assembly and worn replace the worn parts. M201 2014.01...
Page 64 Front coil spring or rear leaf Disassembly spring becomes soft Assembly). Poor driving comfort Refer to: Rear Leaf Spring Assembly (2.1.3 Rear Suspension, Removal and Installation). • • Front or rear suspension Replace the worn suspension assembly assembly worn components. M201 2014.01...
Page 65 • Front or rear suspension Replace the worn suspension assembly assembly worn components. • Replace the stabilizer bar bushing or link. Refer to: Front Stabilizer • Stabilizer bar bushing or link worn (2.1.2 Front Suspension, Removal and Installation). M201 2014.01...
Page 66 • • Front wheel misalignment Inspect and adjust the front wheel alignment. • Steering drive rod loose or • damaged Tighten or replace the drive rod. • • Steering gearbox retaining bolt Tighten the steering gearbox bolt. loose M201 2014.01...
Page 67 Installation). • Inspect the load. • • Overload Inspect the load. Suspension is pressed to • • Shock absorber or strut fault Replace the shock absorber or strut. bottom • • Spring fault or droop Replace the spring. M201 2014.01...
Page 68: Diagnosis Procedure For Vehicle Pull
Is the fault confirmed Inspect influence of tire on symptoms Is the fault confirmed Inspect wheel track Inspect steering gear Inspect driving height Inspect wheel alignment Inspect brake drag Is the fault Inspect front suspension confirmed Inspect rear suspension M201 2014.01...
Page 69 B. Install 4 tires in good state when necessary. Does the vehicle still pull? Go to step 4. Replace the tire. 4. Inspect wheel track A. Inspect the wheel track. Are wheel track same? Go to step 5. Calibrate the wheel track. M201 2014.01...
Page 70 Perform the wheel alignment. 8. Inspect brake drag A. Lift the vehicle. Refer to: Lifting (1.1.3 Traction and Lifting, Description and Operation). B. Inspect the wheel for brake drag. Is there brake drag? Repair the brake drag. Go to step 9. M201 2014.01...
Page 71 Refer to: Rear Leaf Spring Assembly (2.1.3 Rear Suspension, Removal and Installation). Refer to: Rear Shock Absorber Assembly (2.1.3 Rear Suspension, Removal and Installation). Adjust or repair the rear suspension abnormal fault. M201 2014.01...
Page 72: Diagnosis Procedure For Abnormal Driving Track (Vehicle Cannot Keep Straight Driving)
Inspect influence of tire on symptoms Is the fault confirmed Inspect front shaft swing arm bushing Is the fault confirmed Inspect steering connecting rod Inspect wheel alignment Inspect front suspension Is the fault confirmed Inspect rear suspension M201 2014.01...
Page 73 A. Inspect whether the front shaft swing arm bushing is cracked, loose or motional. Is the front shaft swing arm normal? Go to step 4. Replace the front shaft swing arm bushing. Refer to: Front Shaft Swing Assembly (2.1.2 Front Suspension, Removal Installation). M201 2014.01...
Page 74 Refer to: Rear Leaf Spring Assembly (2.1.3 Rear Suspension, Removal and Installation). Refer to: Rear Shock Absorber Assembly (2.1.3 Rear Suspension, Removal and Installation). Adjust or repair the rear suspension abnormal fault. M201 2014.01...
Page 75: Diagnosis Procedure For Vehicle Driving Shimmy
Is the fault confirmed Inspect influence of tire on symptoms Is the fault confirmed Inspect front shaft assembly Is the fault confirmed Inspect steering gear Inspect wheel alignment Is the fault confirmed Inspect left and right sides of suspension M201 2014.01...
Page 76 3. Inspect front shaft assembly A. Inspect the front shaft for any distortion and deformation. Is the front shaft normal? Go to step 4. Replace the front shaft assembly. Refer to: Front Shaft Welding Assembly (2.1.2 Front Suspension, Removal and Installation). M201 2014.01...
Page 77 Is the height or rigidity of left and right sides of the suspension consistent? Repair or replace the damaged components. Inspect the left and right shock absorbers of the suspension for the same effectiveness. In case of any failure, repair or replace with a new one. M201 2014.01...
Page 78: Diagnosis Procedure For Steering Wheel Deviating From Central Position
Go to step 2. 2 Inspect wheel alignment A. Inspect the wheel alignment. Is the wheel alignment data within specified range? Refer to: Diagnosis Procedure Abnormal Driving Track (2.1.1 Suspension System - Overview, Symptom Diagnosis Testing). Perform the wheel alignment. M201 2014.01...
Page 79: Diagnosis Procedure For Excessive Noise
Inspect damping spring Is the fault confirmed Inspect front shaft swing arm of front suspension Is the fault confirmed Inspect steering tie rod and ball joint Inspect front stabilizer bar Is the fault confirmed Inspect front wheel bearing M201 2014.01...
Page 80 Is the front shaft swing arm bushing of front suspension worn? Replace the front shaft swing arm bushing of front suspension. Refer to: Front Shaft Swing Assembly (2.1.2 Front Suspension, Removal Installation). Go to step 4. M201 2014.01...
Page 81 C. Rotate the front wheel and inspect the working condition. Is the bearing loose or noisy? Replace the front wheel bearing if necessary. Refer to: Front Wheel Hub Bearing (2.1.2 Front Suspension, Removal and Installation). Verify the customer concern. M201 2014.01...
Page 82: Diagnosis Procedure For Driving Vibration
2.1.1-32 Suspension System - Overview 2.1.1-32 Diagnosis Procedure for Driving Vibration Driving vibration Inspect tire Is the fault confirmed Inspect front wheel bearing Is the fault confirmed Inspect wheel/tire runout Is the fault confirmed Wheel balance M201 2014.01...
Page 83 Description and Operation). B. Measure the radial and axial runouts of wheel/tire with a dial indicator. Refer to: Wheel Runout Inspection (2.1.4 Wheel Tire, General Inspection). Are they normal? Go to step 4. Replace the wheel and tire. M201 2014.01...
Page 84 B. Remove the wheel and tire. C. Balance the wheel on a balance machine. Carry out the road test. Can the vibration be felt? Repair. Refer to: 1.1.5 Noise, Vibration Harshness. Make sure that the maintenance has been finished. M201 2014.01...
Page 85: Diagnosis Procedure For Abnormal Or Excessive Wheel Wear
Abnormal or excessive wheel wear Inspect tire wear Is the fault confirmed Inspect tire Is the fault confirmed Inspect wheel Is the fault confirmed Inspect tire balance Inspect wheel alignment Is the fault confirmed Inspect front and rear suspension components M201 2014.01...
Page 86: Suspension System - Overview
3. Inspect wheel A. Inspect the wheel for distortion and deformation. B. Inspect the wheel runout. Refer to: Wheel Runout Inspection (2.1.4 Wheel Tire, General Inspection). Is the wheel normal? Go to step 4. Adjust or replace the wheel. M201 2014.01...
Page 87 D. Inspect if the rear suspension axle for any cracks, looseness and missing. Are the front and rear suspension components normal? Inquire about the vehicle load, speed and the driver's habit. Correct the overload, overspeed and any incorrect driving habit. Repair the front and rear suspension faults. M201 2014.01...
Page 89: Front Suspension
40 ~ 60 30 ~ 44 Connecting rod lower retaining nut 18 ~ 28 13 ~ 21 Retaining bolt between steering gear and 50 ± 5 front shaft Front stabilizer bar retaining bolt 20 ~ 30 15 ~ 22 M201 2014.01...
Page 90: Description And Operation
Components Location View Front Suspension Assembly View M2102001 Item Description Item Description Front strut assembly Front shaft welding assembly Front stabilizer bar Steering knuckle Coil spring Steering gear assembly Front shaft swing arm M201 2014.01...
Page 91 2.1.2-3 Front Suspension 2.1.2-3 Components Exploded View Front Suspension Exploded View M2102002 Item Description Front shaft welding assembly Press lever retainer assembly Press lever bushing Washer Front suspension press lever welding assembly Front shaft swing arm assembly M201 2014.01...
Page 92 2.1.2-4 Front Suspension 2.1.2-4 M2102003 Item Description Qty. Front stabilizer bar Connecting rod assembly Connecting rod rubber cushion Washer Front stabilizer bar bracket Front stabilizer bar bushing M201 2014.01...
Page 93: Front Suspension
2.1.2-5 Front Suspension 2.1.2-5 M2102004 Item Description Qty. Front strut assembly Steering knuckle Front wheel hub bearing assembly Wheel hub bearing nut bearing cap Bolt M201 2014.01...
Page 94: Symptom Diagnosis And Testing
2.1.2-6 Front Suspension 2.1.2-6 Symptom Diagnosis and Testing Refer to: Symptom Chart (2.2.1 Suspension System - Overview, Symptom Diagnosis Testing). M201 2014.01...
Page 95: Removal And Installation
5. Remove the connecting bolt (2) between front shaft swing arm and front shaft. Torque: 60 ~ 85 Nm M2102006 6. Remove the front shaft swing arm assembly. Installation 1. Installation is in the reverse order of removal. M201 2014.01...
Page 96: Front Suspension Press Lever Welding Assembly
Torque for upper nut: 40 ~ 60 Nm Torque for lower nut: 18 ~ 28 Nm M2102007 4. Remove the connecting nuts between front suspension press lever and front shaft swing arm. Torque: 80 ~ 110 Nm M2102005 M201 2014.01...
Page 97 5. Remove the retaining nut of front suspension press lever from the lever retainer. Torque: 18 ~ 28 Nm M2102008 6. Remove the front suspension press lever welding assembly. Installation 1. Installation is in the reverse order of removal. M201 2014.01...
Page 98: Front Wheel Steering Knuckle
4. Remove the nut cotter pin and retaining nut from the tie rod ball joint. Torque: 30 ~ 55 Nm M2102009 5. Remove the retaining bolt between front shaft swing arm and steering knuckle. Torque: 45 ~ 65 Nm M2102010 M201 2014.01...
Page 99 2.1.2-11 Front Suspension 2.1.2-11 6. Remove the connecting bolts and nuts between front strut and steering knuckle. Torque: 80 ~ 110 Nm M2102011 7. Remove the steering knuckle. Installation 1. Installation is in the reverse order of removal. M201 2014.01...
Page 100: Front Wheel Hub Bearing
3. Remove the brake disc. Refer to: Brake Disc (2.3.3 Front Disc Brake, Removal and Installation). 4. Use a suitable tool to remove the bearing cap. M2102012 5. Remove retaining nut from the front wheel hub bearing. Torque: 175 Nm M2102013 M201 2014.01...
Page 101 6. Remove the front wheel hub bearing. M2102014 Installation 1. Installation is in the reverse order of removal. CAUTION: Install the front wheel hub bearing retaining nut with a new one, and use chisel to caulk the retaining nut after reaching the torque. M201 2014.01...
Page 102: Front Strut Assembly
5. Remove the connecting bolts and nuts (2) between front strut and steering knuckle. Remove the front strut assembly. Torque: 80 ~ 110 Nm M2102016 Installation 1. Installation is in the reverse order of removal. M201 2014.01...
Page 103: Front Shaft Welding Assembly
Torque: 50 ± 5 Nm ×4 M2102017 5. Remove 4 connecting bolts between front shaft and body. Remove the front shaft. Torque: 75 Nm ×4 M2102018 Installation 1. Installation is in the reverse order of removal. M201 2014.01...
Page 104: Front Stabilizer Bar
Torque for lower nut: 18 ~ 28 Nm M2102007 3. Remove 2 retaining bolts from the left and right sides of front stabilizer bar. Remove the front stabilizer bar. Torque: 20 ~ 30 Nm M2102019 Installation 1. Installation is in the reverse order of removal. M201 2014.01...
Page 105: Disassembly And Assembly
5 Remove the front strut support. 6 Remove the bearing. 7 Remove the upper retainer of coil spring. 8 Remove the rubber cushion. 9 Remove the front coil spring. 10 Remove the anti-collision cushion. 11 Remove the front shock absorber assembly. M2102021 M201 2014.01...
Page 106 2.1.2-18 Front Suspension 2.1.2-18 Assembly 1. Assembly is in the reverse order of disassembly. CAUTION: Put the end of spring correctly on the spring retainer. M201 2014.01...
Page 107: Rear Suspension
48 ~ 63 Rear axle rear shackle nut 70 ~ 80 52 ~ 59 Connecting bolt between leaf spring and 90 ~ 100 66 ~ 74 body Wheel nut 100 ± 10 Brake hose joint 16 ± 2 M201 2014.01...
Page 108: Description And Operation
Components Location View Rear Suspension Assembly View M2103001 Item Description Item Description Rear leaf spring assembly Rear shock absorber assembly Saddle plate welding assembly Rear shackle internal plate assembly Buffer plate assembly Rear shackle external plate U-bolt Rear axle assembly M201 2014.01...
Page 109: Rear Suspension
2.1.3-3 Rear Suspension 2.1.3-3 Symptom Diagnosis and Testing Refer to: Symptom Chart (2.1.1 Suspension System - Overview, Symptom Diagnosis Testing). M201 2014.01...
Page 110: Removal And Installation
Refer to: Brake Drum (2.3.2 Rear Drum Brake, Removal and Installation). 5. Remove the parking brake cable. 1 Remove the retaining bolt between parking brake cable and brake baseplate. Torque: 9 Nm M2203003 2 Remove the parking brake cable from the brake shoe. M2103002 M201 2014.01...
Page 111 7. Remove the retaining bolt from the spring connected to load sensing proportioning valve and rear axle. Torque: 25 ± 5 Nm M2103004 8. Put the jack at the proper position of rear axle. M2103005 M201 2014.01...
Page 112 CAUTION: Tighten the rear suspension parts after the vehicle weight is borne by wheels. 1. Installation is in the reverse order of removal. 2. Bleed the brake system. Refer to: Brake System Bleeding (2.3.1 Brake System - Overview, General Inspection). M201 2014.01...
Page 113: Rear Leaf Spring Assembly
M2103005 4. Remove the rear shock absorbers, U-bolts and nuts. Remove the buffer plate assembly and saddle plate. Torque: 65 ~ 85 Nm ×4 M2103007 5. Remove the retaining screw from the parking brake cable bracket. M2103008 M201 2014.01...
Page 114: Rear Shock Absorber Assembly
1 Remove the lower retaining bolt and nut (1) from the rear shock absorber. Torque: 60 ~ 80 Nm 2 Remove the upper retaining nut (2) from the rear shock absorber, and remove the rear shock absorber. Torque: 60 ~ 80 Nm M2103011 M201 2014.01...
Page 115 2.1.3-9 Rear Suspension 2.1.3-9 Installation 1. Installation is in the reverse order of removal. CAUTION: Tighten the bolts and nuts when the vehicle is lowered without any load. M201 2014.01...
Page 117: Wheel And Tire
2.1.4 Wheel and Tire General Specifications Item Specifications Tire 165/70R14LT Unloaded 250 kPa Front tire pressure Full loaded 270 kPa Unloaded 250 kPa Rear tire pressure Full loaded 370 kPa Torque Specifications Item lb-ft lb-in Wheel nut 100 ± 10 M201 2014.01...
Page 118: Description And Operation
(not at all tires) vehicle LT - Light-duty truck End face width End face height/ Height-to-width ratio width R - Radial tire Structure type B - Bias tire Wheel diameter inch Height-to-width ratio = height (2) ÷ width (1) M2104001 M201 2014.01...
Page 119: Components Exploded View
2.1.4-3 Wheel and Tire 2.1.4-3 Components Exploded View M2104002 Item Description Qty. Item Description Qty. Tire (165/70 R14) Wheel cap Wheel 14 × 5J Air valve Wheel nut M201 2014.01...
Page 120: General Inspection
Failure to follow above instructions may and fuel consumption rising, etc. cause personal injury. 5. The two tires of same axle shall be charged to same value, otherwise it would cause operability reduction, pull during acceleration, driving and braking. M201 2014.01...
Page 121: Tire Rotation
"fan shape" tire. Severe error of rear wheel toe-in would also cause other unusual abrasions. M2104003 Item Description Front tire Rear tire Spare tire M201 2014.01...
Page 122: Wheel Runout Inspection
Wheel with incorrect size or type may affect the service life of wheel and bearing, brake cooling, reading of speedometer/odometer, ground clearance, and clearance between tire and body, chassis. M201 2014.01...
Page 123: Initial Inspection Before Tire Alignment
Tighten the control arm connecting bolt. Replace the control Check if the control arm is loose? arm bushing when necessary. Tire Abrasion Inspection Symptom Reasons • • Insufficient tire charging Tire shoulder quick abrasion • No tire rotation M2104005 M2104006 M201 2014.01...
Page 124 • Tread cracks • Insufficient Charging • Overspeed M2104009 Measures: Adjust the pressure and rotate the tires under cold state according to specifications. • • Unilateral abrasion Too large camber M2104010 M2104011 Measures: Adjust camber to specified value. M201 2014.01...
Page 125 Wheel imbalanced Small pattern polished • Tire defective M2104014 M2104015 Measures: Tire dynamic balance. • Large abrasion for edge pattern • No tire rotation • Suspension abrasion or adjustment required M2104016 Measures: Rotate tires. Measures: Adjust or repair suspension. M201 2014.01...
Page 126: Symptom Diagnosis And Testing
• Vehicle speed at the time of vibration. • Type of vibration that occurs within each speed range. • Mechanical vibration or audible sound. Effect on vibration when the following conditions change: M201 2014.01...
Page 127: Symptom Chart
• Wheel distortion Wear (2.1.1 Suspension System - • Tire out of balance Overview, Symptom • Wheel alignment Diagnosis Tire abrasion • Suspension component Testing). • High speed running • Rear axle • Overload • Poor driving habit M201 2014.01...
Page 128: Wheel And Tire
• Foreign matter between installation • Clean the installation surface. surfaces of wheel and hub. • Replace the front wheel bearing. Refer to: Front wheel Bearing (2.1.2 Front • Front wheel bearing damaged Suspension, Removal Installation). M201 2014.01...
Page 129: Removal And Installation
They may cause the wheel bolts or wheels loose when driving. Failure to follow the above instructions may cause personal injury. Installation 1. Installation is in the reverse order of removal. M201 2014.01...
Page 131 System Overview........................2.2.2-2 Components Exploded View..................... 2.2.2-3 General Inspection........................... 2.2.2-4 Inspect Driveline System Vibration ................... 2.2.2-4 Inspect Dynamic Balance of Propeller Shaft ................2.2.2-4 Balance Propeller Shaft......................2.2.2-5 Inspection ..........................2.2.2-5 Symptom Diagnosis and Testing...................... 2.2.2-7 Removal and Installation........................2.2.2-8 M201 2014.01...
Page 132 2.2.4 Differential Specifications ...........................2.2.4-1 General Specifications ......................2.2.4-1 Torque Specifications........................2.2.4-1 Description and Operation........................2.2.4-2 System Overview ........................2.2.4-2 Symptom Chart .........................2.2.4-2 Components Exploded View.....................2.2.4-3 Symptom Diagnosis and Testing ......................2.2.4-5 Removal and Installation ........................2.2.4-6 Final Drive..........................2.2.4-6 Disassembly and Assembly ......................2.2.4-8 Final Drive..........................2.2.4-8 Differential..........................2.2.4-16 M201 2014.01...
Page 133: Driveline System - Overview
The drive shaft is not flexible and cannot be stretched in and out. The other end of drive shaft is the hub flange, which is connected to the wheel directly as a whole with drive shaft. M201 2014.01...
Page 134: General Inspection
3. Inspect the differential side oil seal installation surface for rust, scratch, burr or other abnormalities. 4. Inspect if the oil seal holder is deformed or broken. M201 2014.01...
Page 135 2.0 kg, the total preload value (kg) of drive and driven bevel gears is 2.2 ~ 2.6 kg. The bearing cover bolts should be tightened as specified torque after adjusting. M201 2014.01...
Page 136 M201 2014.01...
Page 137 35 ~ 50 Nm. thickness of drive bevel gear adjusting shim should be increased. M2201007 Low contact The drive bevel gear is too forward, so the thickness of drive bevel gear adjusting shim should be decreased. M2201008 M201 2014.01...
Page 138: Propeller Shaft Inspection
• After replacement with new final drive flange, the radial runout should be within limit range. • Carry out road test to inspect if the driveline system vibrates. If vibration still exists, balance the propeller shaft. M201 2014.01...
Page 139 If the vibration is not improved, turn the clamp reversely by a equal distance from the position with minimum vibration confirmed previously. Separate collets of two clamps about 8 cm, and carry out road test again to inspect for vibration. M201 2014.01...
Page 140 (2) and spline shaft sleeve (1) with a slip gauge. Standard value: 0.02 ~ 0.01 mm If the sliding spline tooth clearance exceeds standard value, replace the propeller shaft with a new one. M2201018 M201 2014.01...
Page 141: Symptom Diagnosis And Testing
3. If an obvious cause for an observed or reported concern has been found, solve the fault before proceeding to the next step. 4. If the cause is not visually evident, verify the symptom by referring to the Symptom Chart. M201 2014.01...
Page 142: Symptom Chart
• Retaining bolts of driven bevel Diagnosis Drive axle makes noises gear loose Testing). during running • Planetary gear, drive shaft inner end or drive shaft gear spline groove of differential worn or loose • Gear oil insufficient or grade incorrect M201 2014.01...
Page 143 • Tighten the refill or drain plug as tightened as specified torque specified torque. • Retaining bolts of brake • Inspect and repair the rear axle, brake Drive shaft falling-off baseplate and rear axle baseplate, and replace the retaining damaged bolts. M201 2014.01...
Page 144: Diagnosis Procedure For Vehicle Body Shaking And Drive Device Making Impact Sound With Vehicle Starting Or Vehicle Speed Suddenly Changing
Is the fault confirmed Inspect spline tooth at the second shaft of transmission and spline shaft sleeve of propeller shaft for wear Is the fault confirmed Inspect flange spline groove of drive axle final drive for wear M201 2014.01...
Page 145: Driveline System - Overview
Refer to: Propeller Shaft Inspection (2.2.1 Driveline System - Overview, General Inspection). Is it normal? Go to step 4. Repair the fault part, and replace when necessary. M201 2014.01...
Page 146 Drive Differential Assembly (2.2.4 Differential, Removal and Installation). B. Inspect the flange spline groove of drive axle final drive for wear. Is it normal? Make sure the system is normal. Repair the fault part, and replace when necessary. M201 2014.01...
Page 147: Diagnosis Procedure For Drive Axle Noise During Running
Diagnosis Procedure for Drive Axle Noise During Running Drive axle noise during running Inspect oil quantity and grade Is the fault confirmed Inspect inner spline of drive shaft Is the fault confirmed Inspect final drive and differential assembly M201 2014.01...
Page 148 Refer to: Drive Shaft (2.2.3 Drive Shaft, Removal and Installation). B. Inspect the drive shaft. Refer to: Drive Shaft Inspection (2.2.1 Driveline System - Overview, General Inspection). Is the connection normal? Go to step 3. Replace the drive shaft. M201 2014.01...
Page 149 Installation). B. Inspect the final drive and differential assembly. Refer to: Final Drive Differential Assembly Inspection (2.2.1 Driveline System - Overview, General inspection). Is it normal? The system is normal. Replace the final drive and differential assembly. M201 2014.01...
Page 150: Diagnosis Procedure For Drive Shaft Noise
Drive System - Overview 2.2.1-18 Diagnosis Procedure for Drive Shaft Noise Drive shaft noise Inspect drive shaft Is the fault confirmed Inspect spline at inner end of drive shaft Is the fault confirmed Inspect drive shaft outer bearing M201 2014.01...
Page 151 A. Remove the drive shaft. Refer to: Drive Shaft (2.2.3 Drive Shaft, Removal and Installation). B. Inspect the drive shaft outer bearing. Is it normal? Refer to: Drive Shaft Outer Bearing (1.1.5 Noise, Vibration Harshness). Replace the drive shaft outer bearing. M201 2014.01...
Page 152: Diagnosis Procedure For High Drive Axle Temperature After A Certain Mileage
B. Inspect the final drive and differential assembly. Refer to: Final Drive Differential Assembly Inspection (2.2.1 Driveline System - Overview, General inspection). Is it normal? The system is normal. Repair the fault part or replace the final drive and differential assembly. M201 2014.01...
Page 153: Propeller Shaft
2.2.2-1 Propeller Shaft 2.2.2-1 Specifications 2.2.2 Propeller Shaft Grease Item Type High grade grease C Lithium based grease (99000-25030) Torque Specifications Item lb-ft lb-in Connecting bolt between propeller shaft 50 ± 10 and differential M201 2014.01...
Page 154: Description And Operation
CAUTION: Dual nonconstant velocity cross universal joint shall have working angle, no more than 50 degrees. CAUTION: Inspect if the junction surface between propeller shaft and oil seal of transmission output shaft and the internal spline are damaged. M201 2014.01...
Page 155: Components Exploded View
2.2.2-3 Propeller Shaft 2.2.2-3 Components Exploded View M2202001 Item Description Item Description Hexagon bolt and elastic washer Propeller shaft component M201 2014.01...
Page 156: General Inspection
• If the radial runout of rear end is within standard range, inspect driveline system is vibrating during road test. In case of vibration, mark the high point and proceed with next step. M201 2014.01...
Page 157: Balance Propeller Shaft
If the vibration is not improved, turn the clamp reversely by a equal distance from the position with minimum vibration confirmed previously. Separate collets of two clamps about 10 cm, and carry out road test again to inspect for vibration. M201 2014.01...
Page 158 Standard value: 0.02 ~ 0.01 mm If the sliding spline tooth clearance exceeds standard value, replace the propeller shaft with a new one. M2202008 Item Description Spline shaft sleeve Spline shaft Clearance M201 2014.01...
Page 159: Symptom Diagnosis And Testing
2.2.2-7 Propeller Shaft 2.2.2-7 Symptom Diagnosis and Testing Refer to: (2.2.1 Driveline System Overview, Symptom Diagnosis and Testing). M201 2014.01...
Page 160: Propeller Shaft
Do not replace them with other bolts. CAUTION: Before removing propeller shaft, put matchmarks on each flange and propeller shaft. M2202010 4. Remove the propeller shaft. CAUTION: Plug up the transmission output shaft side with a suitable tool to prevent transmission oil leakage. M2202011 M201 2014.01...
Page 161 CAUTION: Inspect for lack of transmission oil, fill when necessary. M201 2014.01...
Page 163: Drive Shaft
Hypoid gear oil SAE90, Gear oil 1.4 L SAE80W or GL-5 85W/90 Sealant Sealant 366E Lithium based grease Suzuki superior grease A Torque Specifications Item lb-ft lb-in Drain plug ± Refill plug Brake baseplate retaining bolt Parking brake cable retaining bolt M201 2014.01...
Page 164: Description And Operation
Before installing the drive shaft, clean the junction surface between brake baseplate and rear drive axle, and apply the sealant again. • Make sure to install the drive shaft in place to prevent deformation and oil leakage due to improper installation of brake baseplate. M201 2014.01...
Page 165: Components Exploded View
2.2.3-3 Drive Shaft 2.2.3-3 Components Exploded View M2203001 Item Description Item Description Oil seal holder Drive shaft bushing Drive axle drive shaft Drive shaft oil seal assembly assembly Drive shaft retaining ring Bolt Drive shaft bearing M201 2014.01...
Page 166: Symptom Diagnosis And Testing
2.2.3-4 Drive Shaft 2.2.3-4 Symptom Diagnosis and Testing Refer to: Symptom Chart (2.2.1 Driveline System - Overview, Symptom Diagnosis and Testing). M201 2014.01...
Page 167: Removal And Installation
Suzuki superior grease A 09942-15510 grease Hypoid gear oil SAE90, Gear oil SAE80W or GL-5 85W/90 Brake drum remover 09943-17912 09943-17912 Oil seal installer 09913-75520 09913-75520 Bearing remover 09921-57810 09921-57810 Universal puller 09927-18411 09927-18411 Bearing outer race remover 09944-96010 09944-96010 M201 2014.01...
Page 168: Drive Shaft
CAUTION: The differential oil drain bolt is one applied with sealant, replace it with new one and reapply the sealant after removing. M2203002 6. Remove the retaining bolt between parking brake cable and brake baseplate. Torque: 9 Nm M2203003 M201 2014.01...
Page 169 Drive Shaft 2.2.3-7 7. Remove 4 brake baseplate retaining bolts. Torque: 23 Nm ×4 M2203004 8. Use the special tool to pull out the drive shaft. Special tool: 09943-17912, 09942-15510 09943-17912 09942-15510 M2203005 9. Remove the drive shaft. M2203006 M201 2014.01...
Page 170 10. Use the special tool to remove the drive shaft bearing, retaining ring and bushing. Special tool: 09921-57810, 09927-18411 09927-18411 09921-57810 M2203007 11. Remove the brake baseplate (1) and bearing plate (2). M2203008 12. Remove the tire bolts. General tool: Hydraulic device M2203009 M201 2014.01...
Page 171 1. Clean the old sealant on the junction surface of brake baseplate and drive shaft. M2203011 2. Use the special tool to install the drive shaft oil seal and oil seal holder. 09913-75520 Special tool: 09913-75520 General tool: Rubber hammer M2203012 M201 2014.01...
Page 172 CAUTION: Install the drive shaft bearing with its sealing surface facing toward brake drum side. M2203015 CAUTION: When installing the drive shaft retaining ring, avoid damage to its outside. M201 2014.01...
Page 173 CAUTION: Apply grease on the tip of drive shaft oil seal before installing the drive shaft. Material: Lithium based grease M2203017 8. Install the drive shaft in place. General tool: Rubber hammer M2203018 9. Install the brake baseplate retaining bolts. Torque: 23 Nm ×4 M2203019 M201 2014.01...
Page 174 2.2.3-12 10. Fill the differential oil. General tool: Oil bucket Material: Gear oil M2203020 11. Install the differential refill plug. Torque: 50 ± 10 Nm M2203021 12. Install the parking brake cable retaining bolt. Torque: 9 Nm M2203003 M201 2014.01...
Page 175 Refer to: Brake Shoe (2.3.2 Rear Drum Brake, Removal and Installation). 15. Install the brake drum. Refer to: Brake Drum (2.3.2 Rear Drum Brake, Removal and Installation). 16. Install the rear wheel. Refer to: Wheel and Tire (2.1.4 Wheel and Tire, Removal and Installation). M201 2014.01...
Page 177: Differential
CAUTION: If the vehicle is running in a area with the temperature lower than -15°C (15°F) in cold seasons, it is recommended to use SAE80W or 75W/80-85 oil for regular maintenance. Torque Specifications Item lb-ft lb-in Differential bearing cover retaining bolt Flange retaining nut Driven gear retaining bolt Final drive retaining nut M201 2014.01...
Page 178: Description And Operation
(Noise occurs while sliding) differential drive shaft • Replace. bearing or rear axle shaft damaged • • Ventilation plug clogged Clean. Oil leakage • • Oil seal worn or damaged Replace. • • Excessive oil Adjust oil level. M201 2014.01...
Page 179: Components Exploded View
2.2.4-3 Differential 2.2.4-3 Components Exploded View M2204001 M201 2014.01...
Page 180 Adjusting shim Planetary gear shaft Rolling bearing Spring pin Rolling bearing Thrust washer Drive bevel gear oil seal Differential case Flange locking nut washer Bolt Flange locking nut Differential bearing Final drive case Gasket Bearing cover bolt Thrust washer M201 2014.01...
Page 181: Symptom Diagnosis And Testing
2.2.4-5 Differential 2.2.4-5 Symptom Diagnosis and Testing Refer to: Symptom Chart (2.2.1 Driveline System - Overview, Symptom Diagnosis and Testing). M201 2014.01...
Page 182: Removal And Installation
Removal and Installation). 3. Remove the propeller shaft. Refer to: Propeller Shaft (2.2.2 Propeller Shaft, Removal and Installation). 4. Remove 8 final drive retaining nuts. Torque: 23 Nm ×8 M2204025 5. Remove the final drive with differential assembly. M201 2014.01...
Page 183 CAUTION: The differential oil drain bolt is one applied with sealant, replace it with new one and reapply the sealant after removing. CAUTION: Before installation, clean the junction surface between front differential assembly and rear axle, and reapply the sealant. M201 2014.01...
Page 184: Disassembly And Assembly
Bearing installer 09913-75520 09913-75520 General Tool Puller Hydraulic device Material Item Type Sealant Sealant 366E Hypoid gear oil SAE90, Gear oil SAE80W or GL-5 85W/90 Lithium based grease Suzuki superior grease A Superior thread sealant Thread sealant 1333B M201 2014.01...
Page 185 3. Remove the flange from the final drive. M2204003 4. Remove the bearing cover. 1 Mark the differential bearing cover. 2 Remove 4 retaining bolts from the right and left differential bearing covers, and remove the bearing covers. M2204004 M201 2014.01...
Page 186 2.2.4-10 Differential 2.2.4-10 5. Remove the differential. M2204005 6. Remove the drive bevel gear shaft. M2204006 7. Remove the drive bevel gear spacer from drive bevel gear shaft. M2204007 8. Remove the drive bevel gear oil seal. M2204008 M201 2014.01...
Page 187 General tool: Puller M2204010 10. Remove the drive bevel gear rear bearing. 1 Use the special tool to remove the rear bearing from drive bevel gear. Special tool: 09921-57810 General tool: Hydraulic device 09921-57810 M2204011 M201 2014.01...
Page 188 1 Use the special tool to install the rear bearing to drive bevel gear. Special tool: 09940-51710 General tool: Hydraulic device 09940-51710 M2204013 2 Use suitable tools to install the rear bearing outer race. Special tool: 09913-75510 09913-75510 General tool: Hydraulic device M2204014 M201 2014.01...
Page 189 General tool: Hydraulic device M2204015 2 Install the front bearing into the final drive case. M2204026 3. Install the drive bevel gear oil seal. M2204008 4. Install the drive bevel gear spacer to the drive bevel gear shaft. M2204016 M201 2014.01...
Page 190: Differential
M2204018 7. Install the left and right differential bearing covers. 1 Align the mark on the bearing cover during installation. 2 Tighten 4 bearing cover retaining bolts. Torque: 50 Nm M2204004 8. Install the final drive flange. M2204003 M201 2014.01...
Page 191 2.2.4-15 Differential 2.2.4-15 9. Install the flange washer and tighten the flange retaining nut. Torque: 200 Nm M2204002 10. Install the final drive assembly. Refer to: Final Drive (2.2.4 Differential, Removal and Installation). M201 2014.01...
Page 192 09913-85230 09913-85230 Spring platinum remover 09922-85811 09922-85811 Bearing installer 09940-53111 09940-53111 General Tool Hammer Hydraulic device Material Item Type Sealant Sealant 366E Hypoid gear oil SAE90, Gear oil SAE80W or GL-5 85W/90 Superior thread sealant Thread sealant 1333B M201 2014.01...
Page 193 Special tool: 09913-60910, 09913-85230 09913-60910 09913-85230 M2204020 3. Remove the driven bevel gear. 1 Mark the driven bevel gear and differential. 2 Remove 10 retaining bolts from the driven bevel gear and remove the driven bevel gear. M2204021 M201 2014.01...
Page 194 Special tool: 09922-85811 09922-85811 General tool: Hammer M2204022 2. Install the driven bevel gear. 1 Align the marks on the driven bevel gear and differential. 2 Install 10 driven gear retaining bolts. Torque: 85 Nm M2204021 M201 2014.01...
Page 195 1 Use the special tool to install the differential bearing. Special tool: 09940-53111 09940-53111 General tool: Hydraulic device M2204023 2 Install the differential bearing outer race. M2204024 4. Install the differential. Refer to: Final Drive (2.2.4 Differential, Disassembly and Assembly). M201 2014.01...
Page 197 Brake Drum Inspection ......................2.3.1-20 Brake Shoe Inspection ......................2.3.1-21 Wheel Cylinder Inspection...................... 2.3.1-21 Front Brake Pad Lining Inspection ..................2.3.1-21 Rear Brake Shoe Inspection....................2.3.1-22 Rear Drum Brake Shoe Adjustment ..................2.3.1-22 Symptom Diagnosis and Testing....................2.3.1-23 Inspection and Verification...................... 2.3.1-23 M201 2014.01...
Page 198 2.3.3 Front Disc Brake Specifications ...........................2.3.3-1 Material Specifications ......................2.3.3-1 Front Disc Brake Specifications ....................2.3.3-1 Torque Specifications........................2.3.3-1 Description and Operation........................2.3.3-2 System Overview ........................2.3.3-2 Components Description......................2.3.3-2 Components Exploded View.....................2.3.3-3 Removal and Installation ........................2.3.3-4 Brake Pad ..........................2.3.3-4 Brake Caliper ..........................2.3.3-7 Brake Disc ..........................2.3.3-9 M201 2014.01...
Page 199 Removal and Installation........................2.3.5-4 Brake Fluid Reservoir ....................... 2.3.5-4 Brake Master Cylinder ......................2.3.5-6 Load Sensing Proportioning Valve ................... 2.3.5-8 6-way Joint ..........................2.3.5-10 Pedal Assembly........................2.3.5-11 2.3.6 Power Brake Specifications ........................... 2.3.6-1 Torque Specifications........................ 2.3.6-1 Description and Operation ....................... 2.3.6-2 M201 2014.01...
Page 200 Brake System System Overview ........................2.3.6-2 Components Location View ......................2.3.6-2 Removal and Installation ........................2.3.6-3 Brake Booster ...........................2.3.6-3 M201 2014.01...
Page 201: Brake System - Overview
WARNING: When the brake drum limit diameter has been reached, install a new brake drum. Take extra care when performing a polishing treatment on the brake drum that has not reached the limit diameter. WARNING: When the brake shoe friction lining limit thickness has been reached, install a new brake shoe. M201 2014.01...
Page 202: Description And Operation
The parking brake lever is located between two front seats, and the system can be enabled by pulling it up. • The vehicle without ABS should have a "Load Sensing Proportioning Valve (LSPV)" installed. M201 2014.01...
Page 203: Components Location View
2.3.1-3 Brake System - Overview 2.3.1-3 Components Location View Brake Pipe M2301001 M201 2014.01...
Page 204 I - front right hose) Brake pipe assembly (6-way Cable equalizer passage I - front left hose) 6-way joint Left parking brake cable Brake pipe assembly (6-way Right parking brake cable passage I - LSPV port 2) M201 2014.01...
Page 205 No.2 parking brake cable Parking brake lever assembly assembly (left) No.2 parking brake cable Handle assembly (right) Hexagonal nut with serrated Parking brake switch assembly flange Hexagon flange bolt Hexagonal cross head screw No.1 parking brake cable Hexagon flange bolt assembly M201 2014.01...
Page 206 Second piston cup Piston stopper Second piston Cylinder head Return spring seat Panel Second piston return spring First piston Second piston stopper bolt Piston cup Brake master cylinder First piston return spring First piston First piston spring holder Second piston M201 2014.01...
Page 207 Air cleaner separator Reaction disc Gas valve return spring Booster piston return spring Gas valve return spring Booster piston rod Control valve spring holder Booster rod adjusting screw Control valve spring Brake pedal Booster control valve Master cylinder M201 2014.01...
Page 208 Still, the brake force by depressing the brake pedal will be transmitted to the valve lever, booster gas valve, valve stopper pin and booster piston, finally push the master cylinder rod. Therefore, there will be no operation fault in the brake itself. M201 2014.01...
Page 209 M2301007 Item Description Item Description LSPV spring support (rear axle From master cylinder housing) LSPV (Load Sensing To rear brakes (left and right) Proportioning Valve) assembly M201 2014.01...
Page 210: Brake System - Overview
M2301008 Item Description Item Description Plunger To rear brake From master cylinder second LSPV control lever piston chamber (front brake) Sensor spring Overflow plug From first piston chamber (rear brake) M201 2014.01...
Page 211: General Inspection
The technician can also put all problems on some particular components, vehicle M201 2014.01...
Page 212: Substandard Or Polluted Brake Fluid
CAUTION: Do not use damper fluid or other fluid with mineral oil. Do not use wet container containing mineral oil. Mineral would cause expansion deformation of rubber components inside the brake system. If the brake fluid contains water, the boiling point will be M201 2014.01...
Page 213: Brake Pedal Free Height Adjustment
If there are a small amount M2301009 of liquid drops, leakage exists. Also, moisture regain of casting is not normal. 2. Inspect the brake lamp switch position; if it doesn't meet the technical requirements, adjust it. M201 2014.01...
Page 214: Pedal Stroke Inspection
(see Brake Drum Inspection); if damaged, repair or replace. Then, inspect if brake drums are stuck and brake system has good performance. Last, lower the vehicle and carry out brake test. M201 2014.01...
Page 215: Parking Brake Inspection And Adjustment
2. M2301014 CAUTION: Inspect if the tooth tip is worn damaged. Otherwise, replace CAUTION: After adjustment, inspect if the parking brake lever. brake drum is stuck. Parking brake travel: M201 2014.01...
Page 216: Brake Hose And Oil Pipe Inspection
3. Depress the brake pedal several times with the equal force as usual, and observe the pedal travel. If the pedal goes down greatly for the first time and the travel decreases for the second and third time, the airtightness has been formed. M2301015 M201 2014.01...
Page 217: Brake System Bleeding
2. Remove the drain plug cover. Insert the WARNING: Drink some water and try vinylite pipe to drain plug, and other end to vomiting, and go to see the doctor right container. away if brake fluid is swallowed. M201 2014.01...
Page 218: Load Sensing Proportioning Valve Inspection And Adjustment
If there is a leakage, replace the the following requirements should be met. damaged elements. • Top up the fuel tank with fuel. • The vehicle is equipped with spare tire, tools, jack and handle. • There is no load on the vehicle. M201 2014.01...
Page 219: Brake Disc Runout And Thickness Inspection
Replace the brake pads with new ones when necessary. Pad thickness (lining + brake pad body) Standard value: 15 mm M2301021 Limit value: 7 mm M201 2014.01...
Page 220: Brake Drum Inspection
It is not safe to continue to use cracked brake drum; replace in time. Do not weld the cracked brake drum. Slight scratches do not affect smoothness greatly. However, too many or too severe scratches would cause the brake pad excessively worn. Repair the brake drum surface. M201 2014.01...
Page 221: Brake Shoe Inspection
Inspect if the dust boot are broken, cracked or damaged; If finding any damage, replace in time. 2. Piston sealing Excessive or uneven abrasion of brake pad lining may cause unsmooth piston return. Under this condition, replace the rubber sealing parts. M201 2014.01...
Page 222: Rear Brake Shoe Inspection
3. Visually inspect the brake shoe thickness through the baseplate hole. If the thickness "e" of one shoe is less than the limit dimension, replace all brake shoes at the same time. M2301027 M201 2014.01...
Page 223: Symptom Diagnosis And Testing
5. If the cause is not visually evident, verify the symptom by referring to the Symptom Chart. General Equipment • Vernier caliper • Dial indicator M201 2014.01...
Page 224: Symptom Chart
9. Do not stick the brake fluid to the body or paintwork. If the brake fluid leaks on the paintwork, it should be cleaned immediately. If the fault occurs, but the brake system operation indicator is normal and the cause cannot be confirmed by basic inspection, diagnose and repair in order of the following table. M201 2014.01...
Page 225: Rear Drum Brake
• Brake caliper assembly failure moves slowly, and properly lubricate the caliper slide bushing to slide the caliper • Loose suspension components • Inspect all the suspension components • Loose caliper • Inspect and tighten the bolts as specified. M201 2014.01...
Page 226 • Brake caliper assembly failure Front Disc Brake, Removal Installation). • Inspect and adjust it. Refer to: Load Sensing Proportioning Valve • Improper length adjustment of Inspection LSPV equipped) sensor Adjustment (2.3.1 spring Brake System Overview, General Inspection). M201 2014.01...
Page 227 Refer to: Load Sensing Proportioning Valve • Improper length adjustment of Inspection Rear brake locks too early LSPV sensor spring Adjustment (2.3.1 (for vehicles with LSPV) Brake System Overview, General Inspection). • LSPV assembly failure • Replace the assembly. M201 2014.01...
Page 228 Refer to: Parking Brake Cable react slowly (2.3.4 Parking Brake and Operation). • Wheel brake pump or caliper • Replace when necessary. piston gets stuck • Piston seals in caliper are worn • Replace the piston seals. severely M201 2014.01...
Page 229 • Insufficient brake fluid • Add brake fluid. Brake warning lamp does not • Replace the lamp bulb or repair the turn on when parking brake is • Brake warning lamp circuit fault circuit. applied M201 2014.01...
Page 230: Diagnosis Procedure For Uneven Braking - Deviation
Inspect brake shoes or brake pads Is the fault confirmed Inspect front brake discs Is the fault confirmed Is the fault confirmed Wheel alignment Inspect rear brake drums Inspect brake wheel cylinders or brake calipers Inspect brake pipe M201 2014.01...
Page 231 4. Inspect front brake discs A. Inspect if the front brake discs are abnormally worn, distorted or deformed. Is it normal? Replace the front brake discs. Refer to: Front Brake Disc (2.3.3 Front Disc Brake, Removal Installation). Go to step 5. M201 2014.01...
Page 232 Replace the brake pipes or hoses. Go to step 8. 8. Wheel alignment A. Inspect if the wheel alignment is normal. Is it normal? Adjust the wheel alignment. Refer to: Wheel Alignment (2.1.1 Suspension System - Overview, General Inspection). The maintenance is finished. M201 2014.01...
Page 233: Diagnosis Procedure For Shaking/Vibration When Braking
(Braking at a speed of 40 ~ 80 km/h) Is the fault confirmed Inspect brake shoes or brake pads Is the fault confirmed Inspect front brake discs Is the fault confirmed Inspect rear brake drums Is the fault confirmed Inspect brake wheel cylinders or brake calipers M201 2014.01...
Page 234 3. Inspect front brake discs A. Inspect if the front brake discs are abnormally worn, distorted or deformed. Is it normal? Replace the front brake discs. Refer to: Front Brake Disc (2.3.3 Front Disc Brake, Removal Installation). Go to step 4. M201 2014.01...
Page 235 B. Inspect if the sliding parts are lack of lubrication. C. Inspect if the wheel hub bolts are loose or lost. Is it normal? Tighten the brake caliper retaining bolts; lubricate the sliding parts; tighten or replace the wheel hub bolts. The maintenance is finished. M201 2014.01...
Page 236: Diagnosis Procedure For Quick Down Of Brake Pedal
Is the fault confirmed Inspect brake fluid level Is the fault confirmed Brake system pressurizing Is the fault confirmed Inspect brake system for leakage Is the fault confirmed Inspect bypass condition of brake master cylinder M201 2014.01...
Page 237 Refer to: Parking Brake Cable Adjustment (2.3.4 Parking Brake Operation, General Inspection). If the fault still exists, bleed air in the brake system. Refer to: Brake System Bleeding (2.3.1 Brake System Overview, General Inspection). Go to step 4. M201 2014.01...
Page 238 Refer to: Bypass Condition Test (2.3.1 Brake System Overview, General Inspection). Is it normal? Replace the brake master cylinder. Refer to: Brake Master Cylinder and Brake Fluid Reservoir (2.3.5 Hydraulic Brake Control, Removal and Installation). The maintenance is finished. M201 2014.01...
Page 239: Diagnosis Procedure For Brake Pedal Low Or Feeling Spongy
Is the fault confirmed Inspect brake fluid level Is the fault confirmed Inspect vent hole on the reservoir cover Is the fault confirmed Inspect brake system bleeding Is the fault confirmed Inspect front wheel hub bearing retaining nuts M201 2014.01...
Page 240 4. Inspect brake system bleeding A. Inspect the air in the brake system. Is there any air in the brake system Bleed air in the brake system. Refer to: Brake System Bleeding (2.3.1 Brake System Overview, General Inspection). Go to step 5. M201 2014.01...
Page 241 A. Inspect if the front wheel hub bearing retaining nuts are loose. Is it normal? Replace and tighten the front wheel hub bearing retaining nuts. Inspect the parking brake adjustment. Refer to: Parking Brake Cable Adjustment (2.3.4 Parking Brake Operation, General Inspection). The maintenance is finished. M201 2014.01...
Page 242: Diagnosis Procedure For Brake Locking With Pedal Depressed Slightly
Inspect tire tread, pressure Is the fault confirmed Inspect brake shoes or brake pads Is the fault confirmed Inspect load sensing proportioning valve Is the fault confirmed Is the fault confirmed Inspect brake wheel cylinders or brake calipers Inspect vacuum booster M201 2014.01...
Page 243 Is it normal? Go to step 4. Replace the brake shoes or brake pads. Refer to: Brake Shoe (2.3.2 Rear drum brake, Removal and Installation) or Brake Pad (2.3.2 Front disc brake, Removal and Installation). M201 2014.01...
Page 244 Refer to: Brake Booster (2.3.6 Booster brake, Removal and Installation). 6. Inspect brake wheel cylinders or brake calipers A. Inspect if the sliding parts are lack of lubrication. Are they lack of lubrication? Lubricate the sliding parts. The maintenance is finished. M201 2014.01...
Page 245: Diagnosis Procedure For Brake Pedal Slow Down When Depressing And Holding Pedal
Inspect if fault symptom exists Is the fault confirmed Inspect brake fluid level Is the fault confirmed Inspect brake system for leakage Is the fault confirmed Inspect brake system for air Is the fault confirmed Inspect brake master cylinder M201 2014.01...
Page 246 4. Inspect brake system for air A. Inspect the brake system for air. Is there any air in the brake system Bleed air in the brake system. Refer to: Brake System Bleeding (2.3.1 Brake System Overview, General Inspection). Go to step 5. M201 2014.01...
Page 247 5. Inspect brake master cylinder A. Inspect if the brake master cylinder is normal. Is it normal? Replace the brake master cylinder. Refer to: Brake Master Cylinder and Brake Fluid Reservoir (2.3.5 Hydraulic Brake Control, Removal and Installation). The maintenance is finished. M201 2014.01...
Page 248: Diagnosis Procedure For Brake Drag
Inspect brake calipers or brake wheel cylinders Is the fault confirmed Inspect brake pads or brake shoes Is the fault confirmed Inspect brake booster Is the fault confirmed Is the fault confirmed Inspect load sensing proportioning valve Inspect brake pedal free travel M201 2014.01...
Page 249 A. Inspect if the brake pads or brake shoes are stuck. Is it normal? Go to step 4. Replace the brake pads. Refer to: Brake Pad (2.3.3 Front Disc Brake, Removal and Installation). Replace the brake shoes. Refer to: Brake Shoe (2.3.2 Rear Drum Brake, Removal and Installation). M201 2014.01...
Page 250 A. Inspect if the load sensing proportioning valve fails. Is it normal? The system is normal. Inspect or adjust the load sensing proportioning valve. Refer to: Load Sensing Proportioning Valve Inspection and Adjustment (2.3.1 Brake System - Overview, General Inspection). M201 2014.01...
Page 251: Rear Drum Brake
WARNING: When the brake drum limit diameter has been reached, install a new brake drum. Take extra care when performing a polishing treatment on the brake drum that has not reached the limit diameter. Torque Specifications Item lb-ft lb-in ± Brake oil pipe retaining nut Brake wheel cylinder retaining bolt M201 2014.01...
Page 252: Description And Operation
Brake Shoe Upper and Lower Return Springs Used to tightly press the two brake shoes on the brake wheel cylinder piston and retaining support pin; when the brake master cylinder returns, the upper spring enables the brake wheel cylinder piston to return automatically. M201 2014.01...
Page 253: Components Exploded View
2.3.2-3 Rear Drum Brake 2.3.2-3 Components Exploded View Rear Drum Brake M2302001 M201 2014.01...
Page 254 Rear brake baseplate Clearance adjusting board Pressure spring push and pull Rod arm Observation hole plug Pressure spring Wheel cylinder assembly Pressure spring seat Upper return spring Lower return spring Upper return spring Rear brake shoe Clearance self-adjusting assembly M201 2014.01...
Page 255: Removal And Installation
3. Lift the vehicle. Refer to: Lifting (1.1.3 Traction and Lifting, Description and Operation). 4. Remove the brake drum. M2302002 Installation 1. Installation is in the reverse order of removal. CAUTION: After installing the brake drum, adjust the shoe clearance. M201 2014.01...
Page 256: Brake Shoe
3. Remove the brake shoe lower return spring. CAUTION: Wear goggles for installation. M2302004 4. Detach the brake shoe from the brake wheel cylinder. CAUTION: Do not damage the brake wheel cylinder dust boot when removing the brake shoe. CAUTION: Wear goggles for installation. M2302005 M201 2014.01...
Page 257 (1). CAUTION: Wear goggles for installation. 6. Remove the clearance self-adjusting unit (2) from the brake shoe. M2302006 7. Remove the adjusting board from the brake shoe. M2302007 8. Remove the parking brake cable and brake shoe. M2302008 M201 2014.01...
Page 258 ×6 CAUTION: For installation, ensure the glove and other things would not leave the oil or grease on the brake shoe. M2302009 2. Install the parking brake cable. M2302008 3. Install the adjusting board. M2302007 M201 2014.01...
Page 259 M2302010 7. Install the brake shoe lower return spring. CAUTION: Wear goggles for installation. M2302004 8. Install the left and right pressure springs of brake shoe. CAUTION: Wear goggles for installation. M2302003 M201 2014.01...
Page 260 9. Adjust the self-adjusting unit to the minimum position. 10. Install the brake drum. Refer to: Brake Drum (2.3.2 Rear Drum Brake, Removal and Installation). 11. Adjust the parking brake cable. Refer to: Parking Brake Cable Adjustment (2.3.4 Parking Brake Operation, General Inspection). M201 2014.01...
Page 261: Brake Wheel Cylinder
5. Remove the brake wheel cylinder pipe. Torque: 16 ± 2 Nm CAUTION: Remove pipes when removing the rear right brake wheel cylinder. CAUTION: If brake fluid is splashed on the paintwork, the affected area must be immediately washed with cold water. M2302012 M201 2014.01...
Page 262 Rear Drum Brake 2.3.2-12 M2302013 6. Remove 2 retaining bolts from the brake wheel cylinder. Torque: 12 Nm CAUTION: Seal the brake wheel cylinder oil inlet to prevent oil loss and dirt. M2302014 7. Remove the brake wheel cylinder. M2302015 M201 2014.01...
Page 263 2.3.2-13 Rear Drum Brake 2.3.2-13 Installation 1. Installation is in the reverse order of removal. 2. Bleed air in the brake system. Refer to: Brake System Bleeding (2.3.1 Brake System Overview, General Inspection). M201 2014.01...
Page 264: Brake Baseplate
4. Remove the brake wheel cylinder. Refer to: Brake Wheel Cylinder (2.3.2 Rear Drum Brake, Removal Installation). 5. Remove the drive shaft. Refer to: Drive Shaft (2.2.3 Half Shaft, Removal and Installation). 6. Remove the brake baseplate. M2302016 M201 2014.01...
Page 265 1. Installation is in the reverse order of removal. CAUTION: When reinstalling the brake baseplate after removed, reapply sealant junction surface between brake baseplate and rear axle. 2. Bleed air in the brake system. Refer to: Brake System Bleeding (2.3.1 Brake System Overview, General Inspection). M201 2014.01...
Page 267: Front Disc Brake
Take extra care when performing a polishing treatment on the brake disc that has not reached the limit thickness. Torque Specifications Item lb-ft lb-in ± Tire nut Brake caliper retaining bolt Brake wheel cylinder support retaining bolt ± Front brake hose joint M201 2014.01...
Page 268: Description And Operation
Brake Caliper Receives the hydraulic pressure from the brake master cylinder and transforms it into mechanical output force to act on the inner brake pad; when the brake master cylinder returns, the brake caliper piston returns automatically. M201 2014.01...
Page 269: Components Exploded View
Front Disc Brake 2.3.3-3 2.3.3-3 Components Exploded View Front Disc Brake M2303001 Item Description Item Description Front hub shaft Hub shaft nut Brake disc dust plate Shaft cover Front hub bearing assembly Brake caliper assembly Front brake disc M201 2014.01...
Page 270: Removal And Installation
CAUTION: Before removing the brake caliper, pull the brake caliper forcibly to two sides of wheel cylinder return a little for removal. M2303002 3. Remove the brake pad. 1 Turn the brake caliper over. 2 Remove the brake pad. M2303003 M201 2014.01...
Page 271 Otherwise displacement or falling off may cause unusual sound for braking. M2303005 3. Install the brake caliper. 1 Install the brake caliper retaining bolt (2). Torque: 85 Nm 2 Install the front brake hose (1). M2303002 M201 2014.01...
Page 272 Without this step, it would cause the missing of brake force for the first two braking! 5. Inspect the brake fluid level and fill when necessary. 6. Install the tire. Refer to: Wheel and Tire (2.1.4 Wheel and Tire, Removal and Installation). M201 2014.01...
Page 273: Brake Caliper
3. Remove the brake pad. Refer to: Brake Pad (2.3.3 Front Disc Brake, Removal and Installation). 4. Remove the dust boot (1) from the brake caliper lower slide pin and remove the brake wheel cylinder (2). M2303007 M201 2014.01...
Page 274 Torque: 95 Nm ×2 M2303008 Installation 1. Installation is in the reverse order of removal. 2. Bleed air in the brake system. Refer to: Brake System Bleeding (2.3.1 Brake System Overview, General Inspection). M201 2014.01...
Page 275: Brake Disc
Refer to: Brake Caliper (2.3.3 Front Disc Brake, Removal and Installation). 3. Use an iron wire (2) to hang the brake caliper (1). CAUTION: Hang the brake caliper to prevent the brake hose from being stretched. M2303009 4. Remove the brake disc. M2303010 M201 2014.01...
Page 276 2.3.3-10 Front Disc Brake 2.3.3-10 Installation 1. Installation is in the reverse order of removal. 2. Bleed air in the brake system. Refer to: Brake System Bleeding (2.3.1 Brake System Overview, General Inspection). M201 2014.01...
Page 277 Torque Specifications Item lb-ft lb-in Parking brake cable adjusting/retaining Parking brake lever retaining bolt 20 ± 2 Parking brake cable retaining nut Parking brake cable retaining bolt Retaining bolt between parking brake cable and brake baseplate M201 2014.01...
Page 278: Description And Operation
"ON". Pull up the lever, press the button on it, and lower it down to release the parking brake, and then the parking brake indicator on the instrument cluster will be turned off. M201 2014.01...
Page 279: General Inspection
3. If the number of teeth does not accord with technical requirements, adjust the cable to obtain specified parking brake travel. CAUTION: Inspect if the tooth tip is worn or damaged, otherwise replace the parking brake lever. M2304002 M201 2014.01...
Page 280 5. Tighten the adjusting nut. Torque: 5 Nm 6. Test the parking brake for normal operation. CAUTION: After adjustment, inspect if the brake drum is stuck. 7. Install the console. Refer to: Console (5.1.6 Instrument Panel Console, Removal Installation). M201 2014.01...
Page 281: Symptom Diagnosis And Testing
4. If an obvious cause for an observed or reported concern has been found, solve the fault before proceeding to the next step. 5. If the cause is not visually evident, verify the symptom by referring to the Symptom Chart. M201 2014.01...
Page 282: Symptom Chart
Refer to: Parking Brake Cable • Cable equalizer (loosen, cracked, (2.3.4 Parking Brake distorted) Operation, Removal Installation). • Replace the brake shoes. • Rear brake shoes (worn to the Refer to: Brake Shoe (2.3.2 Rear limit) Drum Brake, Removal and Installation). M201 2014.01...
Page 283 • Parking brake switch Refer to: Diagnosis Procedure Parking Brake • Wiring harness between parking Indicator Constant ON brake switch and instrument Parking brake indicator is (2.3.4 Parking Brake cluster always on Operation, Symptom Diagnosis • Instrument cluster and Testing). M201 2014.01...
Page 284: Diagnosis Procedure For Parking Brake Not Functioning (Failure)/Poor Parking Brake Force
Inspect parking brake lever Is the fault confirmed Inspect parking brake lever travel Is the fault confirmed Inspect parking brake cables Is the fault confirmed Inspect rear brake shoe thickness Is the fault confirmed Inspect rear brake return springs M201 2014.01...
Page 285 3. Inspect parking brake cables A. Inspect the parking brake cables for damage or sticking. Is it normal? Go to step 4. Repair or replace the parking brake cables. Refer to: Parking Brake Cable (2.3.4 Parking Brake and Operation, Removal and Installation). M201 2014.01...
Page 286 Refer to: Brake Shoe (2.3.2 Rear Drum Brake, Removal Installation). 5. Inspect rear brake return springs A. Inspect if the rear drum brake return springs are normal. Is it normal? The maintenance is finished. Inspect and repair the rear drum brake. M201 2014.01...
Page 287: Diagnosis Procedure For Parking Brake Not Releasing (Dragging)
Inspect parking brake lever Is the fault confirmed Inspect parking brake lever travel Is the fault confirmed Inspect parking brake cables Is the fault confirmed Inspect rear brake shoes Is the fault confirmed Inspect rear brake return springs M201 2014.01...
Page 288 3. Inspect parking brake cables A. Inspect the parking brake cables for damage or sticking. Is it normal? Go to step 4. Repair or replace the parking brake cables. Refer to: Parking Brake Cable (2.3.4 Parking Brake and Operation, Removal and Installation). M201 2014.01...
Page 289 Refer to: Brake Shoe (2.3.2 Rear Drum Brake, Removal Installation). 5. Inspect rear brake return springs A. Inspect if the rear drum brake return springs are normal. Is it normal? The maintenance is finished. Inspect and repair the rear drum brake. M201 2014.01...
Page 290: Diagnosis Procedure For Parking Brake Indicator Constant On
Inspect parking brake warning lamp switch Is the fault confirmed Is the fault confirmed Inspect wiring harness between instrument cluster and parking Inspect wiring harness between brake warning lamp switch instrument cluster and brake fluid level switch M201 2014.01...
Page 291 S18. B. Inspect if the parking brake indicator turns off. Is it normal? Replace the parking brake warning lamp switch. Refer to: Parking Brake Warning Lamp Switch (2.3.4 Parking Brake and Operation, Removal Installation). Go to step 5. M201 2014.01...
Page 292 Refer to: Instrument Cluster (4.2.2 Instrument Cluster, Removal and Installation). M2304005 Inspect and repair the open circuit fault between terminal 1 of parking brake warning lamp wiring harness connector S18 and terminal 27 of instrument cluster wiring harness connector P21. M201 2014.01...
Page 293: Removal And Installation
Torque: 5 Nm M2304006 4. Remove 2 retaining bolts from the parking brake lever. Torque: 20 ± 2 Nm M2304007 5. Remove the parking brake control cable. 6. Disconnect parking brake warning indicator switch wiring harness connector. M2304008 M201 2014.01...
Page 294 Parking Brake and Operation 2.3.4-18 7. Remove the parking brake lever. M2304009 Installation 1. Installation is in the reverse order of removal. 2. Adjust the parking brake cable. Refer to: Parking Brake Cable Adjustment (2.3.4 Parking Brake Operation, General Inspection). M201 2014.01...
Page 295: Parking Brake Cable
Instrument Panel and Console). 2. Release the parking brake lever. M2304002 3. Loosen the tightening nut (1) and adjusting nut (2) and remove the unidirectional clip (3) from the front part of parking brake cable. Torque: 5 Nm M2304010 M201 2014.01...
Page 296 Brake, Removal and Installation). 6. Remove the left brake cable. 1 Remove the seal sleeve (1) from the left parking brake cable. 2 Remove the retaining nut (2) from the left parking brake cable. Torque: 20 Nm M2304013 M201 2014.01...
Page 297 Torque: 9 Nm M2304015 5 Remove the retaining bolt at the rear of left brake cable. Torque: 9 Nm M2304016 6 Remove the retaining bolt between left parking brake cable and brake baseplate. Torque: 9 Nm M2203003 M201 2014.01...
Page 298: Parking Brake And Operation
1. Installation is in the reverse order of removal. CAUTION: Apply the sealant to the lip of brake cables during installation. M2304017 2. Adjust the parking brake cable. Refer to: Parking Brake Cable Adjustment (2.3.4 Parking Brake Operation, General Inspection). M201 2014.01...
Page 299: Parking Brake Warning Lamp Switch
2. Pull the parking brake lever to the maximum position. M2304018 3. Remove the parking brake warning lamp switch. 1 Use a suitable tool to remove 2 rivets from the switch. M2304019 2 Remove the parking brake warning lamp switch, and disconnect the wiring harness connector. M201 2014.01...
Page 300 Installation 1. Use a suitable tool to install the parking brake warning lamp switch, and connect the wiring harness connector. General tool: Rivet gun M2304020 2. Install the console. Refer to: Instrument Panel (5.1.6 Instrument Panel and Console). M201 2014.01...
Page 301: Hydraulic Brake Control
Retaining bolt of spring connected to load 25 ± 5 sensing proportioning valve and rear axle Load sensing proportioning valve brake line Load sensing proportioning valve 25 ± 5 retaining bolt 6-way joint line 6-way joint retaining bolt Pedal assembly M201 2014.01...
Page 302: Description And Operation
Hydraulic pressure is evenly acting on the piston and caliper cylinder bottom to make the piston move outward, and then the caliper moves inward M201 2014.01...
Page 303 Brake Fluid Low Level Warning Indicator maintenance pack. Lubricate parts and The instrument cluster turns on the brake components accordingly. fluid low level warning indicator when it has detected that brake fluid level is over low (the signal circuit is at low potential). M201 2014.01...
Page 304: Removal And Installation
3 Depress the brake pedal repeatedly until all brake fluid is drained from the brake fluid reservoir. 4 Tighten the bleeding nozzle. M2305002 5 Install the reservoir cap. CAUTION: Repeat the drain procedure for both sides to drain the brake fluid in the reservoir. M201 2014.01...
Page 305 1. Installation is in the reverse order of removal. 2. Bleed the brake system. Refer to: Brake System Bleeding (2.3.1 Brake System Overview, General Inspection). CAUTION: If brake fluid is splashed on the paintwork, wash affected area immediately with clear water. M201 2014.01...
Page 306: Brake Master Cylinder
3. Remove the brake fluid reservoir. Refer to: Brake Fluid Reservoir (2.3.5 Hydraulic Brake System, Removal and Installation). 4. Remove the brake pipe from the brake master cylinder. Torque: 16 Nm M2305004 M201 2014.01...
Page 307 CAUTION: If brake fluid is splashed on the paintwork, wash affected area immediately with clear water. CAUTION: Make sure that the brake booster pushrod is correctly positioned before installation. CAUTION: Make sure that the brake master cylinder vacuum sealing correctly positioned. M201 2014.01...
Page 308: Load Sensing Proportioning Valve
CAUTION: Repeat the draining procedure on the opposite side to drain the brake fluid in the reservoir. 3. Remove the retaining bolt from the spring connected to load sensing proportioning valve and rear axle. Torque: 25 ± 5 Nm M2305006 M201 2014.01...
Page 309 1. Installation is in the reverse order of removal. 2. Bleed the brake system. Refer to: Brake System Bleeding (2.3.1 Brake System Overview, General Inspection). CAUTION: If brake fluid is splashed on the paintwork, wash affected area immediately with clear water. M201 2014.01...
Page 310: 6-Way Joint
1. Installation is in the reverse order of removal. 2. Bleed the brake system. Refer to: Brake System Bleeding (2.3.1 Brake System Overview, General Inspection). CAUTION: If brake fluid is splashed on the paintwork, wash affected area immediately with clear water. M201 2014.01...
Page 311: Pedal Assembly
Refer to: Battery (3.1.10 Charging System, Removal and Installation). 2. Remove the brake lamp switch wiring harness connector. M2305010 3. Remove the clutch cable. M2305011 4. Remove the spring pin (1) and remove the brake booster pushrod pin (2). M2305012 M201 2014.01...
Page 312: Hydraulic Brake Control
Torque: 25 ± 5 Nm ×4 M2305013 6. Remove 2 retaining nuts between pedal assembly and body. Torque: 25 ± 5 Nm M2305014 7. Remove the pedal assembly. Installation 1. Installation is in the reverse order of removal. M201 2014.01...
Page 313: Power Brake
2.3.6-1 Power Brake 2.3.6-1 Specifications 2.3.6 Power Brake Torque Specifications Item lb-ft lb-in Brake master cylinder Retaining nut between booster and 25 ± 5 pedal assembly M201 2014.01...
Page 314: Description And Operation
Vacuum booster uses the vacuum source to assist power so as to reduce the pedal effort by the driver during applying the brake. Components Location View M2306001 Item Description Item Description Brake booster Brake master cylinder M201 2014.01...
Page 315: Removal And Installation
CAUTION: The reservoir cap must be clean. 3. Remove the brake fluid reservoir. Refer to: Brake Fluid Reservoir (2.3.5 Hydraulic Brake System, Removal and Installation). 4. Remove the brake master cylinder. Refer to: Brake Master Cylinder (2.3.5 Hydraulic Brake System, Removal and Installation). M201 2014.01...
Page 316 1. Installation is in the reverse order of removal. 2. Bleed the brake system. Refer to: Brake System Bleeding (2.3.1 Brake System Overview, General Inspection). CAUTION: If brake fluid is splashed on the paintwork, wash affected area immediately with clear water. M201 2014.01...
Page 317 Removal and Installation........................2.4.2-4 Tie Rod Ball Joint........................2.4.2-4 Steering Gear Dust Boot......................2.4.2-6 Steering Gear ........................... 2.4.2-7 2.4.3 Steering Column Specifications ........................... 2.4.3-1 Torque Specifications........................ 2.4.3-1 Description and Operation ....................... 2.4.3-2 System Overview........................2.4.3-2 Symptom Diagnosis and Testing...................... 2.4.3-4 M201 2014.01...
Page 318 Steering System Removal and Installation ........................2.4.3-5 Steering Wheel .........................2.4.3-5 Steering Column ........................2.4.3-6 Steering Wheel Anti-theft Lock (Ignition Switch) ...............2.4.3-8 M201 2014.01...
Page 319: Steering System - Overview
2.4.1-1 Steering System - Overview 2.4.1-1 Specifications 2.4.1 Steering System - Overview General Specifications Item Specifications Minimum turning diameter 11 m or less M201 2014.01...
Page 320: Description And Operation
It mainly consists of traditional mechanical steering column, torque sensor, electronic control module and steering power motor. M201 2014.01...
Page 321 2.4.1-3 Steering System - Overview 2.4.1-3 Without Electric Power Steering (EPS) System M2401001 M201 2014.01...
Page 322 2.4.1-4 Steering System - Overview 2.4.1-4 With Electric Power Steering (EPS) System M2401002 M201 2014.01...
Page 323: Components Description
• The steering column with Electric Power Steering (EPS) system adopts a steering power motor. The control module controls the steering power motor to provide power. Without Electric Power Steering (EPS) System A2401003 M201 2014.01...
Page 324 2.4.1-6 Steering System - Overview 2.4.1-6 With Electric Power Steering (EPS) System M2401004 M201 2014.01...
Page 325 Then this power would be transmitted to the steering knuckle and drive wheels via the steering tie rod. This type of steering gear features with simple structure, high drive efficiency, low cost, high rigidity and sound operation stability. M201 2014.01...
Page 326: Steering System - Overview
Without Electric Power Steering (EPS) System M2401005 Item Description Qty. Item Description Qty. Steering gear assembly Cotter pin (without EPS) Clamp Steering rod assembly (right) Steering retaining washer Hexagon flange bolt Steering rod assembly (left) Steering gear assembly fixing bracket M201 2014.01...
Page 327 With Electric Power Steering (EPS) System M2401006 Item Description Qty. Item Description Qty. Steering gear assembly (with Cotter pin EPS) Clamp Steering retaining Steering rod assembly (right) washer Bolt Steering rod assembly (left) Steering gear assembly fixing bracket M201 2014.01...
Page 328: General Inspection
Column, Removal Installation). • Whether the steering shaft joint is worn. 3. If the steering linkage is damaged, replace • Whether the steering pinion or rack is when necessary. worn or broken. • Whether any parts are loose. M201 2014.01...
Page 329: Symptom Diagnosis And Testing
Front strut and spring assembly 3. If an obvious cause has been found, solve the fault before proceeding to the next step. 4. If the concern is not visually evident, verify the symptom by referring to the symptom chart. M201 2014.01...
Page 330: Symptom Chart
Inspect and adjust the front wheel alignment. Refer to: Front Wheel Toe-in Inspection • Incorrect front wheel Adjustment (2.1.1 alignment Suspension System- Overview, General Inspection). • Stabilizer bar link ball joint • Replace the stabilizer bar link ball joint. loose M201 2014.01...
Page 331 Steering tie rod end worn or Refer to: Tie Rod Ball Joint (2.4.2 chug) not flexible. Steering Gear, Removal and Installation). • • Improper adjustment for rack Inspect and adjust the torque for rack and and pinion pinion. M201 2014.01...
Page 332 • Front wheel misalignment Adjustment (2.1.1 Suspension System- Overview, General Inspection). • • Improper adjustment for rack Inspect and adjust the torque for rack and and pinion pinion. • Tire charging pressure • Adjust the tire pressure. improper M201 2014.01...
Page 333 • • Improper adjustment for rack Inspect and adjust the torque for rack and and pinion pinion. • Repair or replace the steering column. Refer to: Steering Column (2.4.3 • Steering column stuck Steering Column, Removal and Installation). M201 2014.01...
Page 334: Diagnosis Procedure For Shaking Of Steering Wheel While Braking
Inspect wheel and tire Is the fault confirmed Inspect brake disc and brake pad Is the fault confirmed Inspect the wheel alignment Is the fault confirmed Inspect tie rod ball joint and front shaft swing arm ball joint M201 2014.01...
Page 335 Refer to: Front Wheel Toe-in Inspection Adjustment (2.1.1 Suspension System - Overview, General Inspection). Are the wheel alignment parameters normal? Go to step 4. Adjust the wheel alignment parameters. Refer to: Front Wheel Toe-in Inspection Adjustment (2.1.1 Suspension System - Overview, General Inspection). M201 2014.01...
Page 336 Gear, Removal and Installation). Replace tie rod ball joint. Refer to: Tie Ball Joint (2.4.2 Steering Gear, Removal and Installation). Replace front shaft swing arm ball joint. Refer to: Front Shaft Swing Assembly (2.1.2 Front Suspension, Removal Installation). M201 2014.01...
Page 337: Steering Gear
Steering tie rod ball joint retaining nut 30 ~ 55 22 ~ 41 Tie rod ball joint locking nut 30 ~ 55 22 ~ 41 Steering gear retaining bolt 50 ± 5 Wheel nut 100 ± 10 M201 2014.01...
Page 338: Description And Operation
Steering tie rod ball joint is connected to tie rod closely with a locking nut. M2402001 Item Description Item Description Steering knuckle Steering tie rod Tie rod ball joint retaining nut Tie rod ball joint locking nut Tie rod ball joint M201 2014.01...
Page 339: Steering Gear
2.4.2-3 Steering Gear 2.4.2-3 Symptom Diagnosis and Testing Refer to: Symptom Chart (2.4.1 Steering System - Overview, Symptom Diagnosis and Testing). M201 2014.01...
Page 340: Removal And Installation
Torque: 30 ~ 55 Nm M2402003 4. Use the ball joint puller to remove the tie rod ball joint. CAUTION: When the tie rod ball joint is separated from the steering knuckle, pay attention to protect the oil seal. M2402004 M201 2014.01...
Page 341 M2402005 CAUTION: Inspect and adjust toe-in when necessary, make four-wheel alignment. Installation 1. Installation is in the reverse order of removal. CAUTION: Inspect and adjust toe-in when necessary, make four-wheel alignment. M201 2014.01...
Page 342: Steering Gear Dust Boot
3. Remove the steering gear dust boot. 1 Remove the metal wire and clamp from the steering gear dust boot. 2 Remove the dust boot from the steering tie rod. M2402006 Installation 1. Installation is in the reverse order of removal. M201 2014.01...
Page 343 Torque: 32 ~ 38 Nm M2402007 5. Remove 4 retaining bolts from the steering gearbox, and remove the steering gear assembly. Torque: 50 ± 5 Nm M2402008 Installation 1. Installation is in the reverse order of removal. M201 2014.01...
Page 345: Steering Column
Steering wheel retaining nut 25 ~ 40 18 ~ 30 Connecting bolt and nut between steering 21 ~ 27 15 ~ 20 upper shaft and steering support Connecting bolt between steering upper 32 ~ 38 24 ~ 28 and lower shafts M201 2014.01...
Page 346: Description And Operation
Without Electric Power Steering (EPS) System M2403001 Item Description Item Description Steering upper shaft Hexagonal nut with serrated assembly flange Steering lower shaft Hexagon bolt and washer assembly Hexagonal nut with serrated Steering shaft dust boot flange assembly Hexagon flange bolt M201 2014.01...
Page 347 Item Description Item Description Steering upper shaft with Hexagonal nut with serrated power steering motor flange assembly Steering lower shaft Hexagon bolt and washer assembly Hexagonal nut with serrated Steering shaft dust boot flange assembly Hexagon flange bolt M201 2014.01...
Page 348: Steering Column
2.4.3-4 Steering Column 2.4.3-4 Symptom Diagnosis and Testing Refer to: Symptom Chart (2.4.1 Steering System - Overview, Symptom Diagnosis and Testing). M201 2014.01...
Page 349: Removal And Installation
CAUTION: Inspect if there is enough lubricant on the metal conductive ring of steering wheel bottom before installation. CAUTION: First make the steering wheel and wheels in straight-running state before tightening the steering wheel retaining according specified torque. M201 2014.01...
Page 350 Removal Installation). 3. Remove the steering lock case upper cover (1) and lower cover (2). M2403006 4. Disconnect the wiring harness connectors from the combination switches and ignition switch. M2403007 5. Remove 2 screws and the combination switches. M201 2014.01...
Page 351 After all bolts are ready, tighten them according to specified torque. CAUTION: Ensure the spline is meshed properly when installing the steering gear and connecting the steering column. CAUTION: Inspect and adjust toe-in when necessary, make four-wheel alignment. M201 2014.01...
Page 352: Steering Wheel Anti-Theft Lock (Ignition Switch)
M2403010 4. Turn the ignition key to "ACC" or "ON", and remove the steering wheel anti-theft lock assembly from the steering column. Installation 1. Installation is in the reverse order of removal. M201 2014.01...
Page 353 3.1.11 Emission Control System ....................3.1.11-1 3.1.12 Electronic Control System - M7 ..................3.1.12-1 3.2 Manual Transmission/Clutch 3.2.1 Manual Transmission/Clutch - Overview................3.2.1-1 3.2.2 Clutch..........................3.2.2-1 3.2.3 Manual Transmission ......................3.2.3-1 3.2.4 Manual Transmission External Control ................3.2.4-1 M201 2014.01...
Page 355 Diagnosis Procedure for Piston and Piston Pin Noise............3.1.2-56 Diagnosis Procedure for Valve Train Noise ................3.1.2-61 Diagnosis Procedure for Engine not Start - Crankshaft not Turn..........3.1.2-67 Removal and Installation........................ 3.1.2-70 Accessory Drive Belt ......................3.1.2-70 Engine Assembly........................3.1.2-73 M201 2014.01...
Page 356 Diagnosis Procedure for Oil Pressure Warning Lamp Not ON ..........3.1.3-14 Diagnosis Procedure for Abnormal Oil Consumption .............3.1.3-16 Removal and Installation ........................3.1.3-18 Oil Pan Lower Part and Oil Strainer..................3.1.3-18 Oil Pan Upper Part........................3.1.3-22 Oil Pump ..........................3.1.3-27 Oil Pan Baffle Plate.........................3.1.3-33 M201 2014.01...
Page 357 Floor Water Pipe........................3.1.4-39 Water Reservoir........................3.1.4-41 3.1.5 Air Intake System Specifications ........................... 3.1.5-1 General Specifications......................3.1.5-1 Torque Specifications........................ 3.1.5-1 Description and Operation ....................... 3.1.5-2 System Overview........................3.1.5-2 Components Description ......................3.1.5-2 Components Exploded View..................... 3.1.5-3 General Inspection........................... 3.1.5-4 M201 2014.01...
Page 358 Diagnosis Procedure for Exhaust System Blockage ..............3.1.6-9 Removal and Installation ........................ 3.1.6-11 Exhaust Manifold ........................3.1.6-11 Three-way Catalytic Converter ....................3.1.6-14 Muffler .............................3.1.6-16 3.1.7 Fuel System Specifications ...........................3.1.7-1 Component Specifications ......................3.1.7-1 General Specifications ......................3.1.7-1 Torque Specifications........................3.1.7-1 Description and Operation........................3.1.7-2 System Overview ........................3.1.7-2 Components Description......................3.1.7-2 M201 2014.01...
Page 359 Inspection and Verification......................3.1.8-5 Symptom Chart......................... 3.1.8-6 Diagnosis Procedure for Spark Plug does not Flash Over ............3.1.8-8 Diagnosis Procedure for Insufficient Engine Power ............... 3.1.8-13 Removal and Installation........................ 3.1.8-17 Ignition Coil..........................3.1.8-17 Spark Plug ..........................3.1.8-18 Ignition Switch ........................3.1.8-19 M201 2014.01...
Page 360 Specifications ..........................3.1.10-1 Component Specifications ......................3.1.10-1 Torque Specifications......................3.1.10-1 Description and Operation......................3.1.10-2 System Overview ........................3.1.10-2 Components Description......................3.1.10-2 Components Location View ....................3.1.10-4 Components Exploded View....................3.1.10-5 General Inspection .........................3.1.10-7 Battery Inspection ........................3.1.10-7 Battery Charging ........................3.1.10-7 Battery Parasitic Current Test ....................3.1.10-8 Alternator Test.........................3.1.10-8 M201 2014.01...
Page 361 Removal and Installation........................ 3.1.11-8 PCV Valve ..........................3.1.11-8 Carbon Canister Control Valve ....................3.1.11-9 Active Carbon Canister......................3.1.11-10 Front Oxygen Sensor ......................3.1.11-11 Rear Oxygen Sensor ......................3.1.11-12 3.1.12 Electronic Control System - M7 Specifications ..........................3.1.12-1 Torque Specifications......................3.1.12-1 M201 2014.01...
Page 362 Failure Protection List ......................3.1.12-77 Data Flow List ........................3.1.12-81 Active Test List........................3.1.12-83 DTC Diagnosis Procedure Index ..................3.1.12-84 DTCs P0030, P0031, P0032, P0053 ..................3.1.12-88 DTCs P0036, P0037, P0038, P0054 ..................3.1.12-94 DTCs P0105, P0106, P0107, P0108 ..................3.1.12-100 DTCs P0112, P0113 ......................3.1.12-108 M201 2014.01...
Page 363 Crankshaft Position Sensor ....................3.1.12-216 Throttle Position Sensor ..................... 3.1.12-217 Idling Stepper Motor ......................3.1.12-218 Coolant Temperature Sensor....................3.1.12-219 Air Intake Pressure/Temperature Sensor ................3.1.12-220 Fuel Injector........................3.1.12-221 Front Oxygen Sensor ......................3.1.12-223 Rear Oxygen Sensor ......................3.1.12-224 Knock Sensor ........................3.1.12-225 M201 2014.01...
Page 365: Engine System - Overview
4. Engine pistons adopt the advanced high temperature aluminum alloy material to make pistons lighter and engine running easier, reducing unnecessary loss, which beneficial to power improvement and fuel M201 2014.01...
Page 367: Mechanical System
5 Installation surface of crankshaft rear end cover and lower surface of crankcase Spark plug guide surface (matching Loctite 962 or Tonsan 1662 surface with cylinder head assembly) Loctite 516 Oil pressure alarm assembly M201 2014.01...
Page 368: Component Specifications
0.045 ~ 0.072 Intake 1.1 ~ 1.3 Valve seat width Valve (after repairs) Exhaust 1.0 ~ 1.4 Intake 3 ~ 3.3 Valve head thickness Exhaust 2.3 ~ 2.7 Intake Min: 1.1 mm, Valve imprint Unevenness: standard width Exhaust 0.4 mm M201 2014.01...
Page 369 Clearance between connecting rod small end 0.003 ~ 0.016 hole and piston pin Side clearance for connecting rod large end 0.10 ~ 0.25 Bending limit 0.05/80 Connecting rod Twisting limit 0.10/80 Connecting rod small end hole diameter 18.003 ~ 18.011 M201 2014.01...
Page 370 49.0121 ~ 49.018 2.005 ~ 2.009 2.002 ~ 2.006 Main bearing 1.999 ~ 2.003 thickness 1.996 ~ 2.000 1.993 ~ 1.997 Flywheel end face runout limit Flatness (standard) 0.05 0.10 Cylinder block Diameter 73.025 or less M201 2014.01...
Page 371: General Specifications
35 Nm + 45° Sensor plate retaining screw 11 ± 1 Crankshaft rear end cover retaining bolt 10 ± 1 Engine trim cover retaining bolt 10 ± 1 Alternator charging cable bolt Compressor connecting bolt 25 ~ 30 M201 2014.01...
Page 372 32 ± 2 Camshaft bearing cap bolt 13 ± 1 Engine bracket retaining bolt 55 ± 10 Connecting bolt between exhaust manifold and 55 ± 5 three-way catalytic converter Rear wind guiding cover bracket retaining bolt Unmarked bolt M201 2014.01...
Page 373: Engine Oil Application Component And Area Chart
As camshaft bearing cap bolt, timing chain slide rail bolt, high rail bolt, high pressure pressure oil plug and clutch pressure plate retaining bolt have Other oil plug, clutch been phosphate coated, if the surface is oilless, apply the pressure plate gasoline engine oil before assembly retaining bolt M201 2014.01...
Page 374: Description And Operation
3.1.2-8 Mechanical System 3.1.2-8 Description and Operation Components Exploded View Timing System and Front Wheel Train M3102001 M201 2014.01...
Page 375 Hexagon flange bolt Water pump pulley Crankshaft timing Hexagon flange bolt sprocket Hydraulic tensioning Alternator belt adjuster assembly Crankshaft pulley Chain slide rail assembly assembly Timing chain guide rail Crankshaft pulley bolt bolt with A/C Elastic belt without M201 2014.01...
Page 376 3.1.2-10 Mechanical System 3.1.2-10 Cylinder Head M3102002 M201 2014.01...
Page 377: Mechanical System
No.3 - No.5 camshaft Camshaft bearing cap bearing cap bolt Cylinder head connecting High pressure oil plug bolt (with washer) No.1 camshaft bearing Bolt No.2 wiring harness No.2 camshaft bearing bracket Bolt Oil filler cap assembly Bolt Intake manifold stud bolt M201 2014.01...
Page 378 3.1.2-12 Valve Mechanism M3102003 Item Description Qty. Item Description Qty. Intake camshaft Valve spring assembly Valve spring lower Valve tappet retainer Exhaust camshaft Valve oil seal assembly assembly Valve spring upper Exhaust valve retainer Taper cotter Intake valve M201 2014.01...
Page 379 3.1.2-13 Mechanical System 3.1.2-13 Crankcase M3102004 M201 2014.01...
Page 380 Crankshaft thrust plate No.1 wiring harness Timing chain nozzle bracket Rear end main bearing Upper main bearing shell No.4 main bearing cap Cylinder head dowel pin No.3 main bearing cap Cylinder head dowel pin No.2 main bearing cap M201 2014.01...
Page 381 Crankshaft speed sensor plate Pressure plate dowel pin Woodruff key Flywheel bolt Connecting rod dowel pin Flywheel gear ring assembly Connecting rod shank Crankshaft Piston pin circlip Connecting rod bearing shell Piston Connecting rod bearing cap Oil control ring M201 2014.01...
Page 382 3.1.2-16 Mechanical System 3.1.2-16 Oil Pump Timing Chain Housing Assembly and Oil Pan Assembly M3102006 M201 2014.01...
Page 383 Hexagon flange bolt Oil pan lower part assembly Hexagon flange nut Oil pan upper and lower parts Oil level gauge assembly connecting stud bolt Hexagon flange nut Hexagon flange bolt Drain plug Oil pump chain cover stud bolt M201 2014.01...
Page 384: General Inspection
3. Remove the fuel pump relay. the highest pressure value and record it. 4. Disconnect the wiring harness connectors CAUTION: To measure the compression between the injectors and ignition coils. pressure, it is necessary to use the fully- M201 2014.01...
Page 385: Accessory Drive Belt Inspection
1 Inspect the belt tension with sonic tension 2 cylinders arranged on the cylinder block meter (sonic tension meter should be "in parallel" are too low. positioned at the center of belt tight side M201 2014.01...
Page 386: Accessory Drive Belt Tension Adjustment
4 Tighten the compressor adjusting bracket bolt (1) in steps. 2 The generator belt tension should be 750 ± 50 N (before the engine is starting). 5 Tighten 2 compressor connecting bolts. 6 Inspect if the compressor belt tension reaches the specified value. M201 2014.01...
Page 387: Valve Clearance Inspection And Adjustment
Valve clearance adjusting set Feeler gauge 1. Disconnect the battery negative cable. 2. Remove the cylinder head cover. 3. Rotate the crankshaft clockwise and measure the clearance between cam base circle and tappet working surface with a feeler gauge. M201 2014.01...
Page 388 4 Finally replace more appropriate tappet according to the specified valve clearance in the Valve Clearance Standard Table and the measured clearance above, for example, if selecting the 3.40 in the group 17, the valve clearance is just 20. M201 2014.01...
Page 389: Symptom Diagnosis And Testing
• Deformed or damaged oil strainer in Lower Part of • Low engine oil pressure Engine (3.1.2 Abnormal noise in lower part of • Excessive matching clearance engine Mechanical between crankshaft and bearing System, Symptom • Excessive crankshaft thrust Diagnosis and clearance Testing). M201 2014.01...
Page 390 Chamber (3.1.2 • Coolant enters combustion Abnormal exhaust (white smoke) Mechanical chamber System, Symptom Chart). Refer to: Diagnosis Procedure for Abnormal Exhaust (Blue Smoke) (3.1.2 Abnormal exhaust (blue smoke) • Engine oil burning Mechanical System, Symptom Diagnosis and Testing). M201 2014.01...
Page 391 • Excessive clearance between Refer to: Piston, Piston increases piston and cylinder wall Ring, Connecting Rod • Alignment of connecting rod (end and Cylinder gap, bend, distortion) (3.1.2 Mechanical System, • Excessive piston pin clearance Disassembly and Assembly). M201 2014.01...
Page 392 Mechanical System, Disassembly and Assembly). • Alignment of connecting rod (end Refer to: Piston, Piston gap, bend, distortion) Ring, Connecting Rod and Cylinder (3.1.2 Mechanical • Excessive piston pin clearance System, Disassembly and Assembly). M201 2014.01...
Page 393 Noise from connecting rod and rod Mechanical • Connecting rod distortion / bend bearing beyonds limit System, Symptom • Connecting rod journal out-of- Diagnosis and round and taper beyond limit Testing). • Connecting rod bearing clearance beyonds limit M201 2014.01...
Page 394 • Seized or cracked valve system Mechanical Engine cannot start - crankshaft components System, cannot turn Symptom • Foreign matters in the cylinder(s) Diagnosis and • Seized crankshaft or connecting Testing). rod bearing • Bent or cracked connecting rod • Cracked crankshaft M201 2014.01...
Page 395 Refer to: Cylinder Head Subassembly • Warped cylinder head and Valve (3.1.2 Mechanical System, Disassembly and Assembly). • Replace cylinder head and gasket. Refer to: Cylinder Head Subassembly • Cracked cylinder head and Valve (3.1.2 Mechanical System, Disassembly and Assembly). M201 2014.01...
Page 396 Refer to: Cylinder Head Subassembly and Valve (3.1.2 • Cylinder head sealing fault Mechanical System, Disassembly and Assembly). • Replace cylinder head and gasket. Refer to: Cylinder Head Subassembly • Warped cylinder head and Valve (3.1.2 Mechanical System, Disassembly and Assembly). M201 2014.01...
Page 397 Valve (3.1.2 Mechanical block System, Disassembly and Assembly). • Replace cylinder head or cylinder block. Refer to: Cylinder Head Subassembly • Pore on the cylinder head or and Valve (3.1.2 cylinder block Mechanical System, Disassembly and Assembly). M201 2014.01...
Page 398: Diagnosis Procedure For Abnormal Noise In Lower Part Of Engine
Inspect oil pan Is the fault confirmed Inspect oil strainer Is the fault confirmed Inspect engine oil pressure Is the fault confirmed Inspect oil pump Is the fault confirmed Inspect bearing shell matching surface clearance and crankshaft thrust clearance M201 2014.01...
Page 399 Go to step 4. 4. Inspect engine oil pressure A. Inspect the engine oil pressure. Refer to: Engine Oil Pressure Inspection (3.1.3 Lubrication System, General Inspection). Is the pressure too low? Go to step 5. Go to step 6. M201 2014.01...
Page 400 Adjust the matching clearance of engine main bearing shell and connecting rod bearing shell as well as the crankshaft thrust clearance to normal values. Refer to: Main Bearing, Crankshaft and Cylinder Block (3.1.2 Mechanical System, Disassembly and Assembly). M201 2014.01...
Page 401: Diagnosis Procedure For Drive Belt Noise
Inspect accessory drive belt Is the fault confirmed Inspect related fasteners Is the fault confirmed Inspect crankshaft pulley and related accessory pulley Is the fault confirmed Inspect alternator, water pump, A/C compressor pulley and bearing one by one M201 2014.01...
Page 402 B. Abnormal scratches, edges and corners are not allowed on the pulley surface. C. Foreign matters are not allowed in the pulley groove. D. Does it conform to above requirements? Go to step 4. Clear, tighten or replace. M201 2014.01...
Page 403 4. Inspect alternator, water pump, A/C compressor pulley and bearing one by one A. Distortion or deformation is not allowed for pulley, and seizure or looseness is not allowed for bearing. B. Abnormal noise is not allowed when rotating the bearing. Does it conform to above requirements? Tighten or replace. M201 2014.01...
Page 404: Diagnosis Procedure For Engine Backfire
Inspect intake system vacuum degree Inspect fuel pressure Is the fault confirmed Inspect fuel injector Is the fault confirmed Test spark plug Is the fault confirmed Inspect cylinder pressure Inspect exhaust system Is the fault confirmed Replace engine control module M201 2014.01...
Page 405 A. Inspect the fuel pressure. Refer to: Fuel System Pressure Test (3.1.7 Fuel System, General Inspection). Is the pressure too low? Take the symptom actions. Refer to: Symptom Chart (3.1.7 Fuel System, Symptom Diagnosis and testing). Go to step 4. M201 2014.01...
Page 406 Refer to: Exhaust Backpressure Test (3.1.6 Exhaust System, General Inspection). Is it blocked? Carry out the diagnosis procedure for exhaust system blockage. Refer to: Diagnosis Procedure Exhaust System Blockage (3.1.6 Exhaust System, Symptom Diagnosis and Testing). Go to step 8. M201 2014.01...
Page 407 3.1.2-41 Mechanical System 3.1.2-41 Test Conditions Details/Results/Actions 8. Replace engine control module A. Replace the engine control module. Refer to: Engine Control Module (3.1.12 Electronic Control System - M7, Removal and Installation). Make sure the system is normal. M201 2014.01...
Page 408: Diagnosis Procedure For Engine Knock
Is the fault confirmed Inspect fuel pressure Is the fault confirmed Inspect fuel injector Is the fault confirmed Test spark plug Is the fault confirmed Inspect cylinder pressure Inspect exhaust system Is the fault confirmed Replace engine control module M201 2014.01...
Page 409 Go to step 4. 4. Test spark plug A. Carry out the spark plug test. Refer to: Ignition Spark Test (3.1.8 Ignition System, General Inspection). Is it within the standard range? Clear or replace. Go to step 5. M201 2014.01...
Page 410 Diagnosis and Testing). Go to step 7. 7. Replace engine control module A. Replace the engine control module. Refer to: Engine Control Module (3.1.12 Electronic Control System - M7, Removal and Installation). Make sure the system is normal. M201 2014.01...
Page 411: Diagnosis Procedure For Abnormal Exhaust (Blue Smoke)
Inspect PCV valve Is the fault confirmed Inspect cylinder compression pressure Is the fault confirmed Inspect piston ring or valve fault Is the fault confirmed Inspect carbon deposit in combustion chamber Is the fault confirmed Inspect valve oil seal M201 2014.01...
Page 412 Replace the PCV valve. Go to step 4. 4. Inspect cylinder compression pressure A. Carry out the cylinder compression pressure inspection. Refer to: Cylinder Compression Pressure Inspection (3.1.2 Mechanical System, General Inspection). Go to step 5. Go to step 6. M201 2014.01...
Page 413 Clean. Go to step 7. 7. Inspect valve oil seal A. Inspect the valve oil seal. Are there any leaks? Replace. Refer to: Cylinder Head Subassembly and Valve (3.1.2 Mechanical System, Disassembly and Assembly). The system is normal. M201 2014.01...
Page 414: Diagnosis Procedure For Abnormal Exhaust (Black Smoke)
Diagnosis Procedure for Abnormal Exhaust (Black Smoke) Abnormal exhaust (black smoke) Inspect engine DTCs Is the fault confirmed Inspect fuel pressure Is the fault confirmed Inspect fuel injector Is the fault confirmed Test spark plug Is the fault confirmed Replace engine control module M201 2014.01...
Page 415 A. Inspect the fuel injector. Are there any leaks? Replace. Go to step 4. 4. Test spark plug A. Carry out the spark plug test. Refer to: Ignition Spark Test (3.1.8 Ignition System, General Inspection). Clear or replace. Go to step 5. M201 2014.01...
Page 416 3.1.2-50 Mechanical System 3.1.2-50 Test Conditions Details/Results/Actions 5. Replace engine control module A. Replace the engine control module. Refer to: Engine Control Module (3.1.12 Electronic Control System - M7, Removal and Installation). Make sure the system is normal. M201 2014.01...
Page 417: Diagnosis Procedure For Noise From Connecting Rod And Rod Bearing
Inspect tightening torque of connecting rod bolts Is the fault confirmed Inspect connecting rod for distortion/bending Is the fault confirmed Inspect connecting rod journal out-of-round and taper Is the fault confirmed Inspect clearance between connecting rod and crank M201 2014.01...
Page 418 A. Inspect the engine oil pump pressure. Refer to: Engine Oil Pressure Inspection (3.1.3 Lubrication System, General Inspection). Is oil pump pressure too low? Repair. Refer to: Symptom Chart (3.1.3 Lubrication System, Symptom Diagnosis and testing). Go to step 4. M201 2014.01...
Page 419 A. Inspect the tightening torque of connecting rod bolts. Refer to: Piston, Piston Ring, Connecting Cylinder (3.1.2 Mechanical System, Disassembly and Assembly). Is it within the specification? Record the torques, and replace the bolts and nuts. Go to step 6. M201 2014.01...
Page 420 A. Inspect the connecting rod journal out-of-round and taper. Refer to: Main Bearing, Crankshaft and Cylinder Block (3.1.2 Mechanical System, Disassembly Assembly). Repair or replace crankshaft. Refer to: Main Bearing, Crankshaft and Cylinder Block (3.1.2 Mechanical System, Disassembly Assembly). Go to step 8. M201 2014.01...
Page 421 Refer to: Piston, Piston Ring, Connecting Cylinder (3.1.2 Mechanical System, Disassembly and Assembly). Is it within the specification? Repair it to the specification. Refer to: Piston, Piston Ring, Connecting Cylinder (3.1.2 Mechanical System, Disassembly and Assembly). The system is normal. M201 2014.01...
Page 422: Diagnosis Procedure For Piston And Piston Pin Noise
Inspect installation of connecting rod and piston Is the fault confirmed Inspect connecting rod for distortion/bending Inspect piston pin clearance Is the fault confirmed Inspect piston ring groove clearance Is the fault confirmed Inspect clearance between piston and cylinder wall M201 2014.01...
Page 423 A. Inspect the engine oil pump pressure. Refer to: Engine Oil Pressure Inspection (3.1.3 Lubrication System, General Inspection). Is oil pump pressure too low? Repair it. Refer to: Symptom Chart (3.1.3 Lubrication System, Symptom Diagnosis and testing). Go to step 4. M201 2014.01...
Page 424 Refer to: Piston, Piston Ring, Connecting Cylinder (3.1.2 Mechanical System, Disassembly and Assembly). Is it within the specification? Replace the connecting rod. Refer to: Piston, Piston Ring, Connecting Cylinder (3.1.2 Mechanical System, Disassembly and Assembly). Go to step 6. M201 2014.01...
Page 425 Refer to: Piston, Piston Ring, Connecting Cylinder (3.1.2 Mechanical System, Disassembly and Assembly). Is it within the specification? Repair to the specification. Refer to: Piston, Piston Ring, Connecting Cylinder (3.1.2 Mechanical System, Disassembly and Assembly). Go to step 8. M201 2014.01...
Page 426 Refer to: Piston, Piston Ring, Connecting Cylinder (3.1.2 Mechanical System, Disassembly and Assembly). Is it within the specification? Repair to the specification. Refer to: Piston, Piston Ring, Connecting Cylinder (3.1.2 Mechanical System, Disassembly and Assembly). The system is normal. M201 2014.01...
Page 427: Diagnosis Procedure For Valve Train Noise
Inspect camshaft journal for wear Inspect camshaft journal clearance Is the fault confirmed Inspect valve spring Inspect valve Inspect valve guide Is the fault confirmed Inspect clearance between valve stem and valve guide Inspect valve seat for looseness M201 2014.01...
Page 428 Refer to: Valve Clearance Inspection and Adjustment (3.1.2 Mechanical System, General Inspection). Is it within the specification? Readjust to the specification. Refer to: Valve Clearance Inspection and Adjustment (3.1.2 Mechanical System, General Inspection). Go to step 3. M201 2014.01...
Page 429 5. Inspect camshaft journal runout limit A. Inspect the camshaft journal runout limit. Refer to: Camshaft (3.1.2 Mechanical System, Removal Installation). Is it within the specification? Repair. Refer to: Camshaft (3.1.2 Mechanical System, Removal Installation). Go to step 6. M201 2014.01...
Page 430 Refer to: Cylinder Head Subassembly and Valve (3.1.2 Mechanical System, Disassembly and Assembly). Is it within the specification? Replace the valve spring. Refer to: Cylinder Head Subassembly and Valve (3.1.2 Mechanical System, Disassembly and Assembly). Go to step 9. M201 2014.01...
Page 431 Refer to: Cylinder Head Subassembly and Valve (3.1.2 Mechanical System, Disassembly and Assembly). Is it within the specification? Repair. Refer to: Cylinder Head Subassembly and Valve (3.1.2 Mechanical System, Disassembly and Assembly). Go to step 11. M201 2014.01...
Page 432 A. Inspect if the valve seat is loose. Refer to: Cylinder Head Subassembly and Valve (3.1.2 Mechanical System, Disassembly and Assembly). Is it within the specification? Repair. Refer to: Cylinder Head Subassembly and Valve (3.1.2 Mechanical System, Disassembly and Assembly). The system is normal. M201 2014.01...
Page 433: Diagnosis Procedure For Engine Not Start - Crankshaft Not Turn
Engine not start - Crankshaft not turn Inspect accessory drive system components Is the fault confirmed Inspect if cylinder is seized due to hydraulic pressure Is the fault confirmed Inspect cylinder head assembly Is the fault confirmed Inspect cylinder block assembly M201 2014.01...
Page 434 Inspect the cylinder block, cylinder head and gasket for cracks. Repair if necessary. Refer to: Cylinder Head Subassembly and Valve (3.1.2 Mechanical System, Disassembly and Assembly). Refer to: Main Bearing, Crankshaft and Cylinder Block (3.1.2 Mechanical System, Disassembly Assembly). Go to step 3. M201 2014.01...
Page 435 Refer to: Main Bearing, Crankshaft and Cylinder Block (3.1.2 Mechanical System, Disassembly Assembly). • Cracked piston. • Foreign matters in the cylinder. • Cracked crankshaft. • Bent or cracked connecting rod. Do the conditions above exist? Repair or replace. The system is normal. M201 2014.01...
Page 436: Removal And Installation
3. Loosen the alternator upper retaining bolt (1), and then loosen the alternator adjusting bracket bolt (2) and (3) in sequence. M3110005 4. Turn the alternator belt to engine side until it can be separated easily, then remove the alternator belt. M3110007 M201 2014.01...
Page 437 3 Turn the water pump pulley to engine side until the compressor belt can be removed. M3104025 6. Remove the elastic belt. (Models without A/C) 1 Turn the water pump pulley to engine side until the compressor belt can be removed. M3104025 M201 2014.01...
Page 438 3.1.2-72 Mechanical System 3.1.2-72 Installation 1. Installation is in the reverse order of removal. CAUTION: Inspect the accessory drive belt tension. Refer to: Accessory Drive Belt Inspection (3.1.2 Mechanical System, General Inspection). M201 2014.01...
Page 439: Engine Assembly
Refer to: Battery (3.1.10 Charging System, Removal and Installation). 3. Disconnect engine wiring harness connector. M3102115 4. Disconnect the A/C compressor magnetic clutch wiring harness connector. M3102116 5. Disconnect the alternator wiring harness connector and remove the alternator charging cable bolt. M3110003 M201 2014.01...
Page 440 6. Disengage the alternator wiring harness retaining clamp. M3102117 7. Disengage 2 engine wiring harness retaining clamps. M3102118 8. Disconnect wiring harness connector. M3102119 9. Disconnect 2 engine wiring harness ground points. Torque: 10 ± 1 Nm M3102120 M201 2014.01...
Page 441 M3102122 13. Remove the throttle body. Refer to: Throttle Body (3.1.5 Air Intake System, Removal and Installation). 14. Recover the A/C refrigerant. Refer to: A/C Refrigerant Recycling and Filling (4.1.1 Heating, Ventilation and Air Conditioning, General Inspection). M201 2014.01...
Page 442 Refer to: Manual Transmission (3.2.3 Manual Transmission, Removal and Installation). 20. Support the engine assembly with the flat jack. WARNING: Make sure that the contact between jack worktable engine assembly is secure, or it may cause personal injury. M3102125 M201 2014.01...
Page 443 27. Remove 4 retaining bolts from rear wind guiding cover bracket. Torque: 25 Nm M3102126 28. Remove 2 connecting bolts between exhaust manifold and three-way catalytic converter. Torque: 55 ± 5 Nm M3106003 M201 2014.01...
Page 444 Be sure to adjust it to a proper position as specified, as excessive pedal free play may cause gear shifting noise disengagement failure insufficient free play may cause severe wear of friction disc, lack of power, and even burnout of friction disc. M201 2014.01...
Page 445: Flywheel
M3202006 3. Remove the clutch pressure plate and clutch driven disc assembly. Refer to: Clutch Pressure Plate Assembly, Clutch Driven Disc Assembly (3.2.2 Clutch, Removal Installation). 4. Remove 6 flywheel retaining bolts. Torque: 74 ± 2 Nm M3202013 M201 2014.01...
Page 446 M3202015 flywheel. CAUTION: Tighten the clutch pressure plate retaining bolts evenly in the diagonal order. Special Tool (A): 09924-17810 (C): 09923-36330 M201 2014.01...
Page 447 "A": Grease 99000-25210 CAUTION: While inserting transmission input shaft into the clutch driven disc assembly, use a wrench to turn the crankshaft from the front side until the splines are engaged. M3202016 M201 2014.01...
Page 448: Cylinder Head Cover
3. Remove the ignition coil. Refer to: Ignition Coil (3.1.8 Ignition System, Removal and Installation). 4. Remove the PCV valve. Refer to: PCV Valve (3.1.11 Emission Control System, Removal and Installation). 5. Loosen the hoop and disconnect the No.1 vent pipe. M3102095 M201 2014.01...
Page 449 M3103025 7. Remove the engine oil filler cap assembly. M3102096 8. Remove the cylinder head cover. 1 Remove 9 retaining bolts from the cylinder head cover. M3102097 2 Remove the gasket from the cylinder head cover. M3102098 M201 2014.01...
Page 450 Apply sealant (Tonsan 1596Fa) to the contact surface between cylinder head subassembly and oil pump timing chain housing assembly during installation. Install the cylinder head cover within 5 minutes after applying sealant to positions (1) and (2) as shown in the figure. M3102099 M201 2014.01...
Page 451: Camshaft
→ I4 → I/E1 → E3 → I3, then remove the I/EI camshaft bearing caps in sequence. M3102100 2 Carefully remove the intake and exhaust camshafts. CAUTION: Keep the camshaft assembly working surface clean and do not impact or scratch it. M201 2014.01...
Page 452 0.03 mm. 2 Radial runout limit for No.2, No.3 and No.4 journals: 0.015 mm. 3 Select a piece of plastic feeler gauge with M3102103 the same width as the camshaft journal and place it parallel to the camshaft. M201 2014.01...
Page 453 Removal Installation). CAUTION: Do not rotate the camshaft. 5 Remove the camshaft bearing caps and measure the clearance width (1) of feeler gauge (2) at its widest point. Standard Limit Clearance 0.045 ~ 0.087 mm 0.117 mm M3102104 M201 2014.01...
Page 454 Measure the camshaft journal outer diameter along the X-axis and Y-axis at sections A and B as shown in the figure. Item Standard M3102105 Cylinder head camshaft 27.000 ~ 27.021 mm bore diameter Camshaft journal outer 22.934 ~ 22.955 mm diameter M3102106 M201 2014.01...
Page 455 Torque: 13 ± 1 Nm CAUTION: After tightening the camshaft bearing cap bolts, rotate the camshaft and inspect if it becomes stuck. If so, inspect M3102100 for proper installation, then remove to inspect the matching surface and reinstall M201 2014.01...
Page 456 System, General Inspection). 6. Install the timing chain while aligning the timing marks. Refer to: Timing System (3.1.2 Mechanical System, Removal Installation). 7. Install the cylinder head cover. Refer to: Cylinder Head Cover (3.1.2 Mechanical System, Removal and Installation). M201 2014.01...
Page 457: Timing System
3 Loosen the hoop and disconnect the water pipe from the major cycletop radiator hose (2). 4 Disconnect the water pipe from the No.2 water outlet pipe (3). M3103026 5 Loosen the hoop and disconnect the water pipe from the A/C heater outlet pipe. M3103027 M201 2014.01...
Page 458 Torque: 10 ± 1 Nm M3104026 5. Remove the cylinder head cover. Refer to: Cylinder Head Cover (3.1.2 Mechanical System, Removal and Installation). 6. Remove the crankshaft pulley. M3103029 M201 2014.01...
Page 459 Replace the crankshaft front oil seal with new one when installing. M3103031 10. Remove the timing chain. 1 Remove 2 retaining bolts from the hydraulic tensioning adjuster. M3102107 2 Remove the timing chain slide rail assembly bolt. M3102108 M201 2014.01...
Page 460 3.1.2-94 Mechanical System 3.1.2-94 3 Remove 2 retaining bolts from the chain guide rail assembly. ×2 M3102109 4 Remove the timing chain. 5 Remove the crankshaft timing sprocket. M3102110 M201 2014.01...
Page 461 4th cylinder piston is at the top dead center as shown in the figure. Crankshaft woodruff key faces upward and aligns with the crankcase mark Timing mark point M3102129 M201 2014.01...
Page 462 3 Install 2 chain guide rail assembly retaining bolts. ×2 Torque: 10 ± 1 Nm M3102109 4 Install the chain slide rail assembly bolt. Torque: 23 ± 2 Nm M3102108 5 Inspect if the timing marks are aligned, and if not, align again. M201 2014.01...
Page 463 4. Install the oil pan upper part. Refer to: Oil Upper Part (3.1.3 Lubrication System, Removal and Installation). 5. Install the oil pan lower part. Refer to: Oil Pan Lower Part and Oil Strainer (3.1.3 Lubrication System, Removal Installation). M201 2014.01...
Page 464 8. Install the accessory drive belt. Refer to: Accessory Drive Belt (3.1.2 Mechanical System, Removal and Installation). 9. Install the water pipe. 10. Install the cylinder head cover. Refer to: Cylinder Head Cover (3.1.2 Mechanical System, Removal and Installation). M201 2014.01...
Page 465: Disassembly And Assembly
Cylinder Head Subassembly and Valve Special Tool 1. Valve opener 09916-14510 2. Valve opener holder 09916-14910 09916-14510 Valve oil seal plier CA301-012 CA301-012 Valve guide installer handle 09916-58210 09916-58210 Tweezer 09916-84511 09916-84511 Valve stem oil seal installer 09917-98221 09917-98221 M201 2014.01...
Page 466 3.1.2-100 Mechanical System 3.1.2-100 General Equipment Dial indicator Micrometer Plastic feeler gauge Straight scale Caliper gauge Vernier caliper Material Item Specifications Tonsan 1596Fa Sealant Tonsan 1591 M201 2014.01...
Page 467 7. Remove the oil pan upper part. Refer to: Oil Upper Part (3.1.3 Lubrication System, Removal and Installation). 8. Remove the timing chain. Refer to: Timing System (3.1.2 Mechanical System, Removal Installation). 9. Remove the camshaft. Refer to: Camshaft (3.1.2 Mechanical System, Removal Installation). M201 2014.01...
Page 468 3 Remove the cylinder head subassembly (1) and cylinder gasket assembly (2) from the cylinder block (3). M3102011 11. Use the magnetic finger to remove the tappets one by one, arrange them in order and do not mix them up. M201 2014.01...
Page 469 13. Use a tweezer (D) to remove the valve cotter (1). （D） Special tool: Tweezer 09916-84511 M3102013 14. Release the tool and then remove the valve spring upper retainer (1) and valve spring (2). M3102014 15. Remove the valve from the combustion chamber side. M3102015 M201 2014.01...
Page 470 Be sure to use a new (oversize) valve guide when assembling. CAUTION: Except for the valve oil seal and M3102017 valve guide, arrange removed components in order so that they can be reassembled to their original positions. M201 2014.01...
Page 471 B and C) along the X-axis and Y-axis as shown in the figure. CAUTION: If the clearance is more than the limit, replace the valve and valve guide. M3102020 CAUTION: If the measured lift is less than the limit, replace the camshaft. M201 2014.01...
Page 472 5. Inspect the valve stem end face for dents or abrasions. CAUTION: If any dent or abrasion is found, trim valve stem face, excessive trimness will cause chamfers to be grinded off. If the chamfers have been grinded off, replace the valve. M3102024 M201 2014.01...
Page 473 Use the first one at an angle of 15° and the second one at an angle of 45°. The width required must be reached at the 45° second repair. Intake valve seat width: 1.1 ~ 1.3 mm 15° M3102027 M201 2014.01...
Page 474 CAUTION: Inspect the uprightness of each spring in accordance with the clearance. Install a new valve spring if the clearance exceeds the limit values shown below. M3102030 Valve spring uprightness limit: 1.0 mm M201 2014.01...
Page 475 Combustible gas leaks from cylinder head surface generally caused wrinkles deformations cylinder head surface, and this may result in output power reduction and engine overheat due to high coolant temperature. M201 2014.01...
Page 476 Deformation limit: 0.05 mm CAUTION: Inspect the cylinder head manifold matching face with a straight scale and a feeler gauge to see if these surfaces need to be leveled or the cylinder head need to be replaced. M3102032 M201 2014.01...
Page 477 M3102034 3. Use a reamer of 5.0 mm diameter to ream the valve guide hole. After reaming, clear the guide hole. 4. Install the valve spring lower retainer to the cylinder head. M201 2014.01...
Page 478 (small pitch end) toward the bottom (valve spring lower retainer) when installing the spring. Big pitch Small pitch Valve spring upper retainer side Valve spring lower retainer side White mark in the elliptic area of figure M3102037 M201 2014.01...
Page 479 Special tool: Valve opener 09916 -14510 Valve opener holder （C） 09916-14910 M3102012 10. Apply an appropriate amount of engine oil to the valve tappets, and then place them into each installation hole in turns. M201 2014.01...
Page 480 With the marked side up, do not install it upside down. 12. Inspect that the high pressure oil plug is installed and not blocked. Torque: 3 ± 0.5 Nm M3102039 M201 2014.01...
Page 481 Refer to: Oil Pan Lower Part and Oil Strainer (3.1.3 Lubrication System, Removal Installation). 19. Install the cylinder head cover. Refer to: Cylinder Head Cover (3.1.2 Mechanical System, Removal and Installation). 20. Install the exhaust manifold. Refer to: Exhaust Manifold (3.1.6 Exhaust System, Removal Installation). M201 2014.01...
Page 482 3.1.2-116 Mechanical System 3.1.2-116 21. Install the intake manifold. Refer to: Intake Manifold (3.1.5 Air Intake System, Removal Installation). 22. Install the accessory drive belt. Refer to: Accessory Drive Belt (3.1.2 Mechanical System, Removal and Installation). M201 2014.01...
Page 483: Piston, Piston Ring, Connecting Rod And Cylinder
3.1.2-117 Mechanical System 3.1.2-117 Piston, Piston Ring, Connecting Rod and Cylinder General Equipment Cylinder bore gauge Micrometer Plastic feeler gauge Straight scale Piston ring expander Piston ring compressor Material Item Specifications Tonsan 1596Fa Sealant Tonsan 1591 M201 2014.01...
Page 484 7. Remove the oil pan upper part. Refer to: Oil Upper Part (3.1.3 Lubrication System, Removal and Installation). 8. Remove the timing chain. Refer to: Timing System (3.1.2 Mechanical System, Removal Installation). 9. Remove the camshaft. Refer to: Camshaft (3.1.2 Mechanical System, Removal Installation). M201 2014.01...
Page 485 13. Remove 4 stud bolts from the oil pan baffle plate. M3102041 14. Remove the piston connecting rod bolts. ×8 M3102073 15. Remove the piston connecting rod bearing cap. M3102043 16. Remove the connecting rod bearing shell from the piston connecting rod bearing cap. M3102044 M201 2014.01...
Page 486 19. Use the piston ring expander to remove the No.1 piston ring (1), No.2 piston ring (2), oil control ring (3) and coil spring (4) from the piston (5) in sequence. M3102047 M3102048 M201 2014.01...
Page 487 M3102049 2 Press out the piston pin. M3102050 3 Separate the piston from the connecting rod. 21. Use a suitable tool to remove the carbon deposit from the piston top and piston ring groove. M201 2014.01...
Page 488 4. The measuring range of piston diameter is from the piston skirt bottom sipigot to vertical position, with 15 mm away from piston pin as shown in the figure. Standard piston diameter: 72.975 ~ 72.99 mm M3102052 M201 2014.01...
Page 489 8. Measure the connecting rod small end hole diameter with a caliper gauge. Standard connecting rod small end hole diameter: 18.003 ~ 18.011 mm M3102054 9. Measure the piston pin diameter with a micrometer. Standard piston pin diameter: 17.995 ~ 18 mm M3102055 M201 2014.01...
Page 490 Item Standard Limit First 0.155 ~ 0.275 mm 0.5 mm ring Piston ring end gap Second 0.28 ~ 0.41 mm 0.5 mm ring Cylinder block 120 mm Feeler gauge Piston ring M3102057 M201 2014.01...
Page 491 If the connecting rod journal is damaged, or the out-of-round or taper is out of tolerance, replace the crankshaft. Connecting rod journal diameter: 37.982 ~ 38.000 mm Connecting rod journal out-of-round and M3102061 taper limit: 0.005 mm M201 2014.01...
Page 492 Tighten the retaining bolts of connecting rod bearing cap to the specified torque. Do M3102064 not rotate the crankshaft with feeler gauge. CAUTION: The bolts cannot be reused if removed. Replace the connecting rod bolts with new ones. M201 2014.01...
Page 493 No.2 cylinder. The third number represents the inside diameter of No.3 cylinder. fourth number represents the inside diameter of No.4 cylinder. XXXXX M3102136 CAUTION: Match piston corresponding cylinder by following the cylinder inside diameter mark on the cylinder block. M201 2014.01...
Page 494 CAUTION: The piston top drop pit and connecting rod large end oil hole should be on the same side. M3102067 Piston top drop pit Connecting rod large end oil hole Connecting rod size grouping Connecting rod quality grouping M201 2014.01...
Page 495 Drop pit on intake side 45° No.1 piston ring opening M3102070 (Lower) oil control ring opening 4. Apply an appropriate amount of engine oil to the pistons, piston rings, cylinder walls, connecting rod bearing shells and crankshaft connecting rod journals. M201 2014.01...
Page 496 The number represents the model of connecting rod large end hole diameter. M3102135 3 Selection of connecting rod bearing cap. Bearing cap = 7 - Number printed on the crankshaft - Number on the connecting rod bearing cap side M201 2014.01...
Page 497 M3102072 7 Point all the boss marks of connecting rod bearing cap at the crankshaft pulley side. M3102128 8 Tighten the connecting rod bearing cap retaining bolts. Torque: 15 Nm + 90° ×8 M3102073 M201 2014.01...
Page 498 12. Remove the oil pan upper part. Refer to: Oil Upper Part (3.1.3 Lubrication System, Removal and Installation). 13. Remove the oil pan lower part. Refer to: Oil Pan Lower Part and Oil Strainer (3.1.3 Lubrication System, Removal Installation). M201 2014.01...
Page 499 System, Removal System, Removal and Installation). Installation). 15. Install the exhaust manifold. 17. Install the accessory drive belt. Refer to: Exhaust Manifold (3.1.6 Exhaust Refer to: Accessory Drive Belt (3.1.2 System, Removal Mechanical System, Removal Installation). and Installation). M201 2014.01...
Page 500: Main Bearing, Crankshaft And Cylinder Block
3.1.2-134 Mechanical System 3.1.2-134 Main Bearing, Crankshaft and Cylinder Block Special Tool Flywheel tightener 09924-17810 09924-17810 General Equipment Micrometer Plastic feeler gauge Straight scale Material Item Specifications Tonsan 1596Fa Sealant Tonsan 1591 M201 2014.01...
Page 501 3 Remove the engine bracket. 3. Remove the intake manifold. Refer to: Intake Manifold (3.1.5 Air Intake System, Removal Installation). 4. Remove the water inlet pipe assembly. 1 Remove 2 water inlet pipe retaining bolts. Torque: 10 ± 1 Nm M3103015 M201 2014.01...
Page 502 7. Remove the alternator adjusting bracket. 1 Remove 2 alternator adjusting bracket retaining bolts. Torque: 23 ± 2 Nm M3103017 2 Remove the alternator adjusting bracket. 8. Remove the A/C compressor. Refer to: Compressor (4.1.1 Heating, Ventilation and Air Conditioning, Removal and Installation). M201 2014.01...
Page 503 10. Remove the right bracket and mounting bush. 1 Remove 5 right bracket retaining bolts. Torque: 70 ± 5 Nm M3103018 2 Remove the right bracket and mounting bush. 11. Remove the carbon canister control valve from the canister control valve mounting bracket. M3111011 M201 2014.01...
Page 504 16. Remove the oil pan lower part. Refer to: Oil Pan Lower Part and Oil Strainer (3.1.3 Lubrication System, Removal Installation). 17. Remove the oil pan upper part. Refer to: Oil Upper Part (3.1.3 Lubrication System, Removal and Installation). M201 2014.01...
Page 505 CAUTION: Replace the rear oil seal assembly with a new one after removing the rear oil seal. M3102075 22. Remove the crankshaft main bearing cap bolts in the order shown in the figure. M3102138 23. Remove the crankshaft main bearing caps in sequence. M201 2014.01...
Page 506 M3102077 25. Remove the crankshaft from the cylinder block. 26. Remove 2 crankshaft thrust plates from the cylinder block between No.2 and No.3 cylinders. M3102078 27. Remove the upper main bearing shells from the cylinder block. M3102079 M201 2014.01...
Page 507 2 Inspect the thrust clearance and read the offset in the axial (thrust) direction with a dial indicator. Install a new thrust plate if the measurement exceeds the limit. Item Standard Limit Crankshaft thrust 0.16 ~ 0.36 mm 0.38 mm clearance M3102082 M201 2014.01...
Page 508 The main bearing cap marked with "1" is installed at the engine front while one marked with "5" is installed on the flywheel side. M3102076 CAUTION: Do not rotate the crankshaft after installing the main bearing cap. M201 2014.01...
Page 509 5. Inspect the crankshaft rear oil seal. 1 Inspect the oil seal for abrasions, and if oil seal lip is worn or damaged. replace it with a new one. M3102087 M201 2014.01...
Page 510 If the flatness exceeds the limit, trim the surface. Inspection and flatness trim methods are the same with that of cylinder head as described previously. Item Standard Limit Flatness 0.05 mm 0.10 mm M3102089 M201 2014.01...
Page 511 1. Install the crankshaft speed sensor plate to the crankshaft and tighten the retaining screws to the specified torque. Torque: 11 ± 1 Nm CAUTION: The screws cannot be reused if ×2 removed. Replace the sensor plate screws with new ones. M3102080 M201 2014.01...
Page 512 2 Select crankshaft main bearing shells that meets the standard according to the numbers printed crankshaft crank characters printed on the cylinder block matching surface plus the following chart. Main bearing journal grouping number Connecting rod journal grouping number M3102132 M201 2014.01...
Page 513 (from left to right) represents the crankshaft bore diameter of bearing cap M3102091 "1", "2", "3", "4" or "5" respectively. There are 3 groups of crankshaft holes: groups 1, 2 and 3, each of which represents the following main bearing hole diameter respectively. M201 2014.01...
Page 514 Apply the sealant continuously and evenly to the inner circle with a diameter of 2 ~ 3 mm. Close the box after applying for a certain period. Clean and reapply the sealant if M3102093 applying time is too long. M201 2014.01...
Page 515 Do not press-fit backwards. Clean the crankshaft rear end cover before installing. 8. Tighten 6 retaining bolts of crankshaft rear end cover. Torque: 10 ± 1 Nm M3102075 M201 2014.01...
Page 516 Refer to: Exhaust Manifold (3.1.6 Exhaust System, Removal Installation). 16. Installation for other components are in the reverse order of removal. CAUTION: Inspect the accessory drive belt tension. Refer to: Accessory Drive Belt Inspection (3.1.2 Mechanical System, General Inspection). M201 2014.01...
Page 517: Lubrication System
10 ± 1 Oil pan upper part retaining bolt 10 ± 1 Oil filter tightening torque 14 ± 2 Oil pressure alarm assembly 21 ± 2 Oil retaining bolt 10 ± 1 Oil level gauge retaining bolt 10 ± 1 M201 2014.01...
Page 518: Description And Operation
Oil Pump The oil pump is rotor pump which is fixed on the oil pump timing chain housing and driven directly by the crankshaft. M201 2014.01...
Page 519: Components Location View
3.1.3-3 Lubrication System 3.1.3-3 Components Location View Oil Pump M3103001 Item Description Item Description Oil pump timing chain housing Oil pump assembly M201 2014.01...
Page 520: Components Exploded View
3.1.3-4 Lubrication System 3.1.3-4 Components Exploded View M3103002 M201 2014.01...
Page 521 Hexagon flange bolt Oil pan lower part assembly Hexagon flange nut Oil pan upper and lower part Oil level gauge assembly connecting stud bolt Hexagon flange nut Hexagon flange bolt Drain plug Oil pump chain cover stud bolt M201 2014.01...
Page 522: General Inspection
Relevant requires of oil pressure standard are as follows: Idling 52 kPa 3000 rpm 200 ~ 480 kPa Rated speed 320 ~ 500 kPa 7. Turn off the engine and remove the oil pressure gauge after oil pressure inspection. M201 2014.01...
Page 523: Oil Level Inspection
CAUTION: Wipe the oil off completely in case you spread it over the exhaust system. If the splashed oil is not wiped off completely, it would cause smog due to high temperature. 1. Park the vehicle on level ground. M201 2014.01...
Page 524: Oil Filter Replacement
3. Use a clean rag to clean the installation surface. 4. Apply clean oil to the gasket of new oil filter. 5. Use a suitable tool to tighten the oil filter in accordance with the indication on the side or package. M201 2014.01...
Page 525: Symptom Diagnosis And Testing
4. If there is no obvious cause, verify the symptom by referring to the Symptom Chart. Visual Inspection Chart Mechanical Electrical • Oil pan • Electrical connector • Oil filter M201 2014.01...
Page 526: Symptom Chart
Symptom • Instrument cluster Diagnosis Testing). Refer to: Diagnosis Procedure • Leak for Abnormal Oil Consumption (3.1.3 • PCV gas leakage consumption Abnormal oil consumption Lubricating System, • Burning consumption in the Symptom Diagnosis combustion chamber and Testing). M201 2014.01...
Page 527: Diagnosis Procedure For Oil Pressure Warning Lamp Constant On
Oil pressure warning lamp constant on Inspect oil pressure alarm Is the fault confirmed Inspect oil pressure Is the fault confirmed Inspect oil pump Is the fault confirmed Inspect fitting clearance bearing shell Is the fault confirmed Inspect circuit M201 2014.01...
Page 528 Go to step 3. 3. Inspect oil pump A. Remove the oil pump. Refer to: Oil Pump (3.1.3 Lubrication System, Removal Installation). B. Inspect the oil pump. Is the oil pump normal? Go to step 4. Replace the oil pump. M201 2014.01...
Page 529: Lubrication System
Repair the short circuit fault between terminal 1 of oil pressure alarm connector E10 and terminal 23 of instrument cluster wiring harness connector P21. Replace the instrument cluster. Refer to: Instrument Cluster (4.2.2 Instrument Cluster, Removal and Installation). M201 2014.01...
Page 530: Diagnosis Procedure For Oil Pressure Warning Lamp Not
3.1.3-14 Lubrication System 3.1.3-14 Diagnosis Procedure for Oil Pressure Warning Lamp Not ON Oil pressure warning lamp not on Inspect circuit Is the fault confirmed Inspect circuit Is the fault confirmed Inspect instrument cluster M201 2014.01...
Page 531 3. Inspect instrument cluster A. Remove the instrument cluster. Refer to: Instrument Cluster (4.2.2 Instrument Cluster, Removal and Installation). B. Inspect the instrument cluster. Is it normal? Replace the instrument cluster. Refer to: Instrument Cluster (4.2.2 Instrument Cluster, Removal and Installation). M201 2014.01...
Page 532: Diagnosis Procedure For Abnormal Oil Consumption
3.1.3-16 Lubrication System 3.1.3-16 Diagnosis Procedure for Abnormal Oil Consumption Abnormal oil consumption Inspect for leaks Is the fault confirmed Inspect amount of PCV gas leakage Is the fault confirmed Inspect if oil is burning M201 2014.01...
Page 533 Is the blue smoke from the engine exhaust pipe? Adjust the fitting clearance between engine valve mechanism and engine piston and cylinder. Refer to: Piston, Piston Ring, Connecting Cylinder (3.1.2 Mechanical System, Disassembly and Assembly). System is normal. M201 2014.01...
Page 534: Removal And Installation
Refer to: Battery (3.1.10 Charging System, Removal and Installation). 2. Lift the vehicle. Refer to: Lifting (1.1.3 Traction and Lifting, Description and Operation). 3. Remove the drain bolt and drain the engine oil. Torque: 45 ± 2 Nm M3103006 M201 2014.01...
Page 535 2 separate points. CAUTION: Avoid damaging joint surface by the tool during separation. M3103009 5. Remove 2 retaining bolts from the oil strainer assembly. M3103010 6. Remove the oil strainer O-ring. M201 2014.01...
Page 536 M3103012 and upper parts of oil pan. 2 Install the oil pan lower part assembly, and tighten the bolts in diagonally opposite sequence before the sealant hardens (within 5 minutes). Torque: 10 ± 1 Nm M3103008 M201 2014.01...
Page 537 Inspection). CAUTION: Wait minutes after installation (it takes 20 minutes for the sealant surface to harden, and if you refill oil before the sealant hardens, problems such as oil exudation and leakage may occur), and refill engine oil. M201 2014.01...
Page 538: Oil Pan Upper Part
1 Remove the connecting nut from the left side of engine bracket. Torque: 70 ± 5 Nm M3103013 2 Remove the connecting nut from the right side of engine bracket. Torque: 70 ± 5 Nm 3 Remove the engine bracket. M3103014 M201 2014.01...
Page 539 5. Remove the alternator. Refer to: Alternator (3.1.10 Charging System, Removal Installation). 6. Remove the alternator adjusting bracket. 1 Remove 2 retaining bolts from the alternator adjusting bracket. Torque: 23 ± 2 Nm M3103017 2 Remove the alternator adjusting bracket. M201 2014.01...
Page 540 2 Remove the right bracket and mounting bush. 8. Remove the carbon canister control valve from the carbon canister control valve mounting bracket. M3111011 9. Remove the retaining bolt from the carbon canister control valve mounting bracket. Torque: 10 ± 1 Nm M3103019 M201 2014.01...
Page 541 11. Remove the oil pan lower part. Refer to: Oil Pan Lower Part and Oil Strainer (3.1.3 Lubrication System, Removal Installation). 12. Remove the oil pan upper part. 1 Remove 16 retaining bolts from the oil pan upper part. M3103021 ×7 M3103022 M201 2014.01...
Page 542 Refer to: Oil Pan Lower Part and Oil Strainer (3.1.3 Lubrication System, Removal Installation). 3. Removal of other components is in the reverse order of installation. CAUTION: Replace the water inlet and outlet pipe O-ring with a new one before installing the water pipe assembly. M201 2014.01...
Page 543: Oil Pump
(2). 4 Disconnect the connection between water pipe and No.2 water outlet pipe (3). M3103026 4. Loosen the hoop, and disconnect the connection between water pipe and A/C heater water outlet pipe. M3103027 M201 2014.01...
Page 544 1 Use a screwdriver to position the water pump pulley, and use a ratchet wrench to remove the retaining bolts from the water pump pulley in sequence. Torque: 10 ± 1 Nm M3104026 8. Remove the crankshaft pulley. M3103029 M201 2014.01...
Page 545 12. Remove the oil pump from the oil pump timing chain housing. 1 Remove 9 retaining bolts from the oil pump. M3103032 2 Remove the oil pump housing (1), outer rotor (2) and inner rotor (3) in sequence. M3103033 M201 2014.01...
Page 546 2. When installing pump crankshaft, install the special tool (oil seal guide) to the crankshaft and apply engine oil to the special tool to prevent the lip of oil seal from damaging or rolling up. M201 2014.01...
Page 547 (1 and 2) of cylinder head and cylinder block. M3103036 2 Tighten the retaining bolts and nut of oil pump timing chain housing. Bolt torque: 23 ± 2 Nm Nut torque: 50 ± 3 Nm M3103031 M201 2014.01...
Page 548 M3103029 3 Installation of other components is in the reverse order of removal. 4 Adjust the accessory drive belt tension. Refer to: Accessory Drive Belt Tension Adjustment (3.1.2 Mechanical System, General Inspection). M201 2014.01...
Page 549: Oil Pan Baffle Plate
1 Remove 3 retaining bolts and 4 retaining nuts from the oil pan baffle plate. Torque: 10 ± 1 Nm M3103038 2 Remove the oil pan baffle plate. Installation 1. Installation is in the reverse order of removal. M201 2014.01...
Page 551: Cooling System
Coolant temperature sensor 15 ± 2 Water pump pulley retaining bolt 10 ± 1 Water pump retaining bolt 10 ± 1 Thermostat cap retaining bolt 23 ± 2 Radiator fan bracket retaining bolt 10 ± 1 M201 2014.01...
Page 552: Description And Operation
Such state is called "minor cycle". head and radiator. Such state is called "major cycle". M201 2014.01...
Page 553 3.1.4-3 M3104021 Item Description Radiator inlet hose Radiator outlet hose Inlet hose Thermostat Water pump Water pump pulley Cylinder block Cylinder head Heater radiator inlet hose Heater radiator outlet hose Radiator water reservoir Water reservoir Radiator filler cap M201 2014.01...
Page 554: Components Description
The coolant flows back to the radiator when system cools down. CAUTION: Coolant such alcohol, methanol or water alone cannot be used for the cooling system, which may cause system malfunction. M201 2014.01...
Page 555 Heater joint with hose assembly Floor water pipe accessory Radiator mounting bracket assembly Clamp Engine inlet hose Screw Clamp Radiator fan Engine to heater hose 3-way with accessory assembly Engine outlet hose Water reservoir assembly Engine reservoir hose M201 2014.01...
Page 556: Components Exploded View
3.1.4-6 Cooling System 3.1.4-6 Components Exploded View M3104018 M201 2014.01...
Page 557 Throttle body water inlet hose Bolster plate of compressor No.1 water outlet hose assembly tension bracket Bolt Thermostat chamber lock Water pump assembly assembly Intake manifold long stud bolt Bolt Thermostat cap assembly Bleed hose hoop Thermostat assembly Intake manifold water hose M201 2014.01...
Page 558: General Inspection
WARNING: Only use soft water (demineralized) in the coolant mixture. Water containing mineral reduces the effectiveness of the coolant. WARNING: Engine coolant will damage the paintwork. Wash engine coolant immediately if it adheres to any painted surfaces. M201 2014.01...
Page 559: Coolant Leak(S) Inspection
2 The compressor belt tension should be controlled within 600 ± 50 N (before igniting the engine). 3 If the belt tension is not as specified, readjust the compressor belt tension, until it meets the requirement. Compressor - Gates Unitta Sonic Tension Meter Test M201 2014.01...
Page 560: Thermostat Test
9. Run the engine for a while, and observe the coolant level. Add coolant until it reaches at the full level if there is no coolant at the radiator filler port. M201 2014.01...
Page 561 (torque: 6 ± 1 Nm). CAUTION: If water leakage occurs on the drain plug, it is necessary to replace the drain plug washer. 粒 M3104039 M201 2014.01...
Page 562: Symptom Diagnosis And Testing
• Water reservoir • Electrical connector • Radiator • Coolant temperature • Water pump sensor • Thermostat cap • Radiator fan • Thermostat chamber • Engine control module lock (ECM) • Heater radiator • Compressor belt • Coolant output connector M201 2014.01...
Page 563: Symptom Chart
• Water reservoir damage. Install a new set of coolant tank if necessary. • Heater radiator • Inspect the heater radiator for any leaks. • Inspect the engine, cylinder head, • Engine cylinder block and cylinder head gasket. M201 2014.01...
Page 564 • Radiator filler cap or sealing or damaged. Install a new set of radiator filler cap if necessary. • Inspect the water reservoir for any • Water reservoir damage. Install a new set of water reservoir if necessary. M201 2014.01...
Page 565 Cooling System. Install a new set of thermostat cap and cap washer if necessary. • Thermostat Refer to: Thermostat (3.1.4 Cooling System, Removal Installation). • Inspect the compressor belt condition. Refer to: Accessory Drive Belt • Compressor belt Inspection (3.1.2 Mechanical System, General Inspection). M201 2014.01...
Page 566 Refer to: Diagnosis Procedure for Radiator Fan Not Running (3.1.4 Cooling • Radiator fan System, Symptom Engine overheating Diagnosis (signs of boiling coolant) Testing). • Inspect the engine, cylinder head, • Engine cylinder block and cylinder head gasket. M201 2014.01...
Page 567: Diagnosis Procedure For Radiator Fan Not Running
Inspect fuse IF03 power supply Inspect radiator fan relay IR03 power supply circuit Inspect radiator fan relay IR03 Is the fault Inspect radiator fan relay control confirmed circuit Inspect radiator fan power supply circuit Inspect radiator fan grounding circuit M201 2014.01...
Page 568 Go to step 3. 3. Inspect fuse A. Inspect the radiator fan fuse IF03. Fuse rated capacity: 30 A Is the fuse normal? Go to step 4. Inspect and repair the fuse circuit, and replace the fuse with rated capacity. M201 2014.01...
Page 569 P40 fuse IF03 and reliable grounding. Standard voltage: 11 ~ 14 V IF03 Is the voltage value normal? Go to step 5. Inspect and repair the open circuit fault between terminal 5 of instrument panel fuse box P40 and battery. M3104034 M201 2014.01...
Page 570 69 of main relay IR05. M3104035 6. Inspect radiator fan relay IR03 A. Remove the radiator fan relay. B. Replace with a normal one of same type. Is the system normal? Replace the radiator fan relay. Go to step 7. M201 2014.01...
Page 571 Standard resistance: less than 5 Ω Is the resistance value normal? Go to step 9. Inspect and repair the open circuit fault between terminal 1 of radiator fan wiring harness connector P10 and terminal 59 of radiator fan relay IR03. IR03 M3104037 M201 2014.01...
Page 572 Standard resistance: less than 5 Ω Is the resistance value normal? Replace the radiator fan. M3104038 Inspect and repair the open circuit fault between terminal 2 of radiator fan wiring harness connector P10 and reliable grounding. M201 2014.01...
Page 573: Diagnosis Procedure For Radiator Fan Constantly Running
Inspect fuse IF03 power supply Inspect radiator fan relay IR03 power supply circuit Inspect radiator fan relay IR03 Inspect radiator fan relay control Is the fault circuit confirmed Inspect radiator fan power supply circuit Inspect radiator fan grounding circuit M201 2014.01...
Page 574 Go to step 3. 3. Inspect fuse A. Inspect the radiator fan fuse IF03. Fuse rated capacity: 30 A Is the fuse normal? Go to step 4. Inspect and repair the fuse circuit, and replace the fuse with rated capacity. M201 2014.01...
Page 575 P40 fuse IF03 and reliable grounding. Standard voltage: 11 ~ 14 V IF03 Is the voltage value normal? Go to step 5. Inspect and repair the open circuit fault between terminal 5 of instrument panel fuse box P40 and battery. M3104034 M201 2014.01...
Page 576 69 of main relay IR05. M3104035 6. Inspect radiator fan relay IR03 A. Remove the radiator fan relay. B. Replace with a normal one of same type. Is the system normal? Replace the radiator fan relay. Go to step 7. M201 2014.01...
Page 577 Standard resistance: less than 5 Ω Is the resistance value normal? Go to step 9. Inspect and repair the open circuit fault between terminal 1 of radiator fan wiring harness connector P10 and terminal 59 of radiator fan relay IR03. IR03 M3104037 M201 2014.01...
Page 578 Standard resistance: less than 5 Ω Is the resistance value normal? Replace the radiator fan. M3104038 Inspect and repair the open circuit fault between terminal 2 of radiator fan wiring harness connector P10 and reliable grounding. M201 2014.01...
Page 579: Removal And Installation
3. Disconnect the radiator fan wiring harness connector. M3104005 4. Remove 2 retaining bolts from the radiator fan. Torque: 10 Nm M3104006 5. Remove the front wind guiding cover. Refer to: Front Wind Guiding Cover (5.1.10 Exterior Trim, Removal Installation). M201 2014.01...
Page 580 CAUTION: Be aware that the clip at the lower part of radiator fan must be seized in the holder at the lower part of radiator when installing the radiator fan. CAUTION: Start engine to inspect cooling system for any leaks. M201 2014.01...
Page 581: Radiator
M3104009 4. Remove the radiator fan. Refer to: Radiator (3.1.4 Cooling System, Removal Installation). 5. Disconnect the condenser fan wiring harness connector. M3104010 M201 2014.01...
Page 582: Cooling System
M3104011 7. Remove 2 retaining bolts from the condenser fan. Torque: 10 Nm M3104012 8. Lift the vehicle, and remove the condenser fan from below of vehicle. 9. Remove 2 connecting screws between condenser and radiator. ×2 M3104013 M201 2014.01...
Page 583 1. Installation is in the reverse order of removal. CAUTION: Be aware that the clip at the lower part of radiator must be seized in the holder of radiator bracket assembly when installing the radiator. CAUTION: Start engine to inspect cooling system for any leaks. M201 2014.01...
Page 584: Thermostat
4. Loosen the hoop, and disconnect the connection between the top radiator hose and thermostat cap. M3105022 5. Remove 2 retaining bolts from the thermostat. Torque: 23 ± 2 Nm M3105020 6. Remove the thermostat. M3105021 M201 2014.01...
Page 585 1. Installation is in the reverse order of removal. CAUTION: thermostat paraffin inductor faces towards the engine side. CAUTION: Falling out of thermostat seal ring is not allowed. CAUTION: Fully turn the thermostat cap. CAUTION: Start engine to inspect cooling system for any leaks. M201 2014.01...
Page 586: Water Pump
5. Remove the compressor belt. (Vehicle with A/C) 1 Loosen 2 compressor connecting bolts. Torque: 25 ~ 30 Nm M3104023 2 Loosen the compressor adjusting bracket bolts (1) and (2) in order. Torque for bolt (1) : 25 ± 1 Nm M3104024 M201 2014.01...
Page 587 Torque: 10 ± 1 Nm M3104026 2 Remove 2 retaining bolts from the bolster plate compressor tension bracket. (Vehicle with A/C) Torque: 23 ± 2 Nm M3104027 M201 2014.01...
Page 588 CAUTION: Inspect the drive belt tension. M3104029 Refer to: Drive Belt Tension Inspection (3.1.4 Cooling System, General inspection). CAUTION: After installing the water pump, do not add coolant within 20 minutes to avoid the sealant to enter the water pump turbine. M201 2014.01...
Page 589: Floor Water Pipe
7. Disconnect the connecting hose (4) between M3104030 floor water pipe rear end and water reservoir. 8. Loosen the hoop, and disconnect the connecting hose (5) between floor water pipe rear end and intake manifold. M201 2014.01...
Page 590 14. Remove 4 retaining screws from the floor water pipe, and remove the floor water pipe. Torque: 10 ± 1 Nm M3104032 Installation 1. Installation is in the reverse order of removal. CAUTION: Start engine to inspect cooling system for any leaks. M201 2014.01...
Page 591: Water Reservoir
The boiling liquid and steam may spurt out under the pressure since the reservoir cap opens earlier. M3104002 2. Pull up the water reservoir to remove it. M3104016 Installation 1. Installation is in the reverse order of removal. M201 2014.01...
Page 593: General Specifications
330 ± 20 kPa Torque Specifications Item lb-ft lb-in Intake manifold retaining bolt 23 ± 2 Throttle body retaining bolt 10 ± 1 Air filter retaining bolt 10 ± 1 Retaining bolt of air intake pressure/ 10 ± 1 temperature sensor M201 2014.01...
Page 594: Description And Operation
Air filter upper case • Air filter element • Air filter lower case M3105001 The dry air enters the air filter base and through air filter element and then the clean air flows from the air filter upper case. M201 2014.01...
Page 595 Intake manifold stud bolt Throttle position sensor Intake manifold gasket No.4 wiring harness bracket Small return hose Throttle body assembly Throttle body hoop Idle stepper motor assembly Intake manifold assembly Intake manifold stiffener Throttle body gasket No.1 engine hook M201 2014.01...
Page 596: General Inspection
6. If an observed or reported problem is obvious and its cause has been found, solve the fault before proceeding to the next step. 7. If the cause is not visually evident, verify the symptom by referring to the Symptom Chart. M201 2014.01...
Page 597 3.1.5-5 Air Intake System 3.1.5-5 Symptom Diagnosis and Testing General Equipment Vacuum gauge Visual Inspection Chart Mechanical • Air filter set • Air filter inlet pipe • Air filter outlet pipe • Throttle body • Intake manifold M201 2014.01...
Page 598: Symptom Chart
Intake blocking • Disassemble the air filter case and inspect the air filter and intake pipe for any possible foreign matters and remove. • Foreign matters in intake pipe Refer to: Air Filter Element (3.1.5 Intake System, Removal Installation). M201 2014.01...
Page 599: Diagnosis Procedure For Intake Air Leak
Air Intake System 3.1.5-7 Diagnosis Procedure for Intake Air Leak Intake air leak Inspect for any leak noise Is the fault confirmed Inspect vacuum degree of air intake system Is the fault confirmed Inspect intake manifold throttle body M201 2014.01...
Page 600 A. Inspect the intake manifold or throttle body for leak tightness. Does the intake manifold or throttle body leak? Repair the seal of intake manifold or throttle body. Inspect the engine valve train. Refer to: Timing System (3.1.2 Mechanical System, Removal and Installation). M201 2014.01...
Page 601: Removal And Installation
Removal 1. Loosen the pipe clip, and disconnect the air filter outlet pipe from the air filter. M3105003 2. Remove 4 retaining screws from the air filter upper case. M3105001 3. Remove the air filter upper case. M3105004 M201 2014.01...
Page 602 If excessively dirty, replace the element. M3105006 Installation 1. Installation is in the reverse order of removal. CAUTION: Align the bulge of air filter case with the groove of air filter outlet pipe. M3105007 M201 2014.01...
Page 603: Air Filter
2. Remove 2 retaining bolts from the air filter. Torque: 10 ± 1 Nm M3105008 Installation 1. Installation is in the reverse order of removal. CAUTION: Align the bulge of air filter case with the groove of air filter outlet pipe. M3105007 M201 2014.01...
Page 604: Throttle Body
2 Disconnect the throttle position sensor wiring harness connector (2). 3 Disconnect the idling stepper motor wiring harness connector (3). M3105010 4. Remove 4 retaining bolts from the throttle body, and remove the throttle body and gasket. Torque: 10 ± 1 Nm M3105031 M201 2014.01...
Page 605 CAUTION: As shown in the figure, ensure that the hoop closed line (1) overlaps with T-mark line (3) of hose, and the hoop outer line (2) is aligned with T-mark line (2) of hose when tightening the hose. M3105011 M201 2014.01...
Page 606: Intake Manifold
(3.1.4 Cooling System, General Inspection). 6. Remove the water outlet pipe holder and No.1 water outlet pipe. 1 Remove the retaining bolt of wiring harness bracket from the water outlet pipe holder. Torque: 10 ± 1 Nm M3105015 M201 2014.01...
Page 607 Refer to: Throttle Body (3.1.5 Air intake System, Removal Installation). 8. Remove the retaining bolt from the air intake pressure/temperature sensor. Torque: 8 ± 2 Nm M3105017 9. Loosen the hoop, and disconnect the vacuum booster hose. M3105018 M201 2014.01...
Page 608 2 Loosen the hoop, and disconnect the connecting hose between top radiator hose and thermostat cap. M3105022 3 Remove 2 retaining bolts from the thermostat. Torque: 23 ± 2 Nm M3105020 4 Remove the thermostat. M3105021 M201 2014.01...
Page 609: Air Intake System
M3105028 15. Remove 2 retaining bolts between crankcase vent pipe and fuel pipe, and move the crankcase vent pipe and fuel main pipe away. Torque: 10 ± 1 Nm M3105024 M201 2014.01...
Page 610 Torque: 23 ± 2 Nm M3105026 18. Remove the retaining bolts and nuts from the intake manifold. Torque: 23 ± 2 Nm M3105029 19. Loosen the hoop, and disconnect the preheating water pipe of throttle body from the intake manifold. M3105030 M201 2014.01...
Page 611 CAUTION: As shown in the figure, ensure that the hoop closed line (1) overlaps with T-mark line (3) of hose, and the hoop outer line (2) is aligned with T-mark line (2) of hose when tightening the hose. M3105011 M201 2014.01...
Page 613: Exhaust System
Connecting bolt between muffler and 55 ± 5 three-way catalytic converter Oxygen sensor tightening torque 50 ± 10 Retaining bolt between engine left mounting and engine Retaining nut between engine left mounting and engine bracket M201 2014.01...
Page 614: Description And Operation
The three-way catalytic converter is shaped like a small muffler. high working temperature, the bodywork near the three-way catalytic converter has been protected with heat insulated panel. The three-way catalytic converter controls three emissions: HC, CO and NOx. M201 2014.01...
Page 615: Components Location View
3.1.6-3 Exhaust System 3.1.6-3 Components Location View M3106014 Item Description Item Description Exhaust manifold Muffler Three-way catalytic converter M201 2014.01...
Page 616 Exhaust Manifold M3106012 Item Description Item Description Exhaust manifold upper heat Hexagon flange nut insulator assembly Exhaust manifold lower heat Exhaust manifold gasket insulator assembly Exhaust manifold assembly Hexagon flange bolt Exhaust manifold assembly Hexagon flange bolt stud bolt M201 2014.01...
Page 617 Pressure spring Rubber shackle Pressure spring bolt Charcoal ring (cermet coating) Three-way catalytic converter Pressure spring lower cover assembly Three-way catalytic converter Pressure spring bolt upper cover assembly Muffler with accessory assembly Hexagon head bolt Rubber shackle M201 2014.01...
Page 618: General Inspection
(engine speed 6000 rpm, throttle full open). Exhaust backpressure standard Exhaust Engine Speed (rpm) Backpressure (kPa) 6000 36 kPa or less 6. Turn the ignition switch off and the engine stops. 7. Remove the exhaust backpressure gauge and install the oxygen sensor. M201 2014.01...
Page 619: Symptom Diagnosis And Testing
Electrical • Damage or leakage of exhaust system pipe • Damage of three-way • Oxygen sensor circuit catalytic converter fault • Looseness of exhaust • Oxygen sensor fault pipe bolt • Aging or damage of exhaust pipe gasket M201 2014.01...
Page 620: Symptom Chart
• Irregular joint surface of flange joint connection • Replace the exhaust manifold. • Cracked or disconnected exhaust Refer to: Exhaust manifold (3.1.6 manifold Exhaust System, Removal • Welded joint of exhaust system Installation). component leak(s) • Replace the leaking parts. M201 2014.01...
Page 621: Diagnosis Procedure For Exhaust System Blockage
3.1.6-9 Exhaust System 3.1.6-9 Diagnosis Procedure for Exhaust System Blockage Exhaust system blockage Visually inspect exhaust port Is the fault confirmed Inspect exhaust backpressure Is the fault confirmed Inspect three-way catalytic converter Is the fault confirmed Inspect muffler M201 2014.01...
Page 622: Exhaust System
Converter (3.1.6 Exhaust System, Removal and Installation). 4. Inspect muffler A. Remove the muffler. B. Inspect the muffler. Is the muffler normal? Inspect the exhaust system component joints and test the system for normal operation. Replace the muffler. M201 2014.01...
Page 623: Removal And Installation
Bolt torque: 45 Nm Nut torque: 70 ± 5 Nm M3106002 5. Remove 2 connecting bolts between exhaust manifold and three-way catalytic converter. Torque: 55 ± 5 Nm M3106003 M201 2014.01...
Page 624 8. Remove the exhaust manifold upper heat insulator. 1 Remove 4 retaining bolts from the exhaust manifold upper heat insulator. Torque: 10 ± 1 Nm M3106006 2 Remove the exhaust manifold upper heat insulator. M201 2014.01...
Page 625 Special tool: Oxygen sensor sleeve CA301- CA301 -022 M3106007 Installation 1. Installation is in the reverse order of removal. CAUTION: Inspect exhaust leakage, and tighten the trouble part to prevent leakage if leakage is present. Replace the damaged components when necessary. M201 2014.01...
Page 626: Three-Way Catalytic Converter
M3106008 4. Remove 2 connecting bolts between exhaust manifold and three-way catalytic converter. Torque: 55 ± 5 Nm M3106003 5. Remove 2 connecting bolts between three- way catalytic converter and muffler. Torque: 55 ± 5 Nm M3106009 M201 2014.01...
Page 627 Special tool: Oxygen sensor sleeve CA301- CA301-022 M3106010 Installation 1. Installation is in the reverse order of removal. CAUTION: Inspect exhaust leakage, and tighten the trouble part to prevent leakage if leakage is present. Replace the damaged components when necessary. M201 2014.01...
Page 628: Muffler
M3106011 4. Remove the muffler. Installation 1. Installation is in the reverse order of removal. CAUTION: Inspect exhaust leakage, and tighten the trouble part to prevent leakage if leakage is present. Replace the damaged components when necessary. M201 2014.01...
Page 629: Fuel System
Specifications Fuel pipe pressure 0.4 Mbar Torque Specifications Item lb-ft lb-in Fuel tank retaining bolt Fuel filter bracket bolt Fuel pump flange bolt Fuel main pipe retaining bolt 23 ± 2 Accelerator pedal retaining bolt 10 ± 1 M201 2014.01...
Page 630: Description And Operation
Components Description Fuel Pump The fuel pump is installed in the fuel tank, and form an assembly together with the fuel level sensor. It is installed through plastic locking ring and sealed by rubber washer. ×6 M3107013 M201 2014.01...
Page 631 Description Item Description Fuel tank Fuel vapor pipe Carbon canister with accessory Fuel pump assembly assembly Nylon fuel pipe assembly Fuel filter assembly Nylon return pipe assembly Fuel filler cap assembly Fuel vapor hose Fuel filler pipe assembly M201 2014.01...
Page 632: Fuel System Pressure Testing
Place a cleaning cloth into the specified container after test is completed. Clean the fuel pipe joint before removing the fuel pipe. M201 2014.01...
Page 633: Symptom Diagnosis And Testing
3. If an observed or reported problem is obvious and the cause has been found, solve the fault before proceeding to the next step. 4. If there is no obvious cause, verify the symptom by referring to the Symptom Chart. M201 2014.01...
Page 634: Symptom Chart
Procedure for Heavy Fuel Smell • Fuel filter (3.1.7 Fuel System, • Fuel tank vent hole Symptom Diagnosis Heavy fuel smell • Carbon canister control valve and Testing). • Carbon canister • Fuel system leakage • Fuel pressure M201 2014.01...
Page 635 Surging during driving • Throttle body fault • Engine overheating • Spark plug fault • Ignition timing • Exhaust system restrictions • Inadequate fuel pressure • Fuel pump mechanical fault • Fuel injector • Unstable signal from TP sensor M201 2014.01...
Page 636: Diagnosis Procedure For Fuel Pump Fault
Inspect fuel pump grounding circuit Inspect fuel pump relay Is the fault Is the fault confirmed confirmed Inspect engine control module Inspect fuel pump relay power circuit supply circuit Inspect fuel pump relay control circuit Inspect fuel pump power supply circuit M201 2014.01...
Page 637 "Executor test" - "Fuel pump". D. Measure the voltage between terminal 2 of fuel pump wiring harness connector S01 and reliable grounding. Standard voltage: 11 ~ 14 V Is the voltage value normal? M3107025 Go to step 4. Go to step 5. M201 2014.01...
Page 638 Repair the wiring harness between terminal 2 of fuel pump wiring harness connector S01 and grounding. 5. Inspect fuel pump relay A. Replace the fuel pump relay with a normal one. Is the fuel pump normal? Replace the relay. Go to step 6. M201 2014.01...
Page 639 Inspect and repair the faulty circuit between 84 83 terminal 82 of feul pump relay IR08 and terminal 69 of main relay IR05. Inspect and repair the faulty circuit between terminal 83 of fuel pump relay IR08 and battery. M3107027 M201 2014.01...
Page 640 D. Measure the circuit resistance between terminal 60 of ECM wiring harness connector E18 and terminal 80 of fuel pump relay IR08. Standard resistance: less than 5 Ω Is the resistance value normal? IR08 Go to step 8. Inspect and repair the faulty circuit. M3107028 M201 2014.01...
Page 641 5, 43 and 48 is normal. Is the engine control module circuit normal? Replace the engine control module. Refer to: Engine Control Module (3.1.12 M3108011 Electronic Control System - M7, Removal and Installation). Repair the circuit. M201 2014.01...
Page 642: Diagnosis Procedure For Heavy Fuel Smell
Heavy fuel smell General inspection Is the fault confirmed Inspect fuel pressure Is the fault confirmed Inspect carbon canister control valve sealing carbon canister Is the fault confirmed Inspect carbon canister control valve M201 2014.01...
Page 643 A. Inspect if the pipe connected with the carbon canister control valve leaks. B. Inspect if the carbon canister leaks. Is the inspection normal? Go to step 4. Repair the leaking part, repair or replace the carbon canister. M201 2014.01...
Page 644 Refer to: DTC P0444, P0458, P0459 (3.1.12 Electronic Control System - M7, DTC Diagnosis and Testing). Is the carbon canister control valve normal? Repair the fuel tank breather hole. Repair or replace the carbon canister control valve and the circuit. M201 2014.01...
Page 645: Removal And Installation
Refer to: Battery (3.1.10 Charging System, Removal and Installation). 3. Lift the vehicle. Refer to: Lifting (1.1.3 Traction and Lifting, Description and Operation). 4. Disconnect the fuel pipe wiring harness connectors on both sides of fuel filter in sequence. M3107004 M201 2014.01...
Page 646 Clean if necessary. 4 Do not damage the disconnected fuel pipe or wiring harness connectors, wrap them with plastic bag (1) to prevent the entry of foreign matter. M3107005 M201 2014.01...
Page 647 3.1.7-19 5. Remove the fuel filter retaining bolt and then remove the fuel filter. Torque: 10 Nm M3107006 Installation 1. Installation is in the reverse order of removal. CAUTION: Do not reverse the installation direction of fuel filter. M201 2014.01...
Page 648 1. Disconnect the negative battery cable. Refer to: Battery (3.1.10 Charging System, Removal and Installation). 2. Drain the fuel tank. 3. Lift the vehicle. Refer to: Lifting Vehicle (1.1.3 Traction and Lifting). 4. Disconnect the fuel pump wiring harness connector. M3107008 M201 2014.01...
Page 649: Fuel Tank
M3107003 6. Loosen the clamp and remove the fuel tank filler hose. M3107007 7. Loosen the hoop and disconnect the fuel tank vent hose. M3107009 8. Use a flat jack to support the fuel tank. M3107010 M201 2014.01...
Page 650 M3107011 10. Slowly lower the fuel tank about 20 cm to expose the joints of fuel pump, fuel outlet and return pipe on the top of fuel tank. M3107012 M201 2014.01...
Page 651 CAUTION: Do not apply excessive force to bend or twist the fuel pipe. CAUTION: Use plastic bags to wrap the joint ends avoid damage contamination. 15. Slowly lower the bracket to remove the fuel tank. M201 2014.01...
Page 652 After installing the fuel pipe joint clips, inspect and confirm that the fuel pipe joint cannot be pulled out. Be care not to damage the joint. Replace with new ones if the clips are damaged. M201 2014.01...
Page 653: Fuel Pump
CAUTION: The new components of fuel pump must have the same part number with that of original fuel pump. CAUTION: Do not operate fuel pump when it is free of fuel or in water, otherwise, fuel pump will be damaged. M201 2014.01...
Page 654 1 Remove 6 retaining bolts from the fuel pump pressure cover. Torque: 10 Nm ×6 M3107013 2 Pull upward the fuel pump to pull out the fuel tank. Inspection 1. Inspect the operating condition of fuel pump. 1 Remove the fuel pump. M201 2014.01...
Page 655 (not on the fuel pump side). M3107015 Test Conditions Specifications Battery positive (+) to terminal 4 Fuel pump operates Battery negative (-) to terminal 2 Replace the fuel pump if it does not operate. M201 2014.01...
Page 656 After installing the fuel pipe joint clips, inspect and confirm that the fuel pipe joint clips cannot be pulled out. Be care not to damage the joint. Replace with new ones if the clips are damaged. M201 2014.01...
Page 657: Fuel Main Pipe
2. Release the fuel system pressure. Refer to: Fuel System Pressure Test (3.1.7 Fuel System, General Inspection). 3. Turn over the driver side seat. 4. Remove the fuel main pipe. 1 Loosen the hoop, and then disconnect 2 crankcase vent hoses. M3107016 M201 2014.01...
Page 658: Fuel System
3 Remove the retaining bolt from fuel injector wiring harness grounding point. Torque: 10 ± 1 Nm M3107018 4 Disconnect the fuel injector wiring harness connectors in sequence. M3107019 5 Disconnect 2 fuel injector wiring harness retaining clamps in sequence. M3107020 M201 2014.01...
Page 659 CAUTION: Inspect and confirm that fuel pipe joint is securely inserted into the pipe. CAUTION: Turn the ignition switch to "ON" (do not start engine) to apply fuel pressure to fuel supply system, and then inspect the connecting part for leakage. M201 2014.01...
Page 660: Accelerator Pedal Assembly
M3107022 2. Remove 2 retaining bolts from accelerator pedal assembly and then remove the accelerator pedal assembly. Torque: 10 ± 1 Nm M3107023 Installation 1. Installation is in the reverse order of removal. M201 2014.01...
Page 661: Ignition System
Ignition type Sub-cylinder independent ignition Ignition sequence 1 - 3 - 4 - 2 Torque Specifications Item lb-ft lb-in Engine plaque 10 ± 1 Spark plug tightening torque 22 ± 2 Ignition coil retaining bolt 10 ± 1 M201 2014.01...
Page 662: Description And Operation
• Spark plug DG sensor (speed sensor) use induction type speed sensor to coordinate with pulse wheel to provide the information of engine speed and crankshaft top dead center in the ignition system. M201 2014.01...
Page 663: Components Location View
3.1.8-3 Ignition System 3.1.8-3 Components Location View M3108001 Item Description Item Description Engine trim cover Spark plug Ignition coil Cylinder head cover M201 2014.01...
Page 664 "Diagnosis". 4. Install ignition coil assembly to cylinder head and connect wiring harness connectors, and 6. After inspection, install the spark plugs and connect the negative battery cable. ignition coil. 7. Connect the fuel injector wiring harness connectors. M201 2014.01...
Page 665: Symptom Diagnosis And Testing
4. If the cause is not visually evident, verify the symptom by referring to the Symptom Chart. Visual Inspection Chart Electrical • Return circuit • Wiring harness • Electrical connector • Spark plug • Ignition coil • Engine control module (ECM) M201 2014.01...
Page 666: Symptom Chart
• Ignition coil electric leakage • Replace and power is insufficient engine in accelerating and • Ignition coil wiring harness power • Replace or reassembly. climbing connector loose • Severe spark plug carbon deposit • Adjust, clean or replace. M201 2014.01...
Page 667 Inspect the coil one by one and inspect if the coil results are consistent with requirements Spark plug inspection Ignition system Replace the faulty ignition is in good Inspect the spark plug one by one and inspect if coil condition the results are consistent with requirements M201 2014.01...
Page 668: Diagnosis Procedure For Spark Plug Does Not Flash Over
Inspect engine DTC Is the fault confirmed Inspect spark plug Is the fault confirmed Inspect engine control module circuit Inspect ignition coil power supply circuit Is the fault confirmed Is the fault confirmed Inspect ignition coil signal circuit M201 2014.01...
Page 669: Ignition System
B. Use multimeter to measure the voltage between terminal 29 of fuse IF15 and reliable grounding. Standard voltage: 11 ~ 14 V Is the voltage value normal? IF15 Go to step 3. Inspect and repair the ignition switch and fuse power supply circuit. M3108010 M201 2014.01...
Page 670 Replace the spark plug. 5. Inspect ignition coil A. Carry out ignition coil inspection procedure. Refer to: Ignition Coil Test (3.1.8 Ignition System, General Inspection). Is the ignition coil normal? Go to step 6. Replace the ignition coil. M201 2014.01...
Page 671 16 17 normal. D. Turn the ignition switch to "LOCK". Inspect if the grounding of terminals 5, 43 and 48 is normal. Is the circuit of engine control module normal? Go to step 8. M3108011 Repair the circuit. M201 2014.01...
Page 672 1 of engine ignition coil wiring harness connector E03. Standard resistance: less than 5 Ω Is the resistance value normal? Replace the engine control module. Refer to: Engine Control Module (3.1.12 Electronic Control System - M7, Removal and Installation). Inspect and repair the circuit. M201 2014.01...
Page 673: Diagnosis Procedure For Insufficient Engine Power
Insufficient engine power Inspect engine DTC Is the fault confirmed Inspect spark plug Is the fault confirmed Inspect ignition coil signal circuit Is the fault confirmed Inspect ignition coil Is the fault confirmed Inspect engine control module circuit M201 2014.01...
Page 674 Go to step 2. 2. Inspect spark plug A. Execute the testing procedure of spark plug Refer to: Spark Plug Test (3.1.8 Ignition System, General Inspection). Is the spark plug normal? Go to step 3. Replace the spark plug. M201 2014.01...
Page 675 A. Carry out ignition coil testing procedure. Refer to: Ignition Coil Test (3.1.8 Ignition System, General Inspection). Is the ignition coil normal? Go to step 5. Replace the ignition coil. Refer to: Ignition Coil (3.1.8 Ignition System, Removal Installation). M201 2014.01...
Page 676 5, 43 and 48 is normal. Is the circuit of the engine control module normal? Replace the engine control module. Refer to: Engine Control Module (3.1.12 Electronic Control System - M7, Removal and Installation). Repair the circuit. M201 2014.01...
Page 677: Removal And Installation
3. Disconnect 4 ignition coil wiring harness connectors in sequence. M3108003 4. Remove 4 retaining bolts from the ignition coil. Torque: 8 ± 2 Nm M3108004 5. Disconnect 4 ignition coils in sequence. Installation 1. Installation is in the reverse order of removal. M201 2014.01...
Page 678: Spark Plug
Spark plug electrode clearance "a": 0.85 mm M3108008 0.95 mm Installation CAUTION: The junction surface of spark plug installation hole must absolutely free of foreign matters. 1. Installation is in the reverse order of removal. M201 2014.01...
Page 679: Ignition Switch
Column, Removal Installation). 3. Remove 3 retaining screws from the steering lock upper and lower housings. ×3 M4206022 4. Separate the upper and lower housings of steering lock. M4206023 5. Disconnect the ignition switch wiring harness connector. M3108006 M201 2014.01...
Page 680 3.1.8-20 Ignition System 3.1.8-20 6. Remove 2 retaining screws from the ignition switch. M3108007 Installation 1. Installation is in the reverse order of removal. M201 2014.01...
Page 681: Starting System
3.1.9 Starting System Torque Specifications Item lb-ft lb-in Starting motor retaining bolt 23 ± 2 Starting motor main power supply wiring 10 ± 2 harness retaining nut Starting motor magnetic clutch wiring 7 ± 1 harness retaining nut M201 2014.01...
Page 682: Description And Operation
Drive lever separates the drive gear from flywheel ring gear by the action of torsional spring, then master contactor is disconnected, starter circuit is cut off. So the starting motor stops running and the starting process of engine is finished. M201 2014.01...
Page 683: Components Location View
3.1.9-3 Starting System 3.1.9-3 Components Location View Starting Motor M3109003 M201 2014.01...
Page 684: Components Exploded View
3.1.9-4 Starting System 3.1.9-4 Components Exploded View M3109004 M201 2014.01...
Page 685: Starting System
Description Starting motor assembly Bushing Magnetic switch assembly Drive lever Housing Brush holder plate Spring washer Bushing Retaining screw Rotor assembly Spring Overdrive clutch assembly Retainer ring Retainer ring Protective cover Special washer Screw Rotor front bracket assembly M201 2014.01...
Page 686: General Inspection
S17. original position. 3. Starting motor pinion should move out. 4. Disconnect the jumper wire from the positive battery, and the pinion should quickly return. S17-1 S17-1 M3109005 M3109007 M201 2014.01...
Page 687: Test Without Load
4. When the starting motor operates, measure voltage and current. 5. If either of them is not within the specified range, replace the starting motor. M3109008 Item Specifications Current without load 78 A Voltage drop without load 11.6 V M201 2014.01...
Page 688: Symptom Diagnosis And Testing
3. If an obvious cause for an observed or reported concern has been found, solve the fault before proceeding to the next step. 4. If the cause is not visually evident, verify the symptom by referring to the Symptom Chart. M201 2014.01...
Page 689: Symptom Chart
• Inspect whether the starting motor is • Starting motor Starting motor abnormal properly aligned or the housing is cracked. noise • Flywheel ring gear Ensure all the retaining bolts are well locked. If necessary, replace new starting motor or retaining bolts. M201 2014.01...
Page 690: Diagnosis Procedure For Starting Motor Fault
Inspect battery voltage Is the fault confirmed Inspect magnetic switch power supply voltage Is the fault confirmed Inspect magnetic switch power supply circuit Inspect starting motor Is the fault confirmed Is the fault confirmed Inspect ignition switch M201 2014.01...
Page 691 A. Turn the ignition switch to "ST". B. Measure the grounding voltage of terminal 1 of starting motor magnetic switch wiring harness connector S16. Is the voltage higher than 10 V? Go to step 4. Go to step 5. M3109009 M201 2014.01...
Page 692 P31 and reliable power supply. Is the starting motor normal? Go to step 6. Inspect and repair the open circuit fault between terminal 6 of wiring harness connector P31 and terminal 1 of starting motor wiring harness connector S16. M201 2014.01...
Page 693 Circuit between terminal 1 of starting motor wiring harness connector S17 and terminal 1 of battery wiring harness connector S19. • Circuit between terminal 1 of battery wiring harness connector S20 and M3109010 grounding. Replace the ignition switch. M201 2014.01...
Page 694: Diagnosis Procedure For Starting Motor Fails To Stop
Refer to: Starting Motor (3.1.9 Starting M31090012 System, Removal Installation). Repair the power supply short circuit between terminal 6 of ignition switch wiring harness connector P31 and terminal 1 of starting motor magnetic switch wiring harness connector S16. M201 2014.01...
Page 695: Diagnosis Procedure For Starting Motor Slow Run
Inspect if resistance of cable between battery and starting motor magnetic switch is too high Is the fault confirmed Inspect if resistance of grounding circuit between battery and starting motor is too high Is the fault confirmed Inspect battery and charging system M201 2014.01...
Page 696 Refer to: Starting Motor (3.1.9 Starting System, Removal Installation). Clean and lock all the battery negative connectors and tie band among starting motor holder, body and engine grounding. Test if the system works normally. If the problem continues, install new negative battery cable. M201 2014.01...
Page 697 4. Inspect battery and charging system A. Inspect the battery and charging system. Is the starting voltage higher than 10.5 V? Refer to: Battery (3.1.10 Charging System, Removal and Installation). Is the fault solved? Replace or repair the battery, repair the charging system. M201 2014.01...
Page 698: Removal And Installation
1 Disconnect the wiring harness from wiring harness retaining clamp. 2 Remove the starting motor retaining bolts. Torque: 32 ± 2 Nm M3109002 6. Remove the starting motor from the vehicle. Installation 1. Installation is in the reverse order of removal. M201 2014.01...
Page 699: Disassembly And Assembly
4. Remove the insulator and brush spring, then remove the brush holder. 5. Remove the stator, armature and drive lever. 6. Use snap ring pliers and screwdriver to remove the armature pressure plate, and then pull out the pinion snap ring and overdrive clutch. M3109014 M201 2014.01...
Page 700 CAUTION: When installing the brush, make sure to remove the grease from the brush and commutator completely. CAUTION: Make sure that there is no unnecessary contact between the brush and other component. M3109015 M201 2014.01...
Page 701 14 V Rated current 70 A Torque Specifications Item lb-ft lb-in Battery retaining pressure plate retaining nut Positive battery cable nut Negative battery cable nut Alternator upper retaining bolt Alternator adjusting bracket bolt 2 Alternator charging cable retaining nut M201 2014.01...
Page 702: Description And Operation
Alternator is characterized by built-in solid state regulator. All components of the regulator are turned off over the whole night. installed in an sealed box. The regulator and 2. Slow speed and stop and go. brush holder assembly are installed on the slip M201 2014.01...
Page 703 2. After turn the ignition switch to ON with key to start the engine, the alternator voltage is lower than the regulating voltage, and alternator starts to operate. At this time the P M201 2014.01...
Page 704: Components Location View
3.1.10-4 Charging System 3.1.10-4 Components Location View M3110015 M201 2014.01...
Page 705: Components Exploded View
M5 nut Front bearing M5 bolt Screw Conducting plate Rotor Cover Rear cover M4 screw Washer Screw Regulator Rectifier M5 nut Stud bolt M8 nut Rear bearing Insulation sleeve Stator Brush Cover M4 screw Front cover Rubber cover M201 2014.01...
Page 706: Charging System
3.1.10-6 Charging System 3.1.10-6 Battery and Accessory M3110002 Item Description Item Description Negative battery grounding Battery assembly cable Battery retaining pressure plate Positive battery cable retaining nut Battery retaining pressure plate Battery tray Battery retaining screw M201 2014.01...
Page 707: General Inspection
CAUTION: Do not charge the battery in the discharging detector or resistance wire, it vehicle. will generate spark and cause the gas exploded causing injury and damage. M201 2014.01...
Page 708: Battery Parasitic Current Test
HVAC motors. Measure the current, if it is less than 20 A, repair or replace 1. Connect the test equipment and select the the motor. appropriate range, connect the voltmeter between alternator B terminal and grounding. M201 2014.01...
Page 709: Alternator Belt Tension Inspection
3 If the belt tension is not as specified, readjust the alternator belt tension until it is within the specified range. MASS = 4.4 g/m Parameter setting WIDTH = 17.8 mm/R SPAN = 208 mm 3. Connect the negative battery cable. M201 2014.01...
Page 710: Inspection And Verification
4. If there is no obvious cause, verify the symptom by referring to the Symptom Chart. Visual Inspection Chart Mechanical Electrical • Fuse • Wiring harness • Electrical connector • Accessory drive belt • Battery • Alternator • Battery circuit • Charging system warning lamp M201 2014.01...
Page 711: Symptom Chart
• Diagnosis Procedure for Charging Indicator not on indicator not on • Poor contact between brushes and slip rings • Voltage regulator • Belt Alternator noise • Bearing • Diagnosis Procedure for Alternator Noise • Stator and rotor M201 2014.01...
Page 712: Diagnosis Procedure For Insufficient Battery Charging
3.1.10-12 Charging System 3.1.10-12 Diagnosis Procedure for Insufficient Battery Charging Insufficient battery charging Inspect alternator charging voltage Is the fault confirmed Inspect battery parasitic current Is the fault confirmed Inspect alternator M201 2014.01...
Page 713 Inspection) or Battery (3.1.10 Charging System, Removal and Installation). 3. Inspect alternator A. Perform the alternator test procedures. Is it normal? Charge the battery. Inspect the alternator. Refer to: Diagnosis Procedure Charging Indicator Constant ON (3.1.10 Charging System, Symptom Diagnosis Testing). M201 2014.01...
Page 714: Diagnosis Procedure For Battery Overcharging
Go to step 2. The system is normal. 2.Inspect alternator regulator A. Replace the alternator regulator. Is the alternator charging voltage normal? The system is normal. Disassemble and inspect the alternator. Refer to: Alternator (3.1.10 Charging System, Disassembly Assembly). M201 2014.01...
Page 715: Diagnosis Procedure For Charging Indicator Constant On
Diagnosis Procedure for Charging Indicator Constant ON Charging indicator constant on Inspect alternator belt Is the fault confirmed Inspect alternator charging voltage Is the fault confirmed Inspect alternator regulator power supply circuit Is the fault confirmed Inspect alternator regulator M201 2014.01...
Page 716 P03 and reliable grounding. Standard voltage: 11 ~ 14 V. E. Connect the alternator wiring harness connector P03. Is the voltage value within the standard range? M3110017 Go to step 4. Repair the alternator regulator power supply circuit. M201 2014.01...
Page 717 3.1.10-17 Charging System 3.1.10-17 Test Conditions Details/Results/Actions 4. Inspect alternator regulator A. Replace the alternator regulator. Is the alternator charging voltage normal? The system is normal. Replace the alternator. M201 2014.01...
Page 718: Diagnosis Procedure For Charging Indicator Not On
Inspect charging indicator LED Is the fault confirmed Inspect circuit resistance between instrument cluster and voltage regulator Is the fault confirmed Inspect circuit between instrument cluster and voltage regulator Is the fault confirmed Inspect alternator regulator M201 2014.01...
Page 719 A. Turn the ignition switch to "LOCK". Disconnect the instrument cluster wiring harness connector P21, and measure the resistance between terminal 24 and grounding. Is the resistance value less than 1 Ω? Repair or replace instrument cluster. Go to step 3. M3110018 M201 2014.01...
Page 720 Repair the circuit between regulator and instrument cluster. M3110019 4. Inspect alternator regulator A. Replace the alternator regulator. Refer to: Alternator (3.1.10 Charging System, Disassembly Assembly). Does the fault solved? End. Replace the brush. Refer to: Alternator (3.1.10 Charging System, Disassembly Assembly). M201 2014.01...
Page 721: Diagnosis Procedure For Alternator Noise
2. Inspect alternator charging voltage A. Remove the alternator belt. B. Start the engine. Does the alternator noise still exist? Inspect the noise from compressor and booster pump. Repair the alternator. Refer to: Alternator (3.1.10 Charging System, Disassembly Assembly). M201 2014.01...
Page 722: Removal And Installation
Torque: 9 Nm M3110003 3. Remove the alternator wiring harness bracket retaining bolt. Torque: 8 Nm M3110004 4. Loosen the alternator upper retaining bolt (1), and loosen the alternator adjusting bracket bolt (2) and bolt (3) in sequence. M3110005 M201 2014.01...
Page 723 7. Remove the alternator upper retaining bolt. Torque: 50 Nm M3110009 Installation 1. Installation is in the reverse order of removal. CAUTION: Inspect the alternator belt tension. Refer to: Alternator Belt Tension Inspection (3.1.10 Charging system, General Inspection). M201 2014.01...
Page 724: Battery
1. Disconnect the negative battery cable (1) and positive cable (2). Torque for positive cable: 9 Nm Torque for negative cable: 8 Nm M3110010 2. Remove the battery pressure plate retaining nut. Torque: 8 Nm M3110011 3. Remove the battery. M3110012 M201 2014.01...
Page 725 3.1.10-25 Charging System 3.1.10-25 4. Remove the battery tray. M3110013 Installation 1. Installation is in the reverse order of removal. M201 2014.01...
Page 726: Disassembly And Assembly
1. Remove the retaining bolts and conducting plate at the rear cover. ×3 M3110020 2. Remove alternator output terminal insulation sleeve. M3110021 3. Remove the brush. 1 Remove the brush dustproof cover. ×2 2 Remove the brush retaining bolts. M3110022 M201 2014.01...
Page 727 Charging System 3.1.10-27 4. Remove the regulator retaining bolts, and remove the regulator. ×3 M3110023 5. Remove the retaining screws from stator output terminal and rectifier. M3110024 6. Remove the rubber cover. M3110025 7. Remove the alternator pulley. M3110026 M201 2014.01...
Page 728 M3110028 10. Measure resistance between rotor conducting ring and rotor housing. It should be infinite, if the resistance value is abnormal, replace the rotor assembly. M3110029 Assembly 1. Assembly is in the reverse order of disassembly. M201 2014.01...
Page 729: Emission Control System
The positive crankcase ventilation valve below following table: the lower O-ring are partially exposed in the intake manifold vacuum. The part between lower and upper O-ring is exposed in the crankcase M201 2014.01...
Page 730 (PWM) to precisely control the fuel vapor flowing into the engine. In some testing processes of evaporative emissions system, this valve will open to make the engine vacuum enter the evaporative emissions system. M3211016 M201 2014.01...
Page 731: Components Location View
3.1.11-3 Emission Control System 3.1.11-3 Components Location View M3111004 Item Description Item Description Engine assembly Air intake hose PCV valve M201 2014.01...
Page 732: Emission Control System
3.1.11-4 Emission Control System 3.1.11-4 M3111005 Item Description Item Description Carbon canister control valve Carbon canister emission outlet hose Carbon canister gas outlet hose Carbon canister control valve Carbon canister control valve Fuel vapor pipe inlet hose M201 2014.01...
Page 733: General Inspection
5. Use suitable air source to blow from one pipe • Engine idle speed is too high inlet of the carbon canister, gas should flow • Engine oil leakage out from the other two orifices, otherwise, replace the carbon canister. M201 2014.01...
Page 734: Symptom Diagnosis And Testing
3. If an obvious cause for an observed or reported concern is found, solve the fault before proceeding to the next step. 4. If the cause is not visually evident, verify the symptom by referring to the Symptom Chart. M201 2014.01...
Page 735: Symptom Chart
• Replace the carbon canister control valve fault valve. • ECM fault • Replace the ECM. Diagnosis Procedure for Carbon Canister Control Solenoid Fault Refer to: DTC P0444, P0458, P0459 (3.1.12 Electronic Control System - M7, DTC Diagnosis and Testing). M201 2014.01...
Page 736: Removal And Installation
PCV valve vacuum tube. M3111007 2. Remove the PCV valve. M3111008 3. Remove the PCV valve seal boot. 4. Inspect the PCV valve seal boot, replace when necessary. M3111001 Installation 1. Installation is in the reverse order of removal. M201 2014.01...
Page 737: Carbon Canister Control Valve
3. Disconnect the carbon canister control valve from carbon canister control valve support. M3111011 4. Loosen the carbon canister control valve hose retaining clamp and disconnect the carbon canister control valve hose. Installation 1. Installation is in the reverse order of removal. M201 2014.01...
Page 738: Active Carbon Canister
Besides take appropriate measures such as filtration or purification, to prevent foreign objects (particles, etc.) entering the carbon canister control valve from carbon canister or hose. 1. Installation is in the reverse order of removal. M201 2014.01...
Page 739: Front Oxygen Sensor
2. Disconnect the front oxygen sensor wiring harness connector. M3106001 3. Use the special tool to remove the front oxygen sensor. Torque: 50 ± 10 Nm Special tool: oxygen sensor sleeve CA301- CA301-022 M3111015 Installation 1. Installation is in the reverse order of removal. M201 2014.01...
Page 740: Rear Oxygen Sensor
2. Disconnect the rear oxygen sensor wiring harness connector. M3106008 3. Use the special tool to remove the rear oxygen sensor. Torque: 50 ± 10 Nm Special tool: oxygen sensor sleeve CA301- CA301-022 M3106010 Installation 1. Installation is in the reverse order of removal. M201 2014.01...
Page 741: Electronic Control System - M7
4 ± 0.4 Coolant temperature sensor 20 or less 15 or less Retaining bolt of intake pressure/temperature sensor 8 ± 2 Front oxygen sensor 50 ± 10 Rear oxygen sensor 50 ± 10 Knock sensor retaining bolt 20 ± 5 M201 2014.01...
Page 742: System Overview
Coolant temperature sensor Carbon canister control valve Knock sensor Air intake pressure/temperature Crankshaft position sensor sensor Fuel injector Electrical fuel pump Ignition coil Malfunction indicator Stepper motor Data link connector Oxygen sensor Three-way catalytic converter Throttle position sensor M201 2014.01...
Page 743: Control System Function Overview
It ensures that unburned gas will not be different driving conditions. There are two forms discharged and be started again under above of injection timing, one is synchronous injection, different conditions. which always injects at the same crankshaft M201 2014.01...
Page 744 When the oxygen sensor is cooled. Signal to increase injection amount Signal to decrease injection amount Low voltage High voltage Oxygen sensor Fuel injector Air-fuel mixture Oxygen content gets rich decreases Air-fuel mixture Oxygen content increases gets lean M3112002 M201 2014.01...
Page 745 When the throttle opening is larger than that at idle speed position, it is also calculated based on the initial ignition timing, plus the basic ignition advance angle that is determined by engine speed, air intake pressure and engine cooling compensation, and the idle stability related advance compensation angle. M201 2014.01...
Page 746 Fuel tank pressure control valve is used to maintain constant tank pressure. This valve opens so that the vapor goes into the carbon canister. On the contrary, when the tank pressure becomes negative and reaches its specified value, the valve opens so that air goes into the tank. M201 2014.01...
Page 747: Fault Diagnosis Function Overview
Electronic Injection System Condition Display Cooling system condition, stable condition, dynamic condition, emission control condition, oxygen sensor condition, idle speed condition, M201 2014.01...
Page 748: Components Description
The ignition coil transforms the low voltage of primary winding into high voltage of secondary winding, and the spark is discharged through the spark plug, igniting the mixture of air M201 2014.01...
Page 749 The vehicle is equipped with two oxygen sensors, which are located in the front and rear of three- way catalytic converter respectively. The oxygen sensor can detect the oxygen content in the exhaust gas, by which ECM determines whether M201 2014.01...
Page 750 M3112011 intake pressure/temperature sensor Air intake pressure/temperature sensor is located on the intake manifold and integrated with pressure sensor and temperature sensor. Based on sensor signals and other information, ECM regulates the injection amount. M3112012 M201 2014.01...
Page 751 3.1.12-11 Components Location View １０５１０４７ M3112013 Item Description Item Description Air intake pressure/temperature Ignition coil sensor Oxygen sensor Crankshaft position sensor Coolant temperature sensor Knock sensor Idling stepper motor Fuel injector Throttle position sensor M201 2014.01...
Page 752: General Inspection
Active Test Procedure 1. Carry out necessary vehicle preparation and appearance inspection. 2. Connect the diagnostic tool to data link connector in the cab. 3. Use the diagnostic tool to enter Actuators menu, and carry out the desired active test. M201 2014.01...
Page 753: Symptom Diagnosis And Testing
4. If the cause is not visually evident, verify the symptom and diagnose the system with diagnostic tool. Visual Inspection Chart Electrical • Fuse • Relay • Wiring harness • Electrical connector • Sensor • Switch • Engine Control Module (ECM) M201 2014.01...
Page 754: Intermittent Malfunction Diagnosis Procedure
D. Turn on the switch manually. E. When monitoring the data flow, gently shake the M3112015 connector or wiring harness of switch. If the data flow value is unstable, please inspect if there is a poor connection. M201 2014.01...
Page 755 D. Vibrate the actuator or relay with fingers for 3 seconds. M3112017 If you hear unstable "clicking" sound, inspect if there are poor connections or abnormal installation. CAUTION: Strong vibration of relay may open it. M201 2014.01...
Page 756: Symptom Chart
Refer to: Diagnosis Procedure Cold Start • Spark plug Problem (3.1.12 • Fuel pump Electronic Control Cold start problem • Fuel injector System Symptom Diagnosis • Throttle body and Testing). • Engine mechanical • Engine control module circuit M201 2014.01...
Page 757 Electronic Control flameout at acceleration • Fuel injector System Acceleration problem Symptom Diagnosis • Spark plug Acceleration slow reaction and Testing). • Ignition timing Acceleration weak, poor • Fuel performance • Exhaust blockage • Engine control module circuit M201 2014.01...
Page 758 Emergency during vehicle • Main relay and fuel pump running relay intermittent fault • Throttle body • Engine overheating • Spark plug • Ignition timing • Exhaust system restriction • Fuel pressure inadequate • Fuel pump mechanical • Fuel injector M201 2014.01...
Page 759 • ECM circuit and Testing). Refer to: Diagnosis Procedure • MIL indicator bulb P0650 • Instrument cluster circuit (3.1.12 Electronic MIL indicator is not on Control System - M7, • Instrument cluster Symptom Diagnosis • ECM and Testing). M201 2014.01...
Page 760: Diagnosis Procedure For Engine Not Starting At Normal Start Speed
Inspect ignition system Is the fault confirmed Inspect fuel pressure Is the fault confirmed Inspect engine compression pressure Inspect water in fuel Inspect air intake system and exhaust system Is the fault confirmed Inspect engine control module circuit M201 2014.01...
Page 761 3. Inspect fuel pressure A. Turn the ignition switch to "LOCK". B. Measure the fuel pressure. Refer to: Fuel System Pressure Test (3.1.7 Fuel System, General Inspection). Is the fuel pressure normal? Go to step 4. Inspect the fuel system. M201 2014.01...
Page 762 B. Remove the exhaust pipe and three-way catalytic converter, and inspect if there is foreign matter or three-way catalytic converter which comes off due to damage to get the emission system clogged. Are they normal? Go to step 7. Clean or replace the fault parts. M201 2014.01...
Page 763 5, 43 and 48 is normal. Is the engine control module circuit normal? Replace the engine control module. Refer to: Engine Control Module (3.1.12 M3112019 Electronic Control System - M7, Removal and Installation). Repair the circuit. M3112020 M201 2014.01...
Page 764: Diagnosis Procedure For Cold Start Problem
Inspect throttle Is the fault confirmed Inspect ignition system Is the fault confirmed Inspect fuel pressure Inspect coolant temperature sensor Inspect compression pressure in the cylinder Is the fault Inspect fuel injector confirmed Inspect engine control module circuit M201 2014.01...
Page 765 Refer to: Ignition Spark Test (3.1.8 Ignition System, General Inspection). Is the ignition spark test normal? Go to step 4. Inspect the ignition system. Refer to: Diagnosis Procedure for Spark Plugs not Flashing Over (3.1.8 Ignition System, Symptom Diagnosis and Testing). M201 2014.01...
Page 766 Inspect the engine mechanical system. Go to step 7. 7. Inspect fuel injector A. Remove the fuel injectors. B. Inspect the fuel injectors for leakage or blockage. Are they normal? Go to step 8. Replace the fuel injector. M201 2014.01...
Page 767 5, 43 and 48 is normal. Is the engine control module circuit normal? Replace the engine control module. Refer to: Engine Control Module (3.1.12 M3112019 Electronic Control System - M7, Removal and Installation). Repair the circuit. M3112020 M201 2014.01...
Page 768: Diagnosis Procedure For Hot Start Problem
Hot start problem Inspect DTC Is the fault confirmed Inspect ignition system Is the fault confirmed Inspect fuel pressure Is the fault confirmed Inspect coolant temperature sensor Inspect fuel Is the fault confirmed Inspect engine control module circuit M201 2014.01...
Page 769 3. Inspect fuel pressure A. Turn the ignition switch to "LOCK". B. Measure the fuel pressure. Refer to: Fuel System Pressure Test (3.1.7 Fuel System, General Inspection). Is the fuel pressure normal? Go to step 4. Inspect the fuel system fault. M201 2014.01...
Page 770 5, 43 and 48 is normal. Is the engine control module circuit normal? Replace the engine control module. Refer to: Engine Control Module (3.1.12 M3112019 Electronic Control System - M7, Removal and Installation). Repair the circuit. M3112020 M201 2014.01...
Page 771: Diagnosis Procedure For Start Normal But Idle Speed Unstable At Any Time
Inspect air intake system Is the fault confirmed Inspect throttle Is the fault confirmed Inspect spark plug Inspect ignition coil Inspect fuel injector Inspect fuel Inspect compression pressure Is the fault Inspect ignition timing confirmed Inspect engine control module circuit M201 2014.01...
Page 772 Repair the air intake system. 3. Inspect throttle A. Turn the ignition switch to "LOCK". B. Inspect if the throttle is stuck. Is the throttle normal? Go to step 4. Clean the throttle, idling stepper motor or replace the throttle. M201 2014.01...
Page 773 B. Inspect the fuel injectors for leakage, blockage or flow error. Are they normal? Go to step 7. Replace the fuel injector. 7. Inspect fuel A. Is the fault caused by just refueling? Replace the fuel. Go to step 8. M201 2014.01...
Page 774 Inspect the engine mechanical system. Go to step 9. 9. Inspect ignition timing A. Inspect the ignition timing. Refer to: Timing Inspection (3.1.2 Mechanical System, General Inspection). Is the ignition timing normal? Go to step 10. Adjust the ignition timing. M201 2014.01...
Page 775 5, 43 and 48 is normal. Is the engine control module circuit normal? Replace the engine control module. Refer to: Engine Control Module (3.1.12 M3112019 Electronic Control System - M7, Removal and Installation). Repair the circuit. M3112020 M201 2014.01...
Page 776: Diagnosis Procedure For Start Normal But Idle Speed Unstable Or Flameout With Partial Load (A/C
Is the fault confirmed Inspect if engine output power increases when A/C is turned on Is the fault confirmed Inspect engine control module A/C on signal Inspect fuel injector Is the fault confirmed Inspect engine control module circuit M201 2014.01...
Page 777 D. Turn on the A/C, observe the change of data flow parameters. Are there changes? Go to step 4. Inspect the A/C system. Refer to: Diagnosis Procedure Insufficient Refrigeration (4.1.1 Heating, Ventilation and Conditioning, Symptom Diagnosis and Testing). M201 2014.01...
Page 778 5, 43 and 48 is normal. Is the engine control module circuit normal? Replace the engine control module. Refer to: Engine Control Module (3.1.12 M3112019 Electronic Control System - M7, Removal and Installation). Repair the circuit. M3112020 M201 2014.01...
Page 779: Diagnosis Procedure For Start Normal, Idle Speed Too High
Is the fault confirmed Inspect if idling stepper motor is stuck Is the fault confirmed Inspect air intake system Inspect coolant temperature sensor Inspect coolant temperature sensor circuit Is the fault Inspect ignition timing confirmed Inspect engine control module circuit M201 2014.01...
Page 780 A. Inspect the air intake system for leakage. Does the air intake system leak? Repair the air intake system. Refer to: Diagnosis Procedure for Intake Air Leak (3.1.5 Air Intake System, Symptom Diagnosis Testing). Go to step 5. M201 2014.01...
Page 781 Repair the coolant temperature sensor circuit. The system is normal. 7. Inspect ignition timing A. Inspect the ignition timing. Refer to: Timing Inspection (3.1.2 Mechanical System, General Inspection). Is the ignition timing normal? Go to step 8. Adjust the ignition timing. M201 2014.01...
Page 782 5, 43 and 48 is normal. Is the engine control module circuit normal? Replace the engine control module. Refer to: Engine Control Module (3.1.12 M3112019 Electronic Control System - M7, Removal and Installation). Repair the circuit. M3112020 M201 2014.01...
Page 783: Diagnosis Procedure For Acceleration Fault
Inspect throttle Is the fault confirmed Inspect spark plug Inspect fuel injector Inspect fuel Inspect air intake pressure sensor and throttle position sensor Inspect ignition timing Is the fault Inspect exhaust backpressure confirmed Inspect engine control module circuit M201 2014.01...
Page 784 B. Inspect the spark plug in each cylinder, and observe whether the model and clearance meet the standard. Refer to: Spark Plug (3.1.8 Ignition System, removal Installation). Is the spark plug in each cylinder normal? Go to step 5. Replace the spark plug. M201 2014.01...
Page 785 Are their data flows normal? Go to step 8. Replace the air intake pressure sensor and throttle position sensor, or repair the sensor circuit. Refer to: (3.1.12 Electronic Control System - M7, Removal and Installation). M201 2014.01...
Page 786 Go to step 9. Adjust the ignition timing. 9. Inspect exhaust backpressure A. Inspect the exhaust backpressure. Refer to: Exhaust Backpressure Test (3.1.6 Exhaust System, General Inspection). Is the exhaust backpressure normal? Go to step 10. Repair the exhaust system. M201 2014.01...
Page 787 5, 43 and 48 is normal. Is the engine control module circuit normal? Replace the engine control module. Refer to: Engine Control Module (3.1.12 M3112019 Electronic Control System - M7, Removal and Installation). Repair the circuit. M3112020 M201 2014.01...
Page 788: Diagnosis Procedure For Unstable Engine Operation
Is the fault confirmed Inspect spark plug Inspect fuel injector Inspect fuel pressure Inspect air intake pressure sensor and throttle position sensor Inspect ignition timing Is the fault Inspect engine support confirmed components Inspect engine control module circuit M201 2014.01...
Page 789 "O2 sensor voltage bank1 sensor 1, O2 sensor voltage bank1 sensor 2". Is the data flow normal? Go to step 4. Repair or replace the oxygen sensor or circuit. M201 2014.01...
Page 790 6. Inspect fuel pressure A. Turn the ignition switch to "LOCK". B. Measure the fuel pressure. Refer to: Fuel System Pressure Test (3.1.7 Fuel System, General Inspection). Is the fuel pressure normal? Go to step 7. Inspect the fuel system. M201 2014.01...
Page 791 Go to step 9. Adjust the ignition timing. 9. Inspect engine support components A. Inspect the engine support components. Is there crack, damage, or loose or lost bolt on the engine support components? Repair the fault parts. Go to step 10. M201 2014.01...
Page 792 5, 43 and 48 is normal. Is the engine control module circuit normal? Replace the engine control module. Refer to: Engine Control Module (3.1.12 M3112019 Electronic Control System - M7, Removal and Installation). Repair the circuit. M3112020 M201 2014.01...
Page 793: Diagnosis Procedure For Easy Flameout At Start
2 circuit Inspect crankshaft position sensor terminal 3 circuit Inspect spark plug Inspect fuel injector Is the fault Inspect fuel pressure confirmed Inspect air intake pressure sensor and throttle position sensor Inspect ignition timing Inspect engine control module circuit M201 2014.01...
Page 794 3. Inspect crankshaft position sensor waveform A. Measure the waveform between terminals 2 and 3 of sensor with an oscilloscope when engine idling. Standard waveform is as shown in left figure. Is it normal? Go to step 6. Go to step 4. M3112106 M201 2014.01...
Page 795 E17 and reliable grounding. Inspect for short to power supply. Standard voltage: 0 V Is the circuit normal? Go to step 5. M3112021 Repair the fault circuit between terminal 2 of crankshaft position sensor E17 and terminal 47 of engine control module E18. M3112022 M3112023 M201 2014.01...
Page 796 Replace the crankshaft position sensor. Refer to: Crankshaft Position Sensor M3112024 (3.1.12 Electronic Control System - M7, Removal and Installation). Repair the fault circuit between terminal 3 of crankshaft position sensor E17 and terminal 40 of engine control module E18. M3112025 M3112026 M201 2014.01...
Page 797 8. Inspect fuel pressure A. Turn the ignition switch to "LOCK". B. Measure the fuel pressure. Refer to: Fuel System Pressure Test (3.1.7 Fuel System, General Inspection). Is the fuel pressure normal? Go to step 9. Inspect the fuel system. M201 2014.01...
Page 798 Electronic Control System - M7, Removal and Installation). 10.Inspect ignition timing A. Inspect the ignition timing. Refer to: Timing Inspection (3.1.2 Mechanical System, General Inspection). Is the ignition timing normal? Go to step 11. Adjust the ignition timing. M201 2014.01...
Page 799 5, 43 and 48 is normal. Is the engine control module circuit normal? Replace the engine control module. Refer to: Engine Control Module (3.1.12 M3112019 Electronic Control System - M7, Removal and Installation). Repair the circuit. M3112020 M201 2014.01...
Page 800: Diagnosis Procedure For Emergency During Vehicle Running
Is the fault confirmed Inspect crankshaft position sensor signal plate Inspect spark plug Inspect fuel injector Inspect fuel pressure Inspect ignition timing Is the fault Inspect carbon canister system confirmed Inspect exhaust backpressure Inspect engine control module circuit M201 2014.01...
Page 801 Engine speed Actual intake manifold pressure Throttle position angle signal Knock sensor signal 1 Knock sensor signal 2 Does the data flow change normally in the specified range? Go to step 4. Repair the corresponding fault. M201 2014.01...
Page 802 Go to step 6. Replace the spark plug. 6. Inspect fuel injector A. Remove the fuel injectors. B. Inspect the fuel injectors for leakage, blockage or flow error. Are they normal? Go to step 7. Replace the fuel injector. M201 2014.01...
Page 803 Adjust the ignition timing. 9. Inspect carbon canister system A. Inspect the carbon canister system. Refer to: Carbon Canister Inspection (3.1.11 Emission Control System, General Inspection). Is the carbon canister system normal? Go to step 10. Repair the carbon canister system. M201 2014.01...
Page 804 5, 43 and 48 is normal. Is the engine control module circuit normal? Replace the engine control module. Refer to: Engine Control Module (3.1.12 M3112019 Electronic Control System - M7, Removal and Installation). Repair the circuit. M3112020 M201 2014.01...
Page 805: Diagnosis Procedure For Flameout During Coasting
Inspect DTC Inspect spark plug Inspect fuel injector Inspect fuel Is the fault confirmed Is the fault confirmed Inspect engine control module circuit Inspect air intake pressure sensor and throttle position sensor Inspect ignition timing Inspect exhaust backpressure M201 2014.01...
Page 806 C. Disconnect the electric fan wiring harness connector. D. Is the A/C system normal? Is the system normal after disconnecting the magnetic clutch and fan wiring harness connectors? Repair magnetic clutch connection fault. Go to step 4. M201 2014.01...
Page 807 B. Inspect the fuel injectors for leakage, blockage or flow error. Are they normal? Go to step 7. Replace or clean the fuel injector. 7. Inspect fuel A. Is the fault caused by just refueling? Replace the fuel. Go to step 8. M201 2014.01...
Page 808 Go to step 10. Adjust the ignition timing. 10.Inspect exhaust backpressure A. Inspect the exhaust backpressure. Refer to: Exhaust Backpressure Test (3.1.6 Exhaust System, General Inspection). Is the exhaust backpressure normal? Go to step 11. Repair the exhaust system. M201 2014.01...
Page 809 5, 43 and 48 is normal. Is the engine control module circuit normal? Replace the engine control module. Refer to: Engine Control Module (3.1.12 M3112019 Electronic Control System - M7, Removal and Installation). Repair the circuit. M3112020 M201 2014.01...
Page 810: Engine Control Module Terminal List
A/C medium pressure switch 0.5 LG/RD Blower switch 0.5 LG/BK Evaporator thermistor 0.5 LG/WH Diagnosis K-line 0.5 PK/BU Continuous power supply 0.5 BU Ignition switch 0.5 BU/BN 5 V power supply 2 0.5 YE/BK 5 V power supply 1 M201 2014.01...
Page 811 A/C switch 0.5 BK/OG Front oxygen sensor 0.5 BU/WH Crankshaft position sensor 0.5 BK Power GND 1 0.5 WH/GN Cylinder 3 fuel injector 0.5 WH/BN Cylinder 1 fuel injector 0.5 RD/BU Non-continuous power supply 0.5 BK/WH Radiator-fan relay M201 2014.01...
Page 812: Diagnostic Trouble Code (Dtc) Type
It is a special diagnostic path for fuel supply system. After the fault is detected in 3 consecutive driving cycles, MIL will come on; then off if it is detected to be repaired in 4 Type 11 consecutive driving cycles; and the fault will be deleted after 40 continuous trouble-free warm-up cycles. M201 2014.01...
Page 813: Dtc Code List
Manifold Abs. Pressure or Bar. Pressure Low Input √ P0108 Manifold Abs. Pressure or Bar. Pressure High Input √ P0112 Intake Air Temp. Circ. Low Input √ P0113 Intake Air Temp. Circ. High Input √ P0117 Engine Coolant Temp. Circ. Low Input √ M201 2014.01...
Page 814 √ or flash P0301 Cyl.1 Misfire Detected √ or flash P0302 Cyl.2 Misfire Detected √ or flash P0303 Cyl.3 Misfire Detected √ or flash P0304 Cyl.4 Misfire Detected √ or flash Ign./Distributor Eng. Speed Inp. Circ. Range/ P0321 √ Performance M201 2014.01...
Page 815 Malfunction Indicator Lamp Control Circ. √ P0691 Cooling Fan 1 Control Circuit Low × P0692 Cooling Fan 1 Control Circuit High × P0693 Cooling Fan 2 Control Circuit Low × P0694 Cooling Fan 2 Control Circuit High × M201 2014.01...
Page 816 O2 Sensor Signal Stuck Lean; Bank 1 Sensor 1 √ P2196 O2 Sensor Signal Stuck Rich; Bank 1 Sensor 1 √ P2270 O2 Sensor Signal Stuck Lean; Bank 1 Sensor 2 √ P2271 O2 Sensor Signal Stuck Rich; Bank 1 Sensor 2 √ M201 2014.01...
Page 817: Failure Protection List
Repair the circuit fault. P0627 P0692, P0691, Low speed fan control circuit fault Repair the circuit fault. P0480 P0694, P0693, High speed fan control circuit fault Repair the circuit fault. P0481 P0650 MIL circuit fault Repair the circuit fault. M201 2014.01...
Page 818 P0304 • Forbid air-fuel ratio self- system. learning • Forbid carbon canister flushing 3. Maximum misfire fault is detected and cylinder cut- off operation is performed: • Turn off Lambda closed loop control M201 2014.01...
Page 819 P2196 diagnosis sensor. • Forbid catalytic converter Repair the fault, diagnosis P0138, P0137, inspect the sensor Rear oxygen sensor circuit P0136, P0140 circuit or replace the • Forbid rear oxygen sensor oxygen sensor. aging diagnosis M201 2014.01...
Page 820 • Ignition angle of each Repair the fault, and cylinder is retarded for - 9 P0328 Knock sensor short fault inspect the knock degrees when entering sensor connection. knock control M201 2014.01...
Page 821: Data Flow List
1.07 V 0.7 V voltage Actual intake manifold pressure 1010 hPa 340 hPa 260 hPa Air mass flow filtered 0.0 kg/h 9.1 kg/h 13.6 kg/h Desired position of stepper motor ADC-signal throttle angle 0.52 V 0.52 V 0.68 V M201 2014.01...
Page 822 Idle speed control desired torque change 0.0% -0.8% 0.0% Relative fuel part of the purge control 0.0% 0.0% 1.2% Canister purge rate 0.0% 0.0% 0.0% Charcoal canister charge 12.6 Operating time since prime start 0 min 0 min 0 min M201 2014.01...
Page 823: Active Test List
Test condition for Fan Relay On: No device control limit for this case. Retard the ignition coil ignition Spark Retard angle Set Stepper Test condition: No stepper actuator test Set the stepper motor position 0-255 Position active. M201 2014.01...
Page 824 Manifold Absolute Pressure/Barometric Refer to: DTCs P0105, P0106, P0105 Pressure Circuit P0107, P0108 Manifold Abs. Pressure or Bar. Pressure P0106 Range/Performance Manifold Abs. Pressure or Bar. Pressure Low P0107 Input Manifold Abs. Pressure or Bar. Pressure High P0108 Input M201 2014.01...
Page 825 Cylinder 4 - Injector Circuit Low P0271 Cylinder 4 - Injector Circuit High P0300 Random/Multiple Cylinder Misfire Detected Refer to: DTCs P0300, P0301, P0302, P0303, P0304 P0301 Cyl.1 Misfire Detected P0302 Cyl.2 Misfire Detected P0303 Cyl.3 Misfire Detected P0304 Cyl.4 Misfire Detected M201 2014.01...
Page 826 Fuel Pump "A" Control Circuit High P0645 AC Clutch Relais Circuit Refer to: DTCs P0645, P0646, P0647 P0646 A/C Clutch Relay Control Circuit Low P0647 A/C Clutch Relay Control Circuit High P0650 Malfunction Indicator Lamp Control Circ. Refer to: DTC P0650 M201 2014.01...
Page 827 O2 Sensor Signal Stuck Rich; Bank 1 Sensor 1 P2195, P2196 P2270 O2 Sensor Signal Stuck Lean; Bank 1 Sensor 2 Refer to: DTCs P0136, P0137, P0138, P0140, P2270, P2271 O2 Sensor Signal Stuck Rich; Bank 1 Sensor 2 P2271 M201 2014.01...
Page 828 P0032 • Sensor circuit • Sensor • Exhaust temperature is within 250°C ~ 550°C Present resistance value • ECM P0053 is greater than threshold • Front oxygen sensor internal value resistance value is higher than about 1600 Ω M201 2014.01...
Page 829 Inspect front oxygen sensor heater resistance Inspect heater working voltage Is the fault confirmed Inspect heater power supply circuit Is the fault confirmed Inspect heater control signal circuit Is the fault confirmed Inspect engine control module circuit M201 2014.01...
Page 830 D. Measure the voltage between terminal 4 of front oxygen sensor wiring harness connector E01 and reliable grounding. Standard voltage: 11 ~ 14 V Is the voltage value normal? M3112028 Go to step 5. Go to step 4. M201 2014.01...
Page 831 Is the fuse normal? Inspect and repair the conductivity between terminal 4 of front oxygen sensor wiring harness connector E01 and terminal 60 of fuse IF30 in the instrument panel fuse box P40. Replace the fuse. Go to step 5. M201 2014.01...
Page 832 Are they normal? Go to step 6. Repair the fault circuit between terminal 3 of front oxygen sensor wiring harness connector E01 and terminal 2 of ECM wiring harness connector E18. Verify that the system is normal. M3112030 M3112031 M201 2014.01...
Page 833 5, 43 and 48 is normal. Is the engine control module circuit normal? Replace the engine control module. Refer to: Engine Control Module (3.1.12 M3112019 Electronic Control System - M7, Removal and Installation). Repair the circuit. M3112020 M201 2014.01...
Page 834 P0038 • Sensor circuit • Sensor • Exhaust temperature is within 250°C ~ 550°C Present resistance value • ECM P0054 is greater than threshold • Rear oxygen sensor internal value resistance value is higher than about 2200 Ω M201 2014.01...
Page 835 Inspect rear oxygen sensor heater resistance Inspect heater working voltage Is the fault confirmed Inspect heater power supply circuit Is the fault confirmed Inspect heater control signal circuit Is the fault confirmed Inspect engine control module circuit M201 2014.01...
Page 836 D. Measure the voltage between terminal 3 of rear oxygen sensor wiring harness connector S14 and reliable grounding. Standard voltage: 11 ~ 14 V Is the voltage value normal? M3112032 Go to step 5. Go to step 4. M201 2014.01...
Page 837 Is the fuse normal? Inspect and repair the conductivity between terminal 3 of rear oxygen sensor wiring harness connector S14 and terminal 60 of fuse IF30 in the instrument panel fuse box P40. Replace the fuse. Go to step 5. M201 2014.01...
Page 838 Standard resistance: 10 MΩ or more Is it normal? Go to step 6. Repair the fault circuit between the terminal 1 of rear oxygen sensor wiring harness connector S14 and terminal 4 of ECM wiring harness connector E18. M3112034 M3112035 M201 2014.01...
Page 839 5, 43 and 48 is normal. Is the engine control module circuit normal? Replace the engine control module. Refer to: Engine Control Module (3.1.12 M3112019 Electronic Control System - M7, Removal and Installation). Repair the circuit. M3112020 M201 2014.01...
Page 840 0.195 V P0107 limit exceeded • Last for more than 1 s • 1 s after start Circuit inspection, upper • Pressure sensor voltage is more P0108 limit exceeded than 4.883 V • Last for more than 1 s M201 2014.01...
Page 841 Inspect grounding circuit of air intake pressure sensor Is the fault confirmed Inspect grounding circuit of air intake pressure sensor Inspect air intake pressure sensor signal circuit Inspect air intake pressure sensor Inspect engine control module circuit M201 2014.01...
Page 842 D. Measure the voltage between terminal 3 of air intake pressure/temperature sensor wiring harness connector E15 and reliable grounding. Standard voltage: 4.5 ~ 5.5 V Is the voltage value normal? M3112036 Go to step 4. Go to step 3. M201 2014.01...
Page 843 Standard voltage: 0 V Are they normal? Go to step 4. M3112037 Repair the fault circuit between terminal 3 of E15 and terminal 19 of E18, and verify that the system is normal. M3112038 M3112039 M201 2014.01...
Page 844 D. Measure the resistance between terminal 1 of air intake pressure/temperature sensor wiring harness connector E15 and reliable grounding. Standard resistance: less than 5 Ω Is the resistance value normal? M3112040 Go to step 6. Go to step 5. M201 2014.01...
Page 845 E15 and reliable grounding. Inspect for short to power supply. Standard voltage: 0 V Is the resistance value normal? Go to step 6. Repair the fault circuit, and verify that the system is normal. M3112041 M3112042 M201 2014.01...
Page 846 E15 and reliable grounding. Inspect for short to power supply. Standard voltage: 0 V Are they normal? Go to step 7. M3112043 Repair the circuit, and verify that the system is normal. M3112044 M3112045 M201 2014.01...
Page 847 5, 43 and 48 is normal. Is the engine control module circuit normal? Replace the engine control module. Refer to: Engine Control Module (3.1.12 M3112019 Electronic Control System - M7, Removal and Installation). Repair the circuit. M3112020 M201 2014.01...
Page 848 • Last for more than 1 s • Sensor circuit • Sensor • 240 s after start • ECM Lower limit exceeded, • Air intake temperature is lower P0113 short to power than -38.25°C • Last for more than 10 s M201 2014.01...
Page 849 Is the fault confirmed Inspect air intake temperature sensor resistance Is the fault confirmed Inspect air intake temperature sensor signal circuit Is the fault confirmed Inspect air intake temperature sensor grounding Is the fault confirmed Inspect engine control module circuit M201 2014.01...
Page 850 C. Measure the resistance of air intake temperature sensor (terminals 1 to 2). Standard resistance: 2.5 kΩ ± 5% at 20°C D. Connect the coolant temperature sensor wiring harness connector E04. Is it normal? Go to step 3. Replace the air intake pressure/temperature sensor. M201 2014.01...
Page 851 Is the resistance value normal? M3112047 Go to step 5. Repair the fault circuit between terminal 1 of air intake pressure/temperature sensor E15 and terminal 40 of engine control module wiring harness connector E18. Verify that the system is normal. M201 2014.01...
Page 852 5, 43 and 48 is normal. Is the engine control module circuit normal? Replace the engine control module. Refer to: Engine Control Module (3.1.12 M3112019 Electronic Control System - M7, Removal and Installation). Repair the circuit. M3112020 M201 2014.01...
Page 853 Coolant temperature measured • Sensor circuit P0117 short to ground value is higher than 135°C for 2 s • Sensor Lower limit exceeded, Coolant temperature measured P0118 • ECM short to power value is lower than -37.5°C for 2 s M201 2014.01...
Page 854 Is the fault confirmed Inspect coolant temperature sensor resistance Is the fault confirmed Inspect coolant temperature sensor signal circuit Is the fault confirmed Inspect coolant temperature sensor grounding circuit Is the fault confirmed Inspect engine control module circuit M201 2014.01...
Page 855 B. Disconnect the coolant temperature sensor wiring harness connector E11. C. Measure the resistance of coolant temperature sensor with a multimeter. Standard resistance: 2.5 kΩ ± 5% for rated resistance at 20°C Is it normal? Go to step 3. Replace the coolant temperature sensor. M201 2014.01...
Page 856 Is the resistance value normal? M3112049 Go to step 5. Inspect and repair the fault circuit between terminal 1 of coolant temperature sensor wiring harness connector E11 and terminal 40 of engine control module wiring harness connector E18. M201 2014.01...
Page 857 5, 43 and 48 is normal. Is the engine control module circuit normal? Replace the engine control module. Refer to: Engine Control Module (3.1.12 M3112019 Electronic Control System - M7, Removal and Installation). Repair the circuit. M3112020 M201 2014.01...
Page 858 1% for 1 s • Sensor • Engine speed is more than • ECM Upper limit of throttle 600 rpm P0123 position angle signal • Throttle position angle signal exceeded is more than 99% for 1 s M201 2014.01...
Page 859 Inspect throttle position sensor Is the fault confirmed Inspect throttle position sensor power supply circuit Is the fault confirmed Inspect throttle position sensor signal circuit Is the fault confirmed Inspect throttle position sensor grounding Inspect engine control module circuit M201 2014.01...
Page 860 Is the voltage value normal? Go to step 4. M3112050 Repair the fault circuit between terminal 2 of throttle position sensor wiring harness connector E16 and terminal 18 of engine control module wiring harness connector E18. Verify that the system is normal. M201 2014.01...
Page 861 Go to step 6. Inspect and repair the fault circuit between terminal 1 of throttle position sensor wiring harness connector E16 and terminal 39 of engine control module wiring harness connector E18. Verify that the system is normal. M201 2014.01...
Page 862 5, 43 and 48 is normal. Is the engine control module circuit normal? Replace the engine control module. Refer to: Engine Control Module (3.1.12 M3112019 Electronic Control System - M7, Removal and Installation). Repair the circuit. M3112020 M201 2014.01...
Page 863 ECM via terminal O2 Sensor Signal Stuck Rich; P2196 1 of E01 connected to terminal 45 of E18 of ECM. Bank 1 Sensor 1 M201 2014.01...
Page 864 • Target λ = 1 Front oxygen sensor P0132 • Exhaust temperature is lower voltage too high than 800°C • Front oxygen sensor reaches working temperature for 150 s • Front oxygen sensor output voltage is higher than 1.5 V M201 2014.01...
Page 865 1.0 s • No catalytic converter fault • No diagnosis stop condition Rear oxygen control P2196 integrator value exceeds • Diagnosis time is 20 s lower limit • Rear oxygen control integrator value is less than -1.0 s M201 2014.01...
Page 866 Inspect oxygen sensor condition (carry out oxygen sensor signal test) Is the fault confirmed Inspect front oxygen sensor signal circuit Inspect front oxygen sensor grounding circuit Is the fault confirmed Inspect front oxygen sensor Inspect engine control module circuit M201 2014.01...
Page 867 Standard voltage: fluctuates between 0.1 ~ 0.9 V Does the voltage of oxygen sensor fluctuate between 0.1 ~ 0.9 V? Refer to: Intermittent Malfunction Diagnosis Procedure (3.1.12 Electronic Control System - M7, Symptom Diagnosis Testing). Go to step 3. M201 2014.01...
Page 868 • In the implementation of above test, the oxygen sensor signal voltage should change significantly as the test continues. Does it change significantly? Refer to: DTCs P2177, P2178, P2187, P2188 (3.1.12 Electronic control System - M7, DTC Diagnosis and Testing). Go to step 4. M201 2014.01...
Page 869 Standard voltage: 0 V Is it normal? Go to step 5. M3112052 Repair the fault circuit between terminal 1 of front oxygen sensor wiring harness connector E01 and terminal 45 of ECM wiring harness connector E18. M3112053 M3112054 M201 2014.01...
Page 870 2 of front oxygen sensor wiring harness connector E01 and terminal 39 of ECM wiring harness connector E18. 6. Inspect front oxygen sensor A. Replace the front oxygen sensor. Is the fault repaired? Diagnosis completes. The system is normal. Go to step 7. M201 2014.01...
Page 871 5, 43 and 48 is normal. Is the engine control module circuit normal? Replace the engine control module. Refer to: Engine Control Module (3.1.12 M3112019 Electronic Control System - M7, Removal and Installation). Repair the circuit. M3112020 M201 2014.01...
Page 872 • Rear oxygen sensor signal voltage is higher than 1.5 V • Rear oxygen sensor reaches the Rear oxygen working temperature P0140 sensor signal open • Rear oxygen sensor voltage is within circuit 0.4 ~ 0.5 V M201 2014.01...
Page 873 • Sensor circuit always low • Access to diagnosis request • Sensor • Rear oxygen sensor voltage is higher Rear oxygen • ECM than 0.619 V P2271 sensor voltage is always high • Access to diagnosis request M201 2014.01...
Page 874 (carry out rear oxygen sensor signal test) Is the fault confirmed Inspect rear oxygen sensor signal circuit Inspect rear oxygen sensor Is the fault grounding circuit confirmed Is the fault confirmed Inspect engine control module circuit Inspect rear oxygen sensor M201 2014.01...
Page 875 "O2 sensor voltage bank 1, sensor 2" parameter. Standard voltage: fluctuates around 0.5 V Does the voltage of oxygen sensor fluctuate around 0.5 V? Refer to: Intermittent Malfunction Diagnosis Procedure (3.1.12 Electronic Control System - M7, Symptom Diagnosis Testing). Go to step 3. M201 2014.01...
Page 876 • In the implementation of above test, the oxygen sensor signal voltage should change significantly as the test continues. Does it change significantly? Refer to: DTCs P2177, P2178, P2187, P2188 (3.1.12 Electronic control System - M7, DTC Diagnosis and Testing). Go to step 4. M201 2014.01...
Page 877 Go to step 5. Inspect and repair the fault circuit between terminal 2 of rear oxygen sensor wiring harness connector M3112056 S14 and terminal 29 of ECM wiring harness connector E18. Verify that the system is normal. M3112057 M3112058 M201 2014.01...
Page 878 E18. 6. Inspect rear oxygen sensor A. Replace the rear oxygen sensor. Refer to: Rear Oxygen Sensor (3.1.12 Electronic Control System - M7, Removal and Installation). Make sure the system is normal. Diagnosis completes. Go to step 7. M201 2014.01...
Page 879 5, 43 and 48 is normal. Is the engine control module circuit normal? Replace the engine control module. Refer to: Engine Control Module (3.1.12 M3112019 Electronic Control System - M7, Removal and Installation). Repair the circuit. M3112020 M201 2014.01...
Page 880 2. Possible Causes Setting Conditions DTC Code Monitor Strategy Faulty Area (Control Strategy) P0201 • Open circuit • Injector circuit Hardware circuit P0261 • Short to ground • Fuel injector inspection • Short to power • ECM P0262 M201 2014.01...
Page 881 Is the fault confirmed Inspect fuel injector Inspect fuel injector working voltage Is the fault confirmed Inspect fuel injector control signal Is the fault confirmed Inspect fuel injector control signal circuit Is the fault confirmed Inspect engine control module circuit M201 2014.01...
Page 882 Standard voltage: 11 ~ 14 V Is the voltage value normal? Go to step 4. Inspect and repair the faulty circuit between terminal 1 of fuel injector wiring harness connector E09 and terminal 69 of main relay IR05. M201 2014.01...
Page 883 CAUTION: LED must connect with 1 ~ 2 kΩ resistor in series, otherwise the LED or ECM may be damaged. D. Start the engine. E. Observe if the test lamp flashes normally. Does the test lamp flash normally? Go to step 6. Go to step 5. M201 2014.01...
Page 884 F. Measure the resistance between terminal 2 of E09 and reliable grounding. Standard resistance: 10 MΩ or more Is it normal? Go to step 6. Repair the fault circuit between the terminal 2 of E09 and terminal 50 of ECM wiring harness connector E18. M3112061 M3112062 M201 2014.01...
Page 885 5, 43 and 48 is normal. Is the engine control module circuit normal? Replace the engine control module. Refer to: Engine Control Module (3.1.12 M3112019 Electronic Control System - M7, Removal and Installation). Repair the circuit. M3112020 M201 2014.01...
Page 886 If the misfire rate exceeds the preprogrammed standard, P0303 Cyl.3 Misfire Detected then ECM will determine the occurrence of poor ignition that can damage the catalytic converter or P0304 Cyl.4 Misfire Detected affect emission performance. M201 2014.01...
Page 887 • Evaporative deteriorates the emission emission control is greater than 3.6% Implausible fault system • Air intake temperature is • Positive crankcase higher than -25°C ventilation system • Air intake system • Exhaust system air vent clog • ECM M201 2014.01...
Page 888 Inspect spark plug Is the fault confirmed Inspect ignition coil Inspect ignition system Is the fault confirmed Is the fault confirmed Inspect engine control module circuit Inspect fuel pressure Inspect fuel injector control circuit Inspect fuel injector Inspect compression pressure M201 2014.01...
Page 889 2. Inspect DTC A. Connect the diagnostic tool. B. Start the engine and diagnose the engine system. C. Inspect DTC. Is there any DTC besides P0300, P0301, P0302, P0303 and P0304? Go to DTC diagnosis procedure. Go to step 3. M201 2014.01...
Page 890 B. Inspect the ignition coil. Refer to: Ignition Coil Test (3.1.8 Ignition System, General Inspection). Is the ignition coil normal? Go to step 6. Replace the ignition coil. Refer to: Ignition Coil (3.1.8 Ignition System, Remove and Installation). M201 2014.01...
Page 891 7. Inspect fuel pressure A. Turn the ignition switch to "LOCK". B. Measure the fuel pressure. Refer to: Fuel System Pressure Test (3.1.7 Fuel System, General Inspection). Is the fuel pressure normal? Go to step 8. Inspect the fuel system. M201 2014.01...
Page 892 Go to step 10. 10.Inspect compression pressure A. Inspect the compression pressure in the cylinder. Refer to: Cylinder Compression Pressure Inspection (3.1.2 Mechanical System, General Inspection). B. Is the compression pressure normal? Go to step 11. Repair engine mechanical system fault. M201 2014.01...
Page 893 5, 43 and 48 is normal. Is the engine control module circuit normal? Replace the engine control module. Refer to: Engine Control Module (3.1.12 M3112019 Electronic Control System - M7, Removal and Installation). Repair the circuit. M3112020 M201 2014.01...
Page 894 • Frequent loss of reference than 2000 mark • ECM • Count of phase signal hop is greater No speed signal detected than 8 P0322 after a certain quantity of phase sensor signal • Low engine speed M201 2014.01...
Page 895 Inspect crankshaft position sensor waveform Is the fault confirmed Inspect crankshaft position sensor terminal 1 circuit Inspect crankshaft position sensor terminal 2 circuit Inspect crankshaft position sensor terminal 3 circuit Is the fault confirmed Inspect engine control module circuit M201 2014.01...
Page 896 "0", it means the wiring harness between crankshaft position sensor and ECM has open or short circuit. Is the data flow normal? Intermittent fault. Refer to: Intermittent Malfunction Diagnosis Procedure (3.1.12 Electronic Control System - M7, Symptom Diagnosis Testing). Go to step 3. M201 2014.01...
Page 897 3. Inspect crankshaft position sensor waveform A. Measure the waveform between terminals 2 and 3 of sensor with an oscilloscope when engine idling. Standard waveform is shown in left figure. Is it normal? Go to step 7. Go to step 4. M3112106 M201 2014.01...
Page 898 E17 and reliable grounding. Standard voltage: 0 V Is the circuit normal? Go to step 5. Repair the fault circuit between terminal 1 of M3112063 crankshaft position sensor E17 and terminal 19 of ECM wiring harness connector E18. M3112064 M3112065 M201 2014.01...
Page 899 E17 and reliable grounding. Inspect for short to power supply. Standard voltage: 0 V Is the circuit normal? Go to step 6. M3112066 Repair the fault circuit between terminal 2 of crankshaft position sensor E17 and terminal 47 of engine control module E18. M3112067 M3112068 M201 2014.01...
Page 900 Refer to: Crankshaft Position Sensor (3.1.12 Electronic Control M3112069 System - M7, Removal and Installation). Repair the fault circuit between terminal 3 of crankshaft position sensor E17 and terminal 40 of ECM wiring harness connector E18. M3112070 M3112071 M201 2014.01...
Page 901 5, 43 and 48 is normal. Is the engine control module circuit normal? Replace the engine control module. Refer to: Engine Control Module (3.1.12 M3112019 Electronic Control System - M7, Removal and Installation). Repair the circuit. M3112020 M201 2014.01...
Page 902 • ECM succession • No dynamics in engine speed Signal range check P0328 • No dynamics in engine load high • No knock control circuit fault • Limp home not active • Engine load is greater than 39.8% M201 2014.01...
Page 903 Is the fault confirmed Inspect knock sensor signal circuit 1 Is the fault confirmed Inspect knock sensor signal circuit 2 Is the fault confirmed Is the fault confirmed Inspect engine control module circuit Inspect knock sensor shielded circuit M201 2014.01...
Page 904 B. Disconnect the knock sensor wiring harness connector E12. C. Measure the resistance between terminals 1 and 2 of knock sensor with a multimeter. Standard resistance: more than 1 MΩ at 25°C Is it normal? Go to step 3. Replace the knock sensor. M201 2014.01...
Page 905 Are they normal? Go to step 4. Repair the fault circuit between terminal 1 of knock M3112072 sensor wiring harness connector E12 and terminal 30 of ECM wiring harness connector E18. Verify that the system is normal. M3112073 M3112074 M201 2014.01...
Page 906 Are they normal? Go to step 5. Repair the fault circuit between terminal 2 of knock M3112075 sensor wiring harness connector E12 and terminal 31 of ECM wiring harness connector E18. Verify that the system is normal. M3112076 M3112077 M201 2014.01...
Page 907 5, 43 and 48 is normal. Is the engine control module circuit normal? Replace the engine control module. Refer to: Engine Control Module (3.1.12 M3112019 Electronic Control System - M7, Removal and Installation). Repair the circuit. M3112020 M201 2014.01...
Page 908 DTC Code Monitor Strategy Faulty Area (Control Strategy) • Catalytic converter • Exhaust leakage Maximum limit • Active monitoring time for catalytic P0420 exceeded converter diagnosis is more than 40 s • Engine mechanical • Oxygen sensor aging M201 2014.01...
Page 909 Inspect exhaust gas leakage Is the fault confirmed Inspect engine mechanical problem Is the fault confirmed Inspect oxygen sensor aging (when a new rear oxygen sensor and an aged front oxygen sensor work together, it may lead to DTC set). M201 2014.01...
Page 910 A. Inspect the exhaust gas for excessive black smoke and blue smoke due to the internal problems of engine. Is the exhaust gas with excessive black smoke and blue smoke? Repair the engine mechanical. Make sure the system is normal. Go to step 4. M201 2014.01...
Page 911 DTC set). A. Inspect the repair record to see if the oxygen sensor has been replaced. Has the rear oxygen sensor rather than front oxygen sensor been replaced? Replace the front oxygen sensor as needed. Replace the catalytic converter. M201 2014.01...
Page 912 E18. 2. Possible Causes Setting Conditions DTC Code Monitor Strategy Faulty Area (Control Strategy) P0444 Open circuit • Solenoid valve Hardware circuit P0458 Short to ground • Solenoid valve circuit inspection • ECM P0459 Short to power supply M201 2014.01...
Page 913 Inspect carbon canister control valve resistance Is the fault confirmed Inspect carbon canister control valve power supply circuit Is the fault confirmed Inspect carbon canister control valve control circuit Is the fault confirmed Inspect engine control module circuit M201 2014.01...
Page 914 Standard resistance: 26 ± 4 Ω at 20°C D. Connect the carbon canister control valve wiring harness connector E13. Is the resistance value normal? Go to step 3. Replace the carbon canister control valve. M201 2014.01...
Page 915 Is the voltage value normal? M3112079 Go to step 4. Inspect and repair the fault circuit between terminal 1 of carbon canister control valve wiring harness connector E13 and terminal 69 of main relay IR05 in the instrument panel fuse box P40. M201 2014.01...
Page 916 Is it normal? Go to step 5. M3112080 Repair the fault circuit between the terminal 2 of carbon canister control valve wiring harness connector E13 and terminal 37 of ECM wiring harness connector E18. Replace when necessary. M3112081 M3112082 M201 2014.01...
Page 917 5, 43 and 48 is normal. Is the engine control module circuit normal? Replace the engine control module. Refer to: Engine Control Module (3.1.12 M3112019 Electronic Control System - M7, Removal and Installation). Repair the circuit. M3112020 M201 2014.01...
Page 918 Open circuit • Relay Hardware circuit P0691 Short to ground • Relay circuit inspection • ECM P0692 Short to power supply 3. Diagnosis Procedure Refer to: Diagnosis Procedure for Non-operation of Radiator-fan (3.1.4 Cooling System, Symptom Diagnosis and Testing). M201 2014.01...
Page 919 Idling stepper motor stuck • Carbon canister is not at high P0507 in the position with large load opening • Vehicle speed sensor diagnosis completes with no fault • Vehicle speed is 0 • Altitude correction factor is greater than 0.703 M201 2014.01...
Page 920 Inspect DTC Is the fault confirmed Inspect air intake system Is the fault confirmed Inspect throttle body state Is the fault confirmed Inspect idling stepper motor and throttle body Is the fault confirmed Inspect engine control module circuit M201 2014.01...
Page 921 C. While the vehicle is running, knock idling stepper motor gently with your hands, and listen to the sound of idle speed rising. Is it normal? Go to step 4. Repair the fault, and replace the idling stepper motor or throttle body assembly when necessary. M201 2014.01...
Page 922 5, 43 and 48 is normal. Is the engine control module circuit normal? Replace the engine control module. Refer to: Engine Control Module (3.1.12 M3112019 Electronic Control System - M7, Removal and Installation). Repair the circuit. M3112020 M201 2014.01...
Page 923 One terminal of stepper motor P0508 is short to ground • Stepper motor circuit Hardware circuit One terminal of stepper motor P0509 • Stepper motor inspection is short to battery positive • ECM One terminal of stepper motor P0511 is open M201 2014.01...
Page 924 Inspect wiring harness connectors (terminal 3 of idling Inspect engine control module stepper motor E14 - terminal circuit 35 of ECM E18) Inspect wiring harness connectors (terminal 4 of idling stepper motor E14 - terminal 36 of ECM E18) M201 2014.01...
Page 925 Standard resistance: 53 ± 5.3 Ω between terminals A and D, B and C 10 MΩ or more between terminals A and C, B and D Is resistance value normal? Go to step 3. Replace the idling stepper motor. M201 2014.01...
Page 926 Standard voltage: 0 V Are they normal? Go to step 4. M3112083 Repair the fault circuit between terminal 1 of idling stepper motor wiring harness connector E14 and terminal 22 of engine control module wiring harness connector E18. M3112084 M3112085 M201 2014.01...
Page 927 Standard voltage: 0 V Are they normal? Go to step 5. M3112086 Repair the fault circuit between terminal 2 of idling stepper motor wiring harness connector E14 and terminal 21 of engine control module wiring harness connector E18. M3112087 M3112088 M201 2014.01...
Page 928 Standard voltage: 0 V Are they normal? Go to step 6. M3112089 Repair the fault circuit between terminal 3 of idling stepper motor wiring harness connector E14 and terminal 35 of engine control module wiring harness connector E18. M3112090 M3112091 M201 2014.01...
Page 929 Standard voltage: 0 V Are they normal? Go to step 7. M3112092 Repair the fault circuit between terminal 4 of idling stepper motor wiring harness connector E14 and terminal 36 of engine control module wiring harness connector E18. M3112093 M3112094 M201 2014.01...
Page 930 5, 43 and 48 is normal. Is the engine control module circuit normal? Replace the engine control module. Refer to: Engine Control Module (3.1.12 M3112019 Electronic Control System - M7, Removal and Installation). Repair the circuit. M3112020 M201 2014.01...
Page 931 • ADC value of battery voltage • Charging system is higher than 17.02 V for 0.2 s Upper limit value P0563 • Vehicle speed is greater than exceeded 25 km/h • Starting time is more than 180 s M201 2014.01...
Page 932 Is the fault confirmed Inspect ECM power supply voltage Is the fault confirmed Inspect ECM power supply circuit Is the fault confirmed Inspect ECM grounding circuit Is the fault confirmed Inspect charging system M201 2014.01...
Page 933 B. Measure the voltages between terminals 16, 17, 8, 51 of ECM wiring harness connector E18 and 16 17 reliable grounding from the backside. Standard voltage: 11 ~ 14 V Are the voltage values normal? Go to step 4. M3112095 Go to step 3. M201 2014.01...
Page 934 IR05 and terminals 8, 51 of ECM wiring harness connector E18. Standard resistance: less than 5 Ω Is the resistance value normal? 16 17 Go to step 4. Repair related circuit. Make sure the system is normal. M3112096 M201 2014.01...
Page 935 D. Inspect the engine charging voltage. Standard voltage: 11.5 ~ 14.5 V Is the voltage value normal? Refer to: Intermittent Malfunction Diagnosis Procedure (3.1.12 Electronic Control System - M7, Symptom Diagnosis Testing). Repair battery or charging system fault. M201 2014.01...
Page 936 ECM internal program processing fault, ECM power P0602 Control Module Programming Error supply and grounding abnormal. 2. Possible Causes Setting Conditions DTC Code Monitor Strategy Faulty Area (Control Strategy) Diagnose the Diagnostic • ECM circuit P0602 Data Identification (DDI) • ECM code programming M201 2014.01...
Page 937 5, 43 and 48 is normal. Is the engine control module circuit normal? Replace the engine control module. Refer to: Engine Control Module (3.1.12 M3112019 Electronic Control System - M7, Removal and Installation). Repair the circuit. M3112020 M201 2014.01...
Page 938 Open circuit • Relay Hardware circuit P0628 Short to ground • Relay circuit inspection • ECM P0629 Short to power supply 3. Diagnosis Procedure Refer to: Diagnosis Procedure for Fuel Pump Failure (3.1.7 Fuel System, Symptom Diagnosis and Testing). M201 2014.01...
Page 939 • Short to ground • Relay circuit inspection • Short to power supply • ECM P0647 3. Diagnosis Procedure Refer to: Diagnosis Procedure for A/C Compressor Clutch Fault (4.1.1 Heating, Ventilation and Air Conditioning, Symptom Diagnosis and Testing). M201 2014.01...
Page 940 MIL by setting it at low potential via special line. 2. Possible Causes Setting Conditions DTC Code Monitor Strategy Faulty Area (Control Strategy) • Open circuit • Instrument cluster Hardware circuit P0650 • Short to ground • MIL circuit inspection • Short to power supply • ECM M201 2014.01...
Page 941 Is the fault confirmed Inspect instrument cluster power supply circuit Is the fault confirmed Inspect instrument cluster fuse Is the fault confirmed Inspect drive circuit Is the fault confirmed Inspect engine control module circuit M201 2014.01...
Page 942 C. Inspect the conductivity between two terminals of fuse with the multimeter. Is the fuse normal? Inspect and repair the fault circuit between terminal 7 of instrument cluster wiring harness connector P21 and fuse IF35. Replace the fuse. Verify that the system is normal. M201 2014.01...
Page 943 Standard voltage: 0 V Are they normal? Go to step 5. Repair the fault circuit between terminal 28 of M3112099 instrument panel wiring harness connector P21 and terminal 20 of engine control module wiring harness connector E18. M3112100 M3112101 M201 2014.01...
Page 944 5, 43 and 48 is normal. Is the engine control module circuit normal? Replace the engine control module. Refer to: Engine Control Module (3.1.12 M3112019 Electronic Control System - M7, Removal and Installation). Repair the circuit. M3112020 M201 2014.01...
Page 945 • Air-fuel ratio adaption on Fuel trim low limits circuit P2178 • Engine speed is 1400 ~ 4000 exceeded • Engine mechanical • ECM • Air mass flow is 18 ~ 70 kg/h • Load is 16% ~ 70% P2187 P2188 M201 2014.01...
Page 946 Inspect compression pressure Inspect ignition timing Inspect front oxygen sensor signal circuit Inspect front oxygen sensor grounding circuit Is the fault Inspect air intake pressure sensor confirmed Inspect coolant temperature sensor Inspect engine control module circuit Is the fault confirmed M201 2014.01...
Page 947 2. Inspect other DTC A. Connect the diagnostic tool. B. Start the engine and diagnose the engine system. C. Inspect DTC. Is there any DTC other than P2177, P2178, P2187 and P2188? Go to DTC diagnosis procedure. Go to step 3. M201 2014.01...
Page 948 Standard voltage: fluctuates between 0.1 ~ 0.9 V. C. Turn the ignition switch to "LOCK" after measurement. Does the voltage of oxygen sensor fluctuate between 0.1 ~ 0.9 V? Go to step 8. Go to step 5. M201 2014.01...
Page 949 In the implementation of above test, the oxygen sensor signal voltage should change significantly as the test continues. Does it change significantly? Go to step 6. Replace the front oxygen sensor. Refer to: Front Oxygen Sensor (3.1.12 Electronic Control System - M7, Removal and Installation). M201 2014.01...
Page 950 Standard voltage: 0 V Is it normal? Go to step 7. M3112102 Repair the fault circuit between terminal 1 of front oxygen sensor wiring harness connector E01 and terminal 45 of ECM wiring harness connector E18. M3112103 M3112104 M201 2014.01...
Page 951 Is the difference between readings on the diagnostic tool and vacuum gauge within 1 in (25 mm)? Go to step 9. Replace the air intake pressure/temperature sensor, and clean the throttle and intake manifold. Verify that the system is normal. M201 2014.01...
Page 952 Refer to: Fuel System Pressure Test (3.1.7 Fuel System, General Inspection). Is the fuel pressure normal? Go to step 11. Inspect the fuel system fault. Refer to: Low Pressure in Fuel System (3.3.7 Fuel System, Symptom Diagnosis and Testing). M201 2014.01...
Page 953 A. Inspect the engine compression pressure. Refer to: Cylinder Compression Pressure Inspection (3.1.2 Mechanical System, General Inspection). Is the compression pressure normal? Go to step 14. Inspect the cause of low compression pressure, and Repair the faulty area. M201 2014.01...
Page 954 5, 43 and 48 is normal. Is the engine control module circuit normal? Replace the engine control module. Refer to: Engine Control Module (3.1.12 M3112019 Electronic Control System - M7, Removal and Installation). Repair the circuit. M3112020 M201 2014.01...
Page 955 Removal and Installation). 2. Disconnect the engine control module wiring harness connector (1). M3112110 3. Remove the engine control module retaining nut (2). Torque: 8 2 Nm ± Installation 1. Installation is in the reverse order of removal. M201 2014.01...
Page 956 4. Remove the crankshaft position sensor retaining bolt. Torque: 10 2 Nm ± M3112130 Installation 1. Installation is in the reverse order of removal. CAUTION: Before installation, apply lubricant to the O-ring and press in the sensor with hands. M201 2014.01...
Page 957 Torque: 1.5 ~ 2.5 Nm Installation 1. Installation is in the reverse order of removal. CAUTION: Make sure the seal ring of sensor is fully inserted to the end and the wiring harness connector is set in place during installation. M201 2014.01...
Page 958 3. Remove 2 retaining bolts from the idling stepper motor. Torque: 4 0.4 Nm ± M3112150 Installation 1. Installation is in the reverse order of removal. CAUTION: Pulling or pushing the shaft of stepper motor is prohibited, or it will cause permanent damage. M201 2014.01...
Page 959 4. Remove the coolant temperature sensor. Torque: 20 Nm or less M3112160 Installation 1. Installation is in the reverse order of removal. CAUTION: Make sure the sensor is fully inserted to the end and there is no coolant leakage. M201 2014.01...
Page 960 Torque: 8 2 Nm ± Installation 1. Installation is in the reverse order of removal. CAUTION: Installing the sensor with any impactive tool (such as hammer) is prohibited. Avoid water, oil etc. entering the sensor. M201 2014.01...
Page 961 3. Disengage 2 clamps and separate 2 hoses. M3112180 4. Disconnect 4 connectors from the fuel injectors. M3112190 5. Remove 2 retaining bolts from the fuel rail and separate the fuel main pipe assembly from the cylinder block. M3112200 M201 2014.01...
Page 962 Prevent the lubricant contaminating the injector plate, and keep the injector mounting hole on the engine clean. Carefully install the fuel rail to the cylinder block with an even force in the axial direction injector. Avoid applying excessive impact during assembly. M201 2014.01...
Page 963 3. Remove the front oxygen sensor with a suitable tool. Torque: 50 10 Nm ± M3112230 Installation 1. Installation is in the reverse order of removal. CAUTION: Applying washer fluid, oily liquid or volatile solid on the oxygen sensor is prohibited. M201 2014.01...
Page 964 3. Remove the rear oxygen sensor (2) with a suitable tool. Torque: 50 10 Nm ± Installation 1. Installation is in the reverse order of removal. CAUTION: Applying washer fluid, oily liquid or volatile solid on the oxygen sensor is prohibited. M201 2014.01...
Page 965 1. Installation is in the reverse order of removal. CAUTION: Make sure that the mounting boss surface is clean with no oil stain. Any type of washer shall not be used between sensor and cylinder block when installing the metal face to the cylinder block. M201 2014.01...
Page 967 Specifications ........................... 3.2.2-1 General Specifications......................3.2.2-1 Torque Specifications........................ 3.2.2-1 Description and Operation ....................... 3.2.2-2 System Overview........................3.2.2-2 Components Exploded View..................... 3.2.2-4 Symptom Diagnosis and Testing...................... 3.2.2-5 Removal and Installation........................3.2.2-6 Clutch Pressure Plate Assembly, Clutch Driven Disc Assembly ..........3.2.2-6 M201 2014.01...
Page 968 Assembly of Intermediate Shaft ....................3.2.3-48 Assembly of Output Shaft .......................3.2.3-52 Assembly of Input Shaft ......................3.2.3-54 Assembly of Transmission ......................3.2.3-58 3.2.4 Manual Transmission External Control Specifications ...........................3.2.4-1 Torque Specifications........................3.2.4-1 Description and Operation........................3.2.4-2 System Overview ........................3.2.4-2 Components Exploded View.....................3.2.4-2 Symptom Diagnosis and Testing ......................3.2.4-3 M201 2014.01...
Page 969 Manual Transmission/Clutch Inspection and Verification......................3.2.4-3 Symptom Chart......................... 3.2.4-4 Diagnosis Procedure for Difficult Operation of Gearshift Mechanism........3.2.4-4 Removal and Installation........................3.2.4-5 Gearshift Mechanism........................ 3.2.4-5 M201 2014.01...
Page 971: Specifications
Clutch pedal free travel standard value 5 ~ 11 mm General Specifications Item Specifications Type Dry clutch with single disc diaphragm spring Operation type Mechanical Torque Specifications Item lb-ft lb-in Clutch pressure plate retaining bolt 32 ± 2 M201 2014.01...
Page 972: General Inspection
Rivet head depth 4. Inspect whether torsion spring deformed. Standard: 1.15 ~ 1.65 mm 5. Inspect whether the pedal pad is worn or Limit: 0.5 mm damaged. 6. Inspect whether the clutch cable is worn, deformed or damaged. M3201002 M201 2014.01...
Page 973: Clutch Pedal Free Travel Inspection
When the clutch pedal is depressed, the clutch disengages completely and returns in time after the pedal is released; Slipping is forbidden after engaging and no unusual noise during operation. M201 2014.01...
Page 974: Symptom Diagnosis And Testing
• Oil stain on clutch driven disc clack or Judder (3.2.1 surface Manual Transmission/ • Diaphragm spring Clutch clickety-clack or Clutch Overview, shudder • Clutch pressure plate Symptom Diagnosis and Testing). • Clutch driven disc surface • Flywheel • Clutch cable M201 2014.01...
Page 975 • Clutch pedal free travel Excessive Noise • Clutch release bearing (3.2.1 Manual • Poor lubrication of clutch Transmission/Clutch release bearing Overview, Symptom Excessive noise • Release bearing Diagnosis and Testing). • Excessive crankshaft thrust clearance • Clutch cable M201 2014.01...
Page 976 • Replace the clutch cable. • Replace the clutch disc assembly. Refer to: Clutch Pressure Plate Clutch stuck (pedal is Assembly and Clutch difficult to push) • Clutch disc is worn too thin Driven Disc Assembly (3.2.2 Clutch, Removal and Installation). M201 2014.01...
Page 977 • Shift gear Refer to: Diagnosis Procedure for Abnormal Driving • Input shaft bearing Noise ((3.2.1 Manual • Output shaft bearing Transmission/Clutch Abnormal driving noise • Clutch Overview, Symptom Diagnosis and Testing). • Wheel bearing • Tire • Universal joint M201 2014.01...
Page 978: Diagnosis Procedure For Clutch Slippage
Is the fault confirmed Inspect clutch pedal free travel Is the fault confirmed Inspect clutch pedal maneuverability Is the fault confirmed Inspect whether clutch system is contaminated by leaking oil Is the fault Inspect clutch driven disc confirmed Inspect flywheel M201 2014.01...
Page 979 A. Remove the transmission. Refer to: Manual Transmission (3.2.3 Manual Transmission, Removal and Installation). B. Inspect whether the clutch system is contaminated by oil leak. Is the clutch system contaminated by oil leak? Repair the oil leak. Go to step 5. M201 2014.01...
Page 980 Refer to: Clutch Driven Disc Inspection (3.2.1 Manual Transmission/ Clutch Overview, General Inspection). Is it normal? Go to step 6. Replace the clutch driven disc. Refer to: Clutch Pressure Plate Assembly Clutch Driven Disc Assembly (3.2.2 Clutch, Removal and Installation). M201 2014.01...
Page 981 Replace the clutch pressure plate with a new one. Refer to: Clutch Pressure Plate Assembly Clutch Driven Disc Assembly (3.2.2 Clutch, Removal and Installation). Repair or replace the flywheel. Refer to: Main Bearing, Crankshaft and Cylinder Block (3.1.2 Mechanical System, Disassembly Assembly). M201 2014.01...
Page 982: Diagnosis Procedure For Clutch Clickety-Clack Or Judder
Diagnosis Procedure for Clutch Clickety-clack or Judder Clutch clickety-clack or judder Inspect clickety-clack or shudder occurs in clutch Is the fault confirmed Inspect engine/transmission mounting bracket bush assembly Is the fault confirmed Inspect clutch pressure plate Is the fault confirmed Inspect clutch driven disc M201 2014.01...
Page 983 Removal and Installation). Is there any wear on the clutch pressure plate? Replace the clutch pressure plate with a new one. Refer to: Clutch Pressure Plate Assembly Clutch Driven Disc Assembly (3.2.2 Clutch, Removal and Installation). Go to step 4. M201 2014.01...
Page 984 Replace the clutch driven disc with a new one. Refer to: Clutch Pressure Plate Assembly Clutch Driven Disc Assembly (3.2.2 Clutch, Removal and Installation). Inspect the flywheel. Refer to: Main Bearing, Crankshaft and Cylinder Block (3.1.2 Mechanical System, Disassembly Assembly). M201 2014.01...
Page 985: Diagnosis Procedure For Clutch Drag
Diagnosis Procedure for Clutch Drag Clutch drag Inspect clutch pedal free travel Is the fault confirmed Inspect backing ring of clutch pressure plate diaphragm spring Is the fault confirmed Inspect splines of clutch driven disc and transmission input shaft M201 2014.01...
Page 986 Is there any wear on clutch pressure plate or diaphragm spring backing ring? Replace the clutch pressure plate with a new one. Refer to: Clutch Pressure Plate Assembly Clutch Driven Disc Assembly (3.2.2 Clutch, Removal and Installation). Go to step 3. M201 2014.01...
Page 987 Go to step 4. Repair or replace the clutch driven disc or transmission input shaft. Refer to: Manual Transmission (3.2.3 Manual Transmission, Removal and Installation). Refer to: Disassembly and Assembly of Transmission (3.2.3 Manual Transmission, Disassembly and Assembly). M201 2014.01...
Page 988: Diagnosis Procedure For Clutch Pedal Pulsation
Manual Transmission/Clutch - Overview 3.2.1-18 Diagnosis Procedure for Clutch Pedal Pulsation Clutch pedal pulsation Inspect clutch pedal Is the fault confirmed Inspect clutch pressure plate Is the fault confirmed Inspect flywheel Is the fault confirmed Inspect clutch driven disc M201 2014.01...
Page 989 C. Inspect the wear depth of clutch pressure plate release lever. Is it normal? Go to step 3. Replace the clutch pressure plate. Refer to: Clutch Pressure Plate Assembly Clutch Driven Disc Assembly (3.2.2 Clutch, Removal and Installation). M201 2014.01...
Page 990 C. Inspect the end face runout of clutch driven disc. Is the clutch driven disc normal? Replace the clutch release bearing. Replace the clutch driven disc. Refer to: Clutch Pressure Plate Assembly Clutch Driven Disc Assembly (3.2.2 Clutch, Removal and Installation). M201 2014.01...
Page 991: Diagnosis Procedure For Clutch Vibration
Is the fault confirmed Inspect accessory drive belt vibration Is the fault confirmed Inspect release bearing noise Is the fault confirmed Inspect clutch pressure plate Inspect clutch driven disc Is the fault confirmed Inspect flywheel M201 2014.01...
Page 992 Installation). Go to step 3. 3. Inspect release bearing noise A. Turn the ignition switch to "START". B. Depress and hold the clutch pedal. Is there any harsh grating? Replace the release bearing. Go to step 4. M201 2014.01...
Page 993 C. Inspect the end face runout of clutch driven disc. Is the clutch driven disc normal? Go to step 6. Replace the clutch driven disc. Refer to: Clutch Pressure Plate Assembly Clutch Driven Disc Assembly (3.2.2 Clutch, Removal and Installation). M201 2014.01...
Page 994 C. Inspect the flywheel roundness. D. Inspect the end face runout of flywheel. Is the flywheel normal? Diagnose the fault of engine vibration. Tighten or replace the flywheel. Refer to: Main Bearing, Crankshaft and Cylinder Block (3.1.2 Mechanical System, Disassembly Assembly). M201 2014.01...
Page 995 3.2.1-25 Diagnosis Procedure for Difficult Gear Shifting Difficult gear shifting Inspect clutch system Is the fault confirmed Inspect gearshift mechanism Is the fault confirmed Inspect gear shift fork inside transmission, fork shaft and synchronizer assembly, self- locking mechanism M201 2014.01...
Page 996: Manual Transmission
Repair the clutch system. 2. Inspect gearshift mechanism A. Inspect the gearshift mechanism. Is the gearshift mechanism normal? Go to step 3. Adjust or replace the gearshift mechanism. Refer to: Gearshift Mechanism (3.2.4 Manual Transmission External Control, Removal Installation). M201 2014.01...
Page 997 D. Inspect whether the synchronizer assembly is normal. E. Inspect the self-locking mechanism, gear shift fork inside transmission, fork shaft and synchronizer. Are they normal? Replace the engine or transmission support. Repair the transmission interior fault. M201 2014.01...
Page 998 Inspect noise in the early stage of clutch disengagement Is the fault confirmed Inspect noise when the clutch is completely disengaged Is the fault confirmed Inspect noise when the clutch is engaged Is the fault confirmed Inspect noises at neutral and other positions M201 2014.01...
Page 999 A. Start the engine. B. Depress the clutch pedal to the bottom. C. Operate the accelerator pedal to change the engine speed. Is there any noise as the engine speed changes? Replace the release bearing. Go to step 4. M201 2014.01...
Page 1000 (3.2.3 Manual Transmission, Removal and Installation). Refer to: Disassembly and Assembly of Transmission (3.2.3 Manual Transmission, Disassembly and Assembly). Inspect the engine system noise. Refer to: Abnormal Interior Noises under Engine (3.1.2 Mechanical System, Symptom Diagnosis and Testing). M201 2014.01...
Page 1001 Diagnosis Procedure for Abnormal Noises in Driving Abnormal noises in driving General inspection (Inspect tire, suspension and universal joint) Is the fault confirmed Inspect wind noise Is the fault confirmed Inspect clutch system Is the fault confirmed Inspect transmission M201 2014.01...
Page 1002 A. Start engine and keep it at the neutral position. B. Operate the clutch. Inspect whether there is abnormal noise during clutch engagement or disengagement. Is the clutch normal? Go to step 4. Before road test, repair and replace with new components when necessary. M201 2014.01...
Page 1003 Is the transmission normal? personal injury. Refer to: Diagnosis Procedures for Noise (1.1.5 Noise, Vibration Harshness, Symptom Diagnosis and Testing). Repair the transmission. Refer to: Manual Transmission (3.2.3 Manual Transmission, Removal and Installation). M201 2014.01...
Page 1005: Specifications
3.2.2-1 Clutch 3.2.2-1 Specifications 3.2.2 Clutch General Specifications Item Specifications Clutch type Dry clutch with single disc diaphragm spring Operation type Mechanical Torque Specifications Item lb-ft lb-in Clutch pressure plate retaining bolt 32 ± 2 M201 2014.01...
Page 1006 M3202004 M201 2014.01...
Page 1007 3.2.2-3 Clutch 3.2.2-3 Item Description Item Description Flywheel ring gear assembly Clutch pressure plate assembly Flywheel bolt Pressure plate dowel pin Clutch pressure plate retaining Clutch driven disc assembly bolt M201 2014.01...
Page 1008 Clutch pressure plate assembly Transmission assembly Clutch pressure plate retaining Clutch release fork return bolt spring bracket Clutch release bearing Clutch release fork bracket bolt Clutch release fork return Clutch release fork spring Clutch release fork clip Release bearing clip M201 2014.01...
Page 1009 3.2.2-5 Clutch 3.2.2-5 Symptom Diagnosis and Testing Refer to: Symptom Chart (3.2.1 Manual Transmission/Clutch - Overview, Symptom Diagnosis and Testing). M201 2014.01...
Page 1010 1 Use the special tool to hold the flywheel 09924-17810 assembly. Special tool: 09924-17810 M3202006 2 Remove the clutch pressure plate retaining bolts, then remove the clutch pressure plate assembly and clutch driven disc assembly in turn. M3202007 M201 2014.01...
Page 1011 3. Apply a small amount of grease to the input shaft, then connect manual transmission and engine. "A": 99000-25210 CAUTION: While inserting transmission input shaft to the clutch driven disc, rotate the crankshaft with the wrench from the front side until the splines are engaged. M3202016 M201 2014.01...
Page 1012 CAUTION: Do not clean release bearing to flush out grease, which will damage the bearing. 2. Inspect the clutch release fork and clip for damage and deformation, as well as the release fork return spring. Replace if any fault is found. M3202010 M201 2014.01...
Page 1013 1. Installation is in the reverse order of removal. CAUTION: Apply the grease as shown in the figure. "A" : 99000-25010 "B" : 99000-25210 CAUTION: Install the release bearing, return spring and clip to their original position. M3202011 M201 2014.01...
Page 1015 11 ~ 16 Reverse gear bolt 23 ± 5 Worm set retaining bolt 10 ± 2 Vehicle speed sensor No.1 wiring harness clamp bracket 10 ± 1 retaining bolt Transmission grounding wiring harness 10 ± 1 retaining bolt M201 2014.01...
Page 1016 3.2.3-2 Manual Transmission 3.2.3-2 Item lb-ft lb-in Transmission dustproof board retaining 10 ± 1 bolt Connecting bolt and nut between 50 ± 5 transmission and engine Transmission rear mounting bolt 70 ± 5 M201 2014.01...
Page 1017: Description And Operation
Transmission MR513C01 moves the gear shaft through the gear shift and select set, to realize the position-shift and the axial movement of shift lever realizes the gear shift. The inertia synchronizer assures the flexible gear shifting. M201 2014.01...
Page 1018 Transmission MR513C01 uses different pairs of gears to realize variable speed, torque, and rotation direction change. The specific transferring route is shown in the figure below: M3203001 Item Description Item Description Reverse gear shaft Intermediate shaft 5th gear synchronizer Output shaft M201 2014.01...
Page 1019 3 seconds; Do not shift into the reverse gear when the vehicle is moving forward and do not shift into the forward gear when the vehicle is reversing. CAUTION: The gearshift principle of transmission can be ignored in emergency when driving. M201 2014.01...
Page 1020: Components Location View
3.2.3-6 Manual Transmission 3.2.3-6 Components Location View Transmission Structure Chart 18 17 16 15 13 12 M3203002 M201 2014.01...
Page 1021 Intermediate shaft Input shaft 5th gear Intermediate shaft 5th gear 5th gear synchronizer Intermediate shaft 2nd gear Input shaft 3rd gear Low-speed synchronizer High-speed synchronizer Intermediate shaft 1st gear Output shaft driven gear Front case Output shaft Input shaft M201 2014.01...
Page 1022: Components Exploded View
3.2.3-8 Manual Transmission 3.2.3-8 Components Exploded View 1. Transmission Reverse Gear Shaft Set M3203003 Item Description Qty. Item Description Qty. Reverse idler gear assembly Reverse gear shaft Reverse gear shaft washer M201 2014.01...
Page 1023 Input shaft 5th gear needle gear ring roller bearing Input shaft gear Input shaft assembly gear needle roller Input shaft front case circlip bearing Reverse gear ring Input shaft bearing 5th gear synchronizer circlip Input shaft bearing circlip 5th gear synchronizer set M201 2014.01...
Page 1024 Intermediate shaft 2nd gear bearing washer assembly gear needle roller Intermediate shaft 1st gear bearing gear needle roller Intermediate shaft bearing 1st gear synchronizer gear Steel ball (φ3) ring Low-speed synchronizer Intermediate shaft rear circlip bearing M201 2014.01...
Page 1025 Output shaft driven gear bearing K182516 High-speed synchronizer Output shaft rear bearing wave spring High-speed synchronizer Output shaft rear bearing gear ring circlip Output shaft Worm steel ball Output shaft front bearing Worm assembly Output shaft front bearing Worm circlip circlip M201 2014.01...
Page 1026 3rd-4th gear shift fork pin Reverse gear select arm 3rd-4th gear shift fork Reverse gear select arm pin 1st-2nd gear shift fork pin Reverse gear select arm 1st-2nd gear shift fork assembly Reverse gear shift fork assembly dowel pin 11x12 M201 2014.01...

Chana M201 2014 Workshop Manual

Service Information 1.1 Service Information

2 Group Chassis

Drive System 2.2 Drive System

Brake System 2.3 Brake System

Steering System 2.4 Steering System

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Summary of Contents for Chana M201 2014