1. Manuals
  2. Brands
  3. Changhe Manuals
  4. Automobile
  5. FREEDOM CH6390 Series 2005
  6. Service manual

Changhe FREEDOM CH6390 Series 2005 Service Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
CHANGHE FREEDOM SERVICE MANUAL
This manual contains procedures for diagnosis, maintenance, adjustments, minor service
operations, replacement of components (Service) and for disassembly and assembly of major
components.
Applicable model: CHANGHE FREEDOM (CH6390 series) VEHICLE
The contents are classified into sections each of which is given a section number as indicated in
the Table of Contents on following page. And on the first page of each individual section is an index of
that section. This manual should be kept in a handy place for ready reference of the service work.
When replacing parts or servicing by disassembling, it is recommended to use genuine parts, tools
and service materials as specified in each description.
All information, illustrations and specifications contained in this literature are based on the latest
product information available at the time of publication approval. And used as the main subject of
description is the vehicle of standard specifications among others.
Therefore, note that illustrations may differ from the vehicle being actually serviced.
The right is reserved to make changes at any time without notice.
© COPYRIGHT: JIANGXI CHANGHE AUTOMOBILE CO., LTD
FOREWORD
JIANGXI CHANGHE AUTOMOBILE CO., LTD
FOREWORD

Advertisement

Table of Contents
loading

Summary of Contents for Changhe FREEDOM CH6390 Series 2005

  • Page 1 (Service) and for disassembly and assembly of major components. Applicable model: CHANGHE FREEDOM (CH6390 series) VEHICLE The contents are classified into sections each of which is given a section number as indicated in the Table of Contents on following page. And on the first page of each individual section is an index of that section.
  • Page 2 The CH6390 series auto is a new generation vehicle developed under own R&D center of JIANGXI CHANGHE AUTOMOBILE CO., LTD. The CH6390 auto structure is compact, flexible, safe and comfortable, economic and applied, satisfied with statute of collision, emission and noise. It is a multifunctional automobile that fits for safety and environment.
  • Page 3 Service on and around the air bag system information, the words WARNING, CAUTION components or wiring must be performed and NOTE have special meanings. Pay special only by an authorized JIANGXI CHANGHE attention to the messages highlighted by these AUTOMOBILE CO., LTD. Please observe all signal words.
  • Page 4 CHANGHE FREEDOM SERVICE MANUAL TABLE OF CONTENTS TABLE OF CONTENTS THE FIRST PART GENERAL INFORMATION ................1 SECTION 1 GENERAL INFORMATION ..............22 SECTION 2 SCHEDULED MAINTENANCE THE SECOND PART ENGINE ......................... 40 SECTION 3 ENGINE ..................51 SECTION 4 ENGINE MECHANICAL ................

  • Page 5: Table Of Contents

    CHANGHE FREEDOM SERVICE MANUAL GENERAL INFORMATION THE FIRST PART GENERAL INFORMATION SECTION 1 GENERAL INFORMATION CONTENTS ............................2 PRECAUTIONS Air Bag System Precautions ........................2 General Precautions ..........................4 Precautions for Catalytic Converter ..................... 6 Precautions for Electrical Circuit Service .................... 6 Intermittent and Poor Connection Inspection ...

  • Page 6: Precautions

    CHANGHE FREEDOM SERVICE MANUAL GENERAL INFORMATION PRECAUTIONS AIR BAG SYSTEM PRECAUTIONS Precautions for Vehicle Equipped with a Supplemental Restrain Air Bag System. WARNING： The configuration of air bag system parts are as shown in the figure. When it is necessary to...
  • Page 7 CHANGHE FREEDOM SERVICE MANUAL GENERAL INFORMATION SERVICING AND HANDLING Handle the trouble of air bag, follow the procedure of removal and installation description in section 15. WARNING： For handling and storage of a live air bag (inflator) module, select a place where the ambient temperature below 65 °...

  • Page 8: General Precautions

    CHANGHE FREEDOM SERVICE MANUAL GENERAL INFORMATION GENERAL PRECAUTIONS The WARNING and CAUTION below describe some general precautions that you should observe when servicing a vehicle. These general precautions apply to many of the service procedures described in this manual, and they will not necessarily be repeated with each procedure to which they apply.
  • Page 9 CHANGHE FREEDOM SERVICE MANUAL GENERAL INFORMATION Whenever you use oil seals, gaskets, packing, oil rings, locking washers, split pins, self-locking nuts, and certain other parts as specified, be sure to use new ones. Also, before installing new gaskets, packing, etc., be sure to remove any residual material form the mating surfaces.

  • Page 10: Precautions For Catalytic Converter

    CHANGHE FREEDOM SERVICE MANUAL GENERAL INFORMATION PRECAUTIONS FOR CATALYTIC CONVERTER Be must to use unleaded gasoline and be careful not to let a large amount of unburned gasoline enter the converter or it can be damaged。 Conduct a spark jump test only when necessary.

  • Page 11: Intermittent And Poor Connection Inspection

    CHANGHE FREEDOM SERVICE MANUAL GENERAL INFORMATION Before measuring voltage at each terminal, check to make sure that battery voltage is 11V or higher. Such terminal voltage check at low battery voltage will lead to erroneous diagnosis. INTERMITTENT AND POOR CONNECTION...

  • Page 12: Identification Information

    CHANGHE FREEDOM SERVICE MANUAL GENERAL INFORMATION BODY IDENTIFICATION INFORMATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number is located on the left front panel in the engine room. ENGINE IDENTIFICATION INFORMATION The number is punched on the cylinder block.

  • Page 13: Vin

    CHANGHE FREEDOM SERVICE MANUAL GENERAL INFORMATION WARNING, CAUTION AND INFORMATION LABELS The figure below shows main labels among others that are attached to vehicle component parts. When servicing and handing parts, refer to WARNING /CAUTION instructions printed on labels. If any WARNING /CAUTION label is found stained or damaged, clean or replace it as necessary.

  • Page 14: Vehcile Lifting Points

    CHANGHE FREEDOM SERVICE MANUAL GENERAL INFORMATION VEHICLE LIFTING POINTS WARNING: Before applying hoist to underbody, always take vehicle balance throughout service into consideration. Vehicle balance on hoist may change depending on what part to be removed. Before lifting up the vehicle, check to be sure that end of hoist arm is not in contact with brake pipe, fuel pipe, bracket or any other part.

  • Page 15: When Using Frame Contact Hoist

    CHANGHE FREEDOM SERVICE MANUAL GENERAL INFORMATION When Using Frame Contact Hoist WARNING: Before lifting up the vehicle, check to be sure that end of hoist arm is not in contact with brake pipe, fuel pipe, bracket or any other part.

  • Page 16: Fasteners Standard Informaiton

    CHANGHE FREEDOM SERVICE MANUAL GENERAL INFORMATION FASTENERS STANDARD INFORMAITON Metric Fasteners Measurement Standard Most of the fasteners used for this vehicle are metric， When replacing any fasteners, it is most important that replacement fasteners be the correct diameter, thread pitch Nut strength mark and strength.

  • Page 17: Metric Fasteners Standard Tightening Torque

    CHANGHE FREEDOM SERVICE MANUAL GENERAL INFORMATION METRIC FASTENERS STANDARD TIGHTENING TORQUE Each fastener should be tightened to the torque specified in each section of this manual. If no description or specification is provided, refer to the following tightening torque chart for the applicable torque for each fastener.

  • Page 18: Special Tools

    CHANGHE FREEDOM SERVICE MANUAL GENERAL INFORMATION SPECIAL TOOLS The main function of special tools：1） Improve the quality of work；2）Increase the efficiency of work；3）Protect parts and components from damage . The special tools use by the model are as follows: Mass Storage Facility...
  • Page 19 CHANGHE FREEDOM SERVICE MANUAL GENERAL INFORMATION 09900-06108 09900-06107 09900-25002 Snap ring pliers 09900-20803 Snap ring pliers Pocket tester （Closing type） Thickness rule （Opening type） 09913-75520A：60.5mm 09913-80112 09913-75510A：70.5mm Bearing installer Differential front and rear 9913-65135 09913-65210 outer race installer Transmission gear remover...
  • Page 20 CHANGHE FREEDOM SERVICE MANUAL GENERAL INFORMATION 1.09916-14510 Valve lifter 2.09916-48210 09915-67310 09915-64510 09916-34520 Valve lifter attachment Vacuum gauge Air pressure gauge Reamer（7mm） 09915-77310 09916-44511 09916-34541 09916-37310 Vacuum gauge Vacuum gauge Reamer handle Reamer（12mm） 09916-57321 09916-84510 09917-47910 09916-77310 Valve guide installer handle...
  • Page 21 CHANGHE FREEDOM SERVICE MANUAL GENERAL INFORMATION 09922-75221 09922-85811 09944-36011 Differential gear 09923-36330 Spring pin remover Steering wheel remover preload adjuster Clutch center guide （4.5mm） 09923-57910 09924-7451 09924-36320 09924-17810 Differential end bearing Bearing installer Differential bevel pinion Flywheel holder adjust revolver...
  • Page 22 CHANGHE FREEDOM SERVICE MANUAL GENERAL INFORMATION 09943-77910 09940-71430 09942-15510 09943-17911 Control arm bush Suspension spring Sliding hammer Brake drum remover remover compressor 09943-88211 09944-18211 09913-60910 09926-18210 Pinion bearing installer Bearing puller Pinion torque check sleeve Oil seal guide 09944-68510 09950-98210...

  • Page 23: Service Auxiliary Material

    CHANGHE FREEDOM SERVICE MANUAL GENERAL INFORMATION SERVICE AUXILIARY MATERIAL The chart below are auxiliary materials that are used in service work, must be prepared for using at any time. In addition to，washing liquid , lubricant must be prepared. The page of the manual explain the use method and time.
  • Page 24 CHANGHE FREEDOM SERVICE MANUAL GENERAL INFORMATION Super grease（E） Apply the steering case（rack and （99000-25050） pinion） interior parts。 Gear oil Transmission case ： 4speed 1.0l[2.1/1.8 Gear oil standard （American/British）pint] Transmission 75W-85 GL-4 ： 5speed 1.3l[2.7/2.3 rank （American/British）pint] Differential oil rank 75W-85 GL-5 Transmission gear and bearing.
  • Page 25 CHANGHE FREEDOM SERVICE MANUAL GENERAL INFORMATION Sealant“CEMEDING”366E Apply steering node，the combine （watertight sealant ） surface of rear axle and brake soleplate （99000-31090） Apply the parts which are 180 毫升 appointed in the manual。 Screw thread releasing agent Super 1333B（99000-32020） Differential and drive fastigiated...
  • Page 26 CHANGHE FREEDOM SERVICE MANUAL SCHEDULED MAINTENANCE SECTION SCHEDULED MAINTENANCE CONTENTS ........................23 MAINTENANCE SCHEDULE Normal Condition Schedule ........................ 23 ........................26 MAINTENANCE SERVICE Engine ..............................26 Ignition System ............................31 Fuel System ............................32 Emission Control System ........................33 Electric Equipment ..........................34...

  • Page 27: Maintenance Schedule

    CHANGHE FREEDOM SERVICE MANUAL SCHEDULED MAINTENANCE MAINTENANCE SCHEDULE NORMAL CONDITION SCHEDULE NOTE： This interval should be judged by odometer reading or months, whichever comes first.. This table includes services as scheduled up to 80000 km .Beyond 80000 km, carry out the same services at the same intervals respectively.
  • Page 28 CHANGHE FREEDOM SERVICE MANUAL SCHEDULED MAINTENANCE 18 、 Idle speed executive electromotor EWD or step motor — — — — — air bypass 19、Throttle body — — — — — 20、Fuel lines and throttle body I、 L — — —...
  • Page 29 CHANGHE FREEDOM SERVICE MANUAL SCHEDULED MAINTENANCE Please test drive every time when you complete 六、Test drive all maintenance work. NOTE: ◆ “I”—— Inspect and correct, replace if necessary ◆ “R”—— Replace or change ◆ “L”—— Lubricate ◆ “T”——Use torque wrench to inspect and tighten。...

  • Page 30: Maintenance Service

    CHANGHE FREEDOM SERVICE MANUAL SCHEDULED MAINTENANCE MAINTENANCE SERVICE ENGINE Electronic injection system [ Inspection ] 1、Turn the ignition switch to “ON” position，find out whether engine malfunction indicator light is on . 2、Connect diagnostic tester to system diagnostic interface to read the malfunction code.
  • Page 31 CHANGHE FREEDOM SERVICE MANUAL SCHEDULED MAINTENANCE Valve Lash Inspection 1) Remove cylinder head cover. 2) Inspect intake and exhaust valve lash and adjust as necessary. 3) About valve lash inspect and adjust to engine specification part. 4) Install cylinder head cover and tighten bolts to specification.
  • Page 32 CHANGHE FREEDOM SERVICE MANUAL SCHEDULED MAINTENANCE Engine Oil and Filter Change 1) Loosen oil filter by using oil filter wrench (A) (special tool 09915-47310). NOTE: Before fitting new oil filter, be sure to oil its O-ring. Use engine oil for this purpose.
  • Page 33 CHANGHE FREEDOM SERVICE MANUAL SCHEDULED MAINTENANCE 20W-50 NOTE: The step 1)-3) above must be performed with 15W-40，15W-50 engine not running. About step 4), when engine is running, make sure ventilate well. 10W-40，10W-50 It is recommended to use engine oil of SE, SF, 10W-30 SG, SH.
  • Page 34 CHANGHE FREEDOM SERVICE MANUAL SCHEDULED MAINTENANCE CAUTION: When changing engine coolant, use mix- ture of 50% water and 50% ethylene-glycol base coolant for the market where ambient temperature falls lower than - 16℃ (3 F) in winter and mixture of 70% water and 30%...

  • Page 35: Ignition System

    CHANGHE FREEDOM SERVICE MANUAL SCHEDULED MAINTENANCE IGNITION SYSTEM Ignition Wiring (High-tension cord) inspect- tion 1 ） Check High-tension cords if cracks and connections if fixed. 2）Use (special tools 09900-25002) to Measu -re High-tension resistance data. 3) Replace High-tension cords that show evidence of deterioration.

  • Page 36: Fuel System

    CHANGHE FREEDOM SERVICE MANUAL SCHEDULED MAINTENANCE FUEL SYSTEM Air Cleaner Filter Clearing and Replacement 1） Dismantle Air Cleaner cover. 2） Take air cleaner filter out of case. 3） Clean filter or replace new one, clean filter with compressed air from air outlet side of filter.

  • Page 37: Emission Control System

    CHANGHE FREEDOM SERVICE MANUAL SCHEDULED MAINTENANCE Engine idle speed inspection Check the rotate speed of idle speed adjust as necessary. A bout the steps of engine idle speed inspection and adjustment, refer to engine service. DA465QE/2F DA471Q Engine Type 850±50r/min...

  • Page 38: Electric Equipment

    CHANGHE FREEDOM SERVICE MANUAL SCHEDULED MAINTENANCE ELECTRONIC EQUIPMENT hook-up, leaks, cracks, wear and other damage. Replace any of these parts as necessary. Wiring Connections Inspection CAUTION： After replacing any brake pipe and hose, 1) Visually inspect all wiring for cracks, insulation.
  • Page 39 CHANGHE FREEDOM SERVICE MANUAL SCHEDULED MAINTENANCE distortion and cracks. A disc in badly damaged Brake Pedal Inspection Check brake pedal free travel. condition must be replaced. For checking procedure, referring to “in 2） Wheel Bearing Section 11”. a. Check front wheel bearing for wear, Brake Lever and Cable Inspection damage, abnormal noise or rattles.
  • Page 40 CHANGHE FREEDOM SERVICE MANUAL SCHEDULED MAINTENANCE Shock Absorber Inspection 1）Inspect Shock Absorber for oil leakage, dents or any other damage on sleeves; and inspect anchor ends for deterioration. 2）Replace Shock Absorber as necessary. Drive Shaft Inspection Inspect drive shaft boot and cardan joint for...
  • Page 41 CHANGHE FREEDOM SERVICE MANUAL SCHEDULED MAINTENANCE 4) Remove level plug of differential. Oil level can be checked roughly by means of level plug hole. That is, if oil flows out of level plug hole or if oil level is found up to hole when level plug is removed, oil is properly filled.
  • Page 42 CHANGHE FREEDOM SERVICE MANUAL SCHEDULED MAINTENANCE Suspension Inspection and Tighten times to insure that oil has worked in effectively. TESTS DRIVE 1) Inspect rear struts for evidence of wear, To finish front all scheduled Inspection, select or damage. crack replace with new one.
  • Page 43 CHANGHE FREEDOM SERVICE MANUAL SCHEDULED MAINTENANCE 5）Steering Check to ensure that steering wheel is free from instability, or abnormally heavy feeling。 6）Engine .● Check that engine responds readily at all speed. ● Check that engine is free from abnormal noise and abnormal vibration.
  • Page 44 CHANGHE FREEDOM SERVICE MANUAL ENGINE THE SECOND PART ENGINE ENGINE SECTION 3 CONTENTS ......................... 41 GENERAL INFORMATION ........................ 41 MAINTENANCE REGULATION ......................42 REQUIRED SERVICE MATERIALS ........................43 ENGINE DIAGNOSIS TABLE ............................49 STARTING MOTOR ..............................50 ALTERNATOR...

  • Page 45: General Information

    CHANGHE FREEDOM SERVICE MANUAL ENGINE GENERAL INFORMATION DA465QE-1A engine is multipoint electricity injection engine、 in-line、 four cylinder、 four-stroke piston engine. The electronic control system is matched by UAES (United Automotive Electronics Co., LTD). MAINTENANCE REGULATION 1. One of the keys to maintain successfully is in an orderly way，you must prepare spare parts kit and parts tack that are used to place disassembled parts.

  • Page 46: Required Service Materials

    CHANGHE FREEDOM SERVICE MANUAL ENGINE REQUIRED SERVICE MATERIALS Ref. Material Additive to engine cooling system for improving Anti-freeze coolant cooling efficiency and for protection of wet walls against rusting。 Clutch release bearing retainer. Clutch release shaft bushing Clutch oil seal.

  • Page 47: Engine Diagnosis Table

    CHANGHE FREEDOM SERVICE MANUAL ENGINE ENGINE DIAGNOSIS TABLE Condition Possible Correction Starter will not run 1. Main fuse blown off Replace Repair or replace 2. Contact not closing in main switch, or this switch open-circuited. Recharge 3. Run-down battery and <8V.
  • Page 48 CHANGHE FREEDOM SERVICE MANUAL ENGINE Condition Possible Correction Inadequate compression Clean o r replace。 1． Air filter dirty and clogged Adjust 2． Improper valve clearance Repair 3． Valves not seating tight Replace 4． Valve stems tending to seize Replace 5． Weakened or broken valve spring Replace 6．...
  • Page 49 CHANGHE FREEDOM SERVICE MANUAL ENGINE Condition Possible Correction Electrical system Adjust 1． Plug gap out of adjustment coil ， or 2． Deteriorated nition crack eplace resulting in leakage Replace 3． Leaky high-tension cords djust 4． Ignition tim ing out of adjustment...
  • Page 50 CHANGHE FREEDOM SERVICE MANUAL ENGINE Condition Possible Correction Erratic Ignition system Adjust 1． Improper ignition timing. 2． Defective spark plug，or improper gap. Replace or adjust eplace 3． High tension cord bad insu lation. Electricity injec tion system Check circuit or replace 1．...
  • Page 51 CHANGHE FREEDOM SERVICE MANUAL ENGINE Condition Possible Correction Lubrication system Replace 1． Clogged oil filter Clean 2． Clogged oil strainer Replace 3． Deteriorated oil pump performa Repair 4． Oil leakage from oil pan pu ． Improper engine oil grade eplace with proper grade oil eplenish 6．...
  • Page 52 CHANGHE FREEDOM SERVICE MANUAL ENGINE Condition Possible Correction Ignition system Adjust 1． Improper ignition timing eplace 2． Le ak or loose connection of high tension cord place 3． Defective s park plug Fuel system repair or r eplace 1． Fuel leakage from tank, pipe...

  • Page 53: Starting Motor

    CHANGHE FREEDOM SERVICE MANUAL ENGINE STARTING MOTOR Condition Cause Correction Replace 1． Worn pinion of starter clutch Repair or replace Starter runs but 2． Defective splines, resulting in sticky pinion plunging motion pinion will not Replace mesh into ring 3． Worn bush...

  • Page 54: Alternator

    CHANGHE FREEDOM SERVICE MANUAL ENGINE ALTERNATOR Condition Cause Correction Battery quickly becomes 1． Look Lose or broken wedge-shaped belt Adjust or replace over-discharged 2． Open-circuit in stator winding Adjust or replace 3． Open-circuit in rotor winding Adjust or replace 4． slip-ring brush defective Replace 5．...
  • Page 55 CHANGHE FREEDOM SERVICE MANUAL ENGINE MECHANICAL SECTION 4 ENGINE MECHANICAL CONTENTS ......................... 52 GENERAL DESCRIPTION ............... 52 MAINTENANCE WITHOUT DISASSEMBLING ENGINE ..........................53 ENGINE DISASSEMBLY ................... 64 INSPECTION AND ADJUST OF ENGINE ........................... 65 SERVICE OF ENGINE ..........................78 ENGINE REASSEMBLE...

  • Page 56: General Description

    CHANGHE FREEDOM SERVICE MANUAL ENGINE MECHANICAL GENERAL DESCRIPTION 1. The engine is a water-cooled, in-line 4 cylinder, 4-stroke cycle gasoline unit with its single overhead camshaft. The single overhead camshaft is mounted over the cylinder head, it is driven from crankshaft through timing belt .this engine has no push rods.

  • Page 57: Engine Disassembly

    CHANGHE FREEDOM SERVICE MANUAL ENGINE MECHANICAL Part or Component Nature or Service 15.Timing belt Replace or inspection 16.Oil pan and oil strainer Replace or inspection 17.Camburetor Replace or inspection 18.Intake manifold Replace 19.Alternator Replace or inspection 20.Starter motor Replace or inspection 21.Fan belt...
  • Page 58 CHANGHE FREEDOM SERVICE MANUAL ENGINE MECHANICAL 2) Loose drain plug and drain out engine oil. Fig. 3-002 3) Remove clutch cover and clutch disc. Fig. 3-003 4) Using special tool, remove oil filter. Fig. 3-004...
  • Page 59 CHANGHE FREEDOM SERVICE MANUAL ENGINE MECHANICAL （一） 、Front cover (1) Take down alternator belt. Fig. 3-005 (2) Take down alternator adjusting arm. Fig. 3-006 (3) Take down crankshaft pulley Fig. 3-007...
  • Page 60 CHANGHE FREEDOM SERVICE MANUAL ENGINE MECHANICAL (4) Remove outside cover on timing belt. Fig. 3-08 (5) Remove tensioner assembly. Fig. 3-09 (6) Remove timing belt. Fig. 3-010 Step： 1、Remove camshaft timing belt pulley securing bolt. 2、Remove timing belt. 3、Remove tensioner assembly.
  • Page 61 CHANGHE FREEDOM SERVICE MANUAL ENGINE MECHANICAL Fig. 3-011 Fig. 3-012 (7) Take down timing belt inside cover. Fig. 3-013 （二） 、Intake and exhaust system (1) Remove exhaust manifold cover. Fig. 3-014...
  • Page 62 CHANGHE FREEDOM SERVICE MANUAL ENGINE MECHANICAL (2) Take off exhaust manifold and its gasket. Fig. 3-015 (3) Remove oil rail. Fig. 3-016 (4) Draw by pass hose off water inlet pipe. Fig. 3-017 (5) Remove intake manifold. Fig. 3-018...
  • Page 63 CHANGHE FREEDOM SERVICE MANUAL ENGINE MECHANICAL (6) Remove water inlet pipe. Fig. 3-019 （三） 、Cylinder head (1) Remove camshaft and cover. Fig. 3-020 (2) Take off cylinder head cover. Fig. 3-021 (3) Loosen 8 valve adjusting screws. Fig. 3-022...
  • Page 64 CHANGHE FREEDOM SERVICE MANUAL ENGINE MECHANICAL (4) Loosen rocker arm shaft securing screws. Fig. 3-023 (5) Drawing out rocket arm shaft. Fig. 3-024 (6) Separate valve rocker arms and arm springs. Fig. 3-025 (7) Remove camshaft thrust plate, and draw camshaft out toward rear end.
  • Page 65 CHANGHE FREEDOM SERVICE MANUAL ENGINE MECHANICAL (8) Remove cylinder head. Fig. 3-027 (9) Use compress tool to remove valve spring and valves. Fig. 3-028 （四） 、Cylinder Block (1) Remove water pump. Fig. 3-029...
  • Page 66 CHANGHE FREEDOM SERVICE MANUAL ENGINE MECHANICAL (2) Remove all brackets of gasoline engine. Fig. 3-030 (3) Remove oil pan. Fig. 3-031 (4) Remove oil pump and oil pump strainer assy. Fig. 3-032...
  • Page 67 CHANGHE FREEDOM SERVICE MANUAL ENGINE MECHANICAL (5) Remove oil seal housing and oil seal. Fig. 3-033 (6) Remove No.1 and No.4 connecting rod bearing gaps, push piston and connecting rod assembly out through the top cylinder bore. Fig. 3-034 Cautions:...

  • Page 68: Inspection And Adjust Of Engine

    CHANGHE FREEDOM SERVICE MANUAL ENGINE MECHANICAL INSPECTION AND ADJUST OF ENGINE Timing belt Timing belt is expendable, so need to inspect damage、 break、 abrasion and whether or not cleanliness, If adhibit all oil or have damage and abrasion conditions, must change it, lest beget serious fault when parted.

  • Page 69: Service Of Engine

    CHANGHE FREEDOM SERVICE MANUAL ENGINE MECHANICAL SERVICE OF ENGINE Notice: During and immediately after disassembly inspect cylinder block and head for evidence of water leakage or damage and, after washing them clean, inspect more closely. Wash all disassembled parts clean, removing grease, slime, carbon and scales, before inspecting them to determine whether repair is necessary or not.
  • Page 70 CHANGHE FREEDOM SERVICE MANUAL ENGINE MECHANICAL Distortion of manifold seating faces: Fig. 3-039 Check the seating faces of cylinder head for manifolds, using a straightedge and thickness gauge, in order to determine whether these faces should be corrected or the cylinder head replaced.
  • Page 71 CHANGHE FREEDOM SERVICE MANUAL ENGINE MECHANICAL Fig. 3-042 Item Standard Limit Rocker arm I.D. 15～15.04mm － Rocker-arm shaft dia. 14.965～14.98mm － Inlet 0.02～0.075mm 0.095mm Arm-to-shaft clearance Exhaust 0.02～0.075mm 0.095mm Fig. 3-043 Runout limit of rocker-arm shaft ≤0.06mm Fig. 3-044 Visually examine each rocker-arm spring for evidence of breakage or weakening. Be sure to replace springs found in bad condition.
  • Page 72 CHANGHE FREEDOM SERVICE MANUAL ENGINE MECHANICAL Valve stem diameter as follows: intake 6.965～6.980mm Valve stem dial. exhaust 6.955～6.970mm Valve guide I.D.: 7.000～7.015mm Intake Valve guide I.D. Exhaust 7.000～7.015mm Gap: Stem-to-guide Intake 0.02～0.05mm 0.07mm clearance Exhaust 0.03～0.06mm 0.09mm Valve Seats: Seating contact width: Produce a contact pattern on each valve in the usual manner, namely, by giving a uniform coat of marking compound (cyan-lead paste) to valve seat and by rotatingly tapping seat with valve head.
  • Page 73 CHANGHE FREEDOM SERVICE MANUAL ENGINE MECHANICAL Valve Spring: Referring to the criterion-date given below, check to be sure that each spring is in sound condition, free of any evidence of breakage or weakening. Spring squareness: Fig. 3-048 Fig. 3-049 Item...
  • Page 74 CHANGHE FREEDOM SERVICE MANUAL ENGINE MECHANICAL Fig. 3-051 Runout of camshaft: Runout limit ≤0.025mm Hold camshaft on two spire, and measure runout by using a dial gauge. If runout exceeds its limit, replace camshaft. Cam wears: With a micrometer, measure height ○ H of cam. If measured height is less than respective one, replace camshaft.
  • Page 75 CHANGHE FREEDOM SERVICE MANUAL ENGINE MECHANICAL Cylinder block Distortion of gasket surface: Fig. 3-054 Using a straightedge and a thickness gauge, check gasket surface for distortion and, if result exceeds specified limit, correct it. Limit of distortion 0.05mm Cylinder bore:...
  • Page 76 CHANGHE FREEDOM SERVICE MANUAL ENGINE MECHANICAL Piston 0.25mm Ⅰ oversize 0.5mm Ⅱ Wear limit on bore 0.05mm Piston-to-cylinder 0.025～ clearance 0.045mm Piston and piston rings Piston diameter is to be measured by measuring at the level of the piston in the direction transverse to piston pin axis, as shown in below Figure.
  • Page 77 CHANGHE FREEDOM SERVICE MANUAL ENGINE MECHANICAL Fig. 3-059 Piston Top ring 1.47～1.49mm Item Standard Limit ring 2nd ring 1.47～1.49mm thickness Oil ring 2.75～2.8mm Ring 0.03~0.07mm 0.12mm ring Top ring 1.52～1.54mm Ring clearance in groove 2nd ring 1.51～1.53mm the groove 0.02~0.06mm 0.1m...
  • Page 78 CHANGHE FREEDOM SERVICE MANUAL ENGINE MECHANICAL Limit on bow 0.10mm Limit on twist 0.10mm Fig. 3-061 Item Standard Limit 0.26～0.44mm Big-end thrust clearance 0.55mm Width of big end① 21.71～21.84mm Width of crank pin② 22.10～22.15mm Fig. 3-062 Connecting rod alignment: Mount connecting rod on aligner to check it for bow and twist and, if either limit is exceeded, replace Inspect small end of each connecting rod for wear and evidence of crack or any other damage, paying particular attention to the condition of its bush.
  • Page 79 CHANGHE FREEDOM SERVICE MANUAL ENGINE MECHANICAL Connecting rod big End Bearings: Inspect bearing shells for signs of fusion, pitting, burn or flaking and observe the contact pattern. Bearings found in defective condition through this inspection must be replaced. ～ Bearing cap 3.2kgf/cm...
  • Page 80 CHANGHE FREEDOM SERVICE MANUAL ENGINE MECHANICAL Fig. 3-065 Out-of-round and taper: An unevenly worn crankshaft journal crankpin shows up as a difference in diameter at a cross section or along its length. This difference, if any, is to be determined from micrometer readings taken as shown in below Figure.
  • Page 81 CHANGHE FREEDOM SERVICE MANUAL ENGINE MECHANICAL Crankshaft Journal Bearings: The method and standard of judgment is the same as connecting-rod big end bearings. Journal-to-bearing clearance: Item Standard Limit Journal-to-bearing clearance 0.02～0.04mm 0.08mm Flywheel: Inspect the friction surface-the surface in contact with clutch disc-for wear and damage. Most of surface flaws, if any, can be removed by simple machining.

  • Page 82: Engine Reassemble

    CHANGHE FREEDOM SERVICE MANUAL ENGINE MECHANICAL diameter of piston 65.465～65.505mm Fig. 3-069 Rubber part: Inspect the rubber part of chipping or any other damage. Replace them as necessary. CAUTION: Do not bend the cumber part. Keep away oil and water from the rubber part. The rubber part must be kept clean.
  • Page 83 CHANGHE FREEDOM SERVICE MANUAL ENGINE MECHANICAL Fig. 3-070 Install thrust bearings to cylinder block before installing crankshaft, and face oil grooves side to crank webs. Fig. 3-071 When fitting crankshaft bearing caps, fist oil crankshaft journals, so do rotary place of connecting rods.
  • Page 84 CHANGHE FREEDOM SERVICE MANUAL ENGINE MECHANICAL After tightening cap bolts, check to be sure that crankshaft rotates smoothly when turned by hand. The specified torque can not be bigger than1.2kg.m Oil Pump Strainer Do not forget the “O” ring when reassembling the oil pump strainer.
  • Page 85 CHANGHE FREEDOM SERVICE MANUAL ENGINE MECHANICAL Fig. 3-076 Installation Of Connecting Rod And Piston Apply engine oil to pistons, rings, cylinder walls, connecting rod bearings and crankshaft pins When installing piston and connecting rod assembly into cylinder bore, point arrow mark on each piston head to front side (crankshaft pulley side).
  • Page 86 CHANGHE FREEDOM SERVICE MANUAL ENGINE MECHANICAL After fitting four big-ends bearing caps, start tightening them uniformly, be sure to equalize tightness between right and left on each cap. After installing crankshaft ,piston and connecting rod, make sure to affirm crankshaft pulley side、 the arrows on piston crowns and the mark of crankshaft bearing caps.
  • Page 87 CHANGHE FREEDOM SERVICE MANUAL ENGINE MECHANICAL Fig. 3-080 Using special tool, compress valve spring and fit two valve cotters to groove provided in valve stem. Fig. 3-081 Installing the head gasket： The head gasket is the pivotal part. It directly affect the power and the else performance parameter.
  • Page 88 CHANGHE FREEDOM SERVICE MANUAL ENGINE MECHANICAL Fig. 3-082 Install cylinder head onto cylinder block. Tighten cylinder head bolts gradually with torque wrench to specified torque. Fig. 3-083 Camshaft Apply engine oil to cams and journals on camshaft, and oil seal on cylinder head. Then install it to cylinder head from transmission case side.
  • Page 89 CHANGHE FREEDOM SERVICE MANUAL ENGINE MECHANICAL Fig. 3-085 Rocker-arm Shafts The two rocker-arm shafts are identical, there is no need to distinguish between the two. However, each shaft takes but one position in place. On the inlet side：the stepped end comes on front side.
  • Page 90 CHANGHE FREEDOM SERVICE MANUAL ENGINE MECHANICAL Fig. 3-087 Fig. 3-088 C、Put tension and spring together before installing them as one to the timing belt cover. Tighten the bolts to the extent that the tensioner can be moved by hand easily.
  • Page 91 CHANGHE FREEDOM SERVICE MANUAL ENGINE MECHANICAL Fig. 3-090...
  • Page 92 CHANGHE FREEDOM SERVICE MANUAL ENGINE COOLING SYSTEM SECTION 5 ENGINE COOLING SYSTEM CONTENTS ..................... 89 THE FUNCTION OF COOLING SYSTEM .......................... 89 GENERAL DESCRIPTION ......................89 COOLING SYSTEM CIRCULATION ................... 91 DESCRIPTION OF MAIN COMPONENTS RADIATOR CAP ............................91 COOLANT RESERVOIR TANK ........................92 WATER PUMP ...............................

  • Page 93: The Function Of Cooling System

    CHANGHE FREEDOM SERVICE MANUAL ENGINE COOLING SYSTEM THE FUNCTION OF COOLING SYSTEM Coolant flows through hoses and radiator, and it is forced to cycle to cool engine. Water pump uses large-capacity centrifuge. Radiator is tube-belt, heat from which radiates is very high. Thermostat is wax type, and expands when heated and contracts when cooled.
  • Page 94 CHANGHE FREEDOM SERVICE MANUAL ENGINE COOLING SYSTEM 2）When coolant is warmed up to normal temperature and the thermostat opens,coolant passes through the radiator core to be cooled as well as the above flow circuit. as well as the above flow circuit：...

  • Page 95: Description Of Main Components

    CHANGHE FREEDOM SERVICE MANUAL ENGINE COOLING SYSTEM DESCRIPTION OF MAIN COMPONENTS 1. RADIATOR CAP A pressure-vent cap is used on the radiator. The cap contains a pressure valve and ventilation valve. The pressure valve is held against its seat by a spring of...

  • Page 96: Coolant Reservoir Tank

    CHANGHE FREEDOM SERVICE MANUAL ENGINE COOLING SYSTEM 2. COOLANT RESERVOIR TANK A "see-through" plastic reservoir tank is connected to the radiator by a hose. As the vehicle is driven, the coolant is heated and expands. The portion of the coolant displaced by this expansion flows from the radiator into the reservoir tank.

  • Page 97: Cooling Fan

    CHANGHE FREEDOM SERVICE MANUAL ENGINE COOLING SYSTEM Thus, the valve remains closed while the coolant is cold, preventing circulation of coolant through the radiator. At this point, coolant is allowed to circulate only throughout the engine to warm it quickly and evenly.

  • Page 98: Diagnosis

    CHANGHE FREEDOM SERVICE MANUAL ENGINE COOLING SYSTEM DIAGNOSIS Condition Possible Cause Correction Loose or broken water pump belt Adjust or replace. Not enough coolant Check coolant level and add as necessary. Faulty thermostat Replace. Faulty water pump Replace. Dirty or bent radiator fins Clean or remedy.

  • Page 99: Coolant Level

    CHANGHE FREEDOM SERVICE MANUAL ENGINE COOLING SYSTEM ANTI-FREEZE PROPORTIONING CHART Vehicle with M/T ℃ Freezing temperature Anti-freeze proportioni Anti-freeze/Anti-corrosio ng chart n coolant concentration cooling water shop sign -35（SH0521-92） Engine radiator and heater 3.55L Coolant Reservoir tank 0.75L capacity Total 4.3L...

  • Page 100: Cooling System Flush And Refill

    CHANGHE FREEDOM SERVICE MANUAL ENGINE COOLING SYSTEM 3) Check coolant for proper level and freeze protection. 4) Using a pressure tester, check system and radiator cap for proper pressure holding capacity 110kPa（1.1kg/cm2）. If replacement of cap is required, use proper cap specified torque for this vehicle.

  • Page 101: Water Pump Belt Tension

    CHANGHE FREEDOM SERVICE MANUAL ENGINE COOLING SYSTEM 5. WATER PUMP BELT TENSION WARNING： Disconnect negative cable at battery before checking and adjusting belt tension. See “WARNING” described in “COOLING SYSTEM SERVICE”. 1) Inspect belt for cracks, cuts, deformation, wear and cleanliness.

  • Page 102: Thermostat

    CHANGHE FREEDOM SERVICE MANUAL ENGINE COOLING SYSTEM INSTALLATION Install removed parts in reverse order of removal procedure noting but the following： Tighten each clamp securely. Refill cooling system with proper coolant, referring to description on COOLANT of MAINTENANCE. 3 THERMOSTAT A.

  • Page 103: Water Pump Belt

    CHANGHE FREEDOM SERVICE MANUAL ENGINE COOLING SYSTEM 4. WATER PUMP BELT A. REMOVAL 1）Disconnect negative cable at battery. 2）Remove air cleaner assembly. 3) Loosen drive belt adjusting bolt and generator pivot bolts. When servicing car equipped with A/C, remove compressor drive belt before removing water pump belt.

  • Page 104: Water Pump

    CHANGHE FREEDOM SERVICE MANUAL ENGINE COOLING SYSTEM 6 WATER PUMP A. REMOVE 1）Discon nect negative cable at battery. 2）Drain coolant. 3）Loosen drive b elt adjusting bolt and generator pivot bolt, then Remove water pump bolt. 4）Disconnect oil pressure swit ch coupler and remove clam 5）...

  • Page 105: Required Service Material

    CHANGHE FREEDOM SERVICE MANUAL ENGINE COOLING SYSTEM REQUIRED SERVICE MATERIAL MATERIALS Ethylene glycol base coolant Additive to engine cooling system for (Anti-freeze/Anti-corrosion coolant) improving cooling efficiency and for protection against rusting...
  • Page 106 CHANGHE FREEDOM SERVICE MANUAL ENGINE LUBRICATE SYSTEM SECTION 6 ENGINE LUBRICATE SYSTEM CONTENTS ..................103 THE FUNCTION OF LUBRICATE SYSTEM .......................... 103 CHOOSING LUBRICANT ....... 103 THE COMPONENT OF LUBRICATE SYSTEM AND ITS WORK FLOW The Component Of Lubricate System ....................103 The Work Flow Of Lubricate System ......................

  • Page 107: The Function Of Lubricate System

    CHANGHE FREEDOM SERVICE MANUAL ENGINE LUBRICATE SYSTEM THE FUNCTION OF LUBRICATE SYSTEM The basic task of the lubricate system is to continually supply oil to parts of engine, and is to decrease grind, drop temperature, wash, remove dust, absorb shake to movement friction surface, at the same time it affects anticorrosive and sealed.

  • Page 108: The Work Flow Of Lubricate System

    CHANGHE FREEDOM SERVICE MANUAL ENGINE LUBRICATE SYSTEM 二、The Work Flow Of Lubricate System (chart 5－1) camshaft bearing journal Piston and cylinder Rocker arm shaft block wall Rocker arm Connecting rod small end 5# camshaft bearing journal 、 4# camshaft 1、 2...

  • Page 109: Disassembling, Checking And Assembling Of Main Parts Of Lube System

    CHANGHE FREEDOM SERVICE MANUAL ENGINE LUBRICATE SYSTEM （1） The oil filled from oil filling port on valve cover flow through cylinder head, oil path in cylinder block, and collect in the oil pan finally. （2） The oil pump mounted on the front end of the crankshaft worked with the rotation of the cranks haft.
  • Page 110 CHANGHE FREEDOM SERVICE MANUAL ENGINE LUBRICATE SYSTEM Take out the outer gear Fig...5-4 Checking of oil pump： Radial clearance of Inner gear and stator standard 0.43~0.53mm Fig...5-5 Radial clearance of outer gear and stator Standard 0.19~0.30mm Fig...5-6 Radial clearance of outer gear and pump shell...
  • Page 111 CHANGHE FREEDOM SERVICE MANUAL ENGINE LUBRICATE SYSTEM Fig...5-7 Side clearance： Standard Limit 0.045~0.12mm 0.17mm Fig...5-8 Assembling of oil pump Make sure that all the components are clean, and meet the items below. 1） The point on the side face must be opposite the back cover.
  • Page 112 CHANGHE FREEDOM SERVICE MANUAL ENGINE LUBRICATE SYSTEM Checking of the oil filter： The oil filter should be changed according to the data below. If the oil filter is dirty, change it immediately. First change (after running in) filter:2500 km Normal Change Oil: 5000km，...
  • Page 113 CHANGHE FREEDOM SERVICE MANUAL ENGINE LUBRICATE SYSTEM Oil level： Oil should be replenished if possible, to make the oil level be on the middle of the upper mark and the lower mark. Fig.5-11...
  • Page 114 CHANGHE FREEDOM SERVICE MANUAL ENGINE MANAGE SYSTEM SECTION 7 ENGINE MANAGE SYSTEM CONTENTS ................................ 111 SUMMARY ................................ 111 SENSORS Throttle position sensor ..........................111 Intake manifold air temperature and pressure sensor ................111 Coolant temperature sensor ........................111 Oxygen sensor ............................112 Knock Sensor ..............................

  • Page 115: Summary

    CHANGHE FREEDOM SERVICE MANUAL ENGINE MANAGE SYSTEM SUMMARY The EMS for DA465QE-1A gasoline engine is made by UAES. The type of UAES EMS is M 7.9.7 system. SENSORS Throttle position sensor It is mounted on the outside of throttle body by the same axle with the throttle valve to measure load and load changing timely.

  • Page 116: Oxygen Sensor

    CHANGHE FREEDOM SERVICE MANUAL ENGINE MANAGE SYSTEM Oxygen sensor It is mounted on the exhaust pipe to measure the thickness of oxygen in exhaust and the signal is used to correct the fuel supply, and realize the close loop control of A/F ratio.

  • Page 117: Actuators

    CHANGHE FREEDOM SERVICE MANUAL ENGINE MANAGE SYSTEM ACTUATORS Fuel Pump: The fuel pump is mounted in the fuel tank, and controlled by ECU. When the engine is shut down, the fuel pump stops automatically. Pumping pressure：>300kPa NOTE: Disassembling of the fuel pump is forbidden to prevent the damage of the sealability.

  • Page 118: Canister Purge Solenoid

    CHANGHE FREEDOM SERVICE MANUAL ENGINE MANAGE SYSTEM Canister purge solenoid： The mass of air is adjusted by duty cycle of the canister purge solenoid in the control of ECU. It leads the fuel vapor into the inlet system. Coil resistance：26Ω@20℃...
  • Page 119 CHANGHE FREEDOM SERVICE MANUAL CLUTCH THE THIRD PART CLUTCH TRANSMISSION DIFFERENTIAL SECTION 8 CLUTCH CONTENTS ........................116 GENERAL DESCRIPTION ............................. 118 DIAGNOSIS TABLE ................................119 REMOVAL ......................120 INSPECTlON OF COMPONENTS .............................. 122 INSTALLATION...

  • Page 120: General Description

    CHANGHE FREEDOM SERVICE MANUAL CLUTCH GENERAL DESCRIPTION The clutch is a diaphragm—spring clutch of a dry single disc type．The diaphragm spring is of a tapering finger type, which is a solid ring in the outer diameter part, with a series of tapering fingers pointing inward．...
  • Page 121 CHANGHE FREEDOM SERVICE MANUAL CLUTCH 1．Clutch disc 7．Bushing 2．Clutch cover 8．Clutch release shaft 3．Lock washer 9．Return spring 4．Cover bolt 10．Reamer bolt 5．Clutch release bearing 11．Clutch release lever 6．Clutch release fork Dir...

  • Page 122: Diagnosis Table

    CHANGHE FREEDOM SERVICE MANUAL CLUTCH DIAGNOSIS TABLE Condition Cause Correction 1． Loss of cleave at the tip of release fork Adjust 2． Clutch facing dirty with oil Replace 3． Clutch facing excessively worn Replace Slipping 4． Weakened diaphragm spring Replace 5．...

  • Page 123: Removal

    CHANGHE FREEDOM SERVICE MANUAL CLUTCH REMOVAL Removal of clutch presupposes that the transmission has been dismounted according to the method outlined in SECTION 9 TRANSMISSION. Clutch Cover and Disc 1) Remove 6 bolts securing clutch cover to flywheel and take off clutch cover and disc．...

  • Page 124: Inspectlon Of Components

    CHANGHE FREEDOM SERVICE MANUAL CLUTCH Clutch Release Shaft Bushes For replacement of bushes, refer to p．13-5 of SECTION 9 TRANSMISSl0N． INSPECTlON OF COMPONENTS Clutch Disc Facing Surface Condition A burnt or glazed (glass-like surface) facing can be reconditioned by grinding it with NO.120—200 sandpaper.
  • Page 125 CHANGHE FREEDOM SERVICE MANUAL CLUTCH Clutch Cover Inspect clutch cover for evidence of diaphragm spring rivets getting loose．If rivets are loose or are getting loose， replace cover assembly as such cover makes rattling noise when clutch pedal is depressed． Inspect tips of tapering fingers which the release bearing exerts a push to disengage clutch for wear．If tips...

  • Page 126: Installation

    CHANGHE FREEDOM SERVICE MANUAL CLUTCH INSTALLATION Install clutch by reversing removal procedure. some important steps will be explained below． Flywheel 1) Tighten bolts to specification N．m kg．m lb-ft Tightening torque for flywheel bolts 40~45 4.0~4.5 29.0~32.5 1.Flywheel 2.Flywheel bolt 3.Input shaft bearing (A):Special tool Flywheel holder 09924—17810...
  • Page 127 CHANGHE FREEDOM SERVICE MANUAL CLUTCH Clutch Release Bearing Before installing bearing, apply grease to its inner surface． ① Grease (SUPER GREASE“A“) Clutch Release Shaft Fork Apply grease to end of fork and input shaft． ① Grease (SUPER GREASE “A“) ②...
  • Page 128 CHANGHE FREEDOM SERVICE MANUAL TRANSMISSION SECTION 9 TRANSMISSION CONTENTS ........................125 GENERAL DESCRIPTION ........................ 126 TRANSMISSION GEAR RATIO ..............................127 DISMOUNTING ............................... 128 DISASSEMBLY ......................139 INSPECTION OF COMPONENTS ..................... 144 IMPORTANT STEPS IN INSTALLATION ......................... 157 MAINTENANCE SERVICE .................. 160...

  • Page 129: General Description

    CHANGHE FREEDOM SERVICE MANUAL TRANSMISSION GENERAL DESCRIPTION 1．Main shaft rear bearing 19．Synchronizer spring 2．5th gear washer 20．2nd gear 3．Main shaft washer ball 21．3rd gear needle bearing 4．5th gear needle bearing 22．3rd gear 5．5th gear 23．High speed synchronizer hub set 6．Circlip 24．Input shaft bearing...

  • Page 130: Transmission Gear Ratio

    CHANGHE FREEDOM SERVICE MANUAL TRANSMISSION TRANSMISSION GEAR RATIO Primary gear ratio 35／23 35／23 Primary speed ratio 1.521 1.521 Shift position Reverse Second Third Fourth Fifth Gear ratio 41/18 36/15 32/25 29/31 23/44 Secondary ratios Speed ratio 2.277 2.400 1.280 0.935 0.522...

  • Page 131: Dismounting

    CHANGHE FREEDOM SERVICE MANUAL TRANSMISSION DISMOUNTING Disconnect negative (-)and positive (+) cords from battery terminals and hoist car． Disconnect back light switch lead wire at coupler． Disconnect Black／Yellow lead wire and positive(+)cord from starter motor． Remove starter motor from transmission case and disconnect battery negative(-)cord from transmission case．...

  • Page 132: Disassembly

    CHANGHE FREEDOM SERVICE MANUAL TRANSMISSION 11) Remove clutch housing lower plate from transmission case． 12) Remove nuts fastening engine cylinder block and transmission case． NOTICE： Before starting to remove transmission check around once again to be sure that there is no connection left undone．...
  • Page 133 CHANGHE FREEDOM SERVICE MANUAL TRANSMISSION Remove clutch release lever from shaft． With clutch release bush remover (A) (special tool) applied in such a position as shown in Fig. 13-3-2，tap its end to take out bush． Clutch release bush remover(A)(09925-48510)． If bush can’t be taken out of transmission case in the above manner，grip bush with pliers or the like...
  • Page 134 CHANGHE FREEDOM SERVICE MANUAL TRANSMISSION Separating Upper Case from Lower Case Remove clutch release bearing from transmission input shaft． Fig．13-4-1 Remove input shaft bearing retainer bolts and pull out retainer by using 3 conventional 6 mm bolts． Fig.．13-4-2 Remove gear shift lever case and speed meter driven gear case．...
  • Page 135 CHANGHE FREEDOM SERVICE MANUAL TRANSMISSION Remove bolts fastening upper and lower cases together. Separate cases and take out main shaft assembly．A steel bar，similar in shape to screwdriver， may have to be used to pry cases apart as shown．In doing so．do not stick bar too far into between two mating faces, or faces may become damaged．...
  • Page 136 CHANGHE FREEDOM SERVICE MANUAL TRANSMISSION Remove countershaft rear bearing Bearing puller (B) (09913—65135) Fig.1 3-7 Remove countershaft 5th gear and countershaft reverse gear． Fig.13-8 Remove circlip from countershaft．Push out countershaft to extensio11 case side by using hydraulic press ， remove bearing ， and take countershaft assembly out of case．...
  • Page 137 CHANGHE FREEDOM SERVICE MANUAL TRANSMISSION Removing Main Shaft and Input Shaft Take out input shaft by hand，taking care not to let high-speed synchronizer ring fall off． Fig.．13·10 Remove circlip retaining hub of high-speed synchronizer sleeve，and slide off sleeve hub，third driven gear and needle bearing from main shaft．...
  • Page 138 CHANGHE FREEDOM SERVICE MANUAL TRANSMISSION Remove circlip retaining rear bearing on main shaft．Remove main shaft bearing. Fig.．13-12 Fig.．13-13 From main shaft，take off 5th gear washer， ball， 5th gear，5th speed synchronizer ring and 5th gear needle bearing. Fig.．13-14...
  • Page 139 CHANGHE FREEDOM SERVICE MANUAL TRANSMISSION Remove circlip retaining reverse synchronizer hub 013 main shaft． Fig.．13-15 Remove reverse synchronizer hub，reverse gear and reverse gear needle bearing． Fig.．13-16 Remove bearing washer and reverse clear bush on main shaft by using hydraulic press．...
  • Page 140 CHANGHE FREEDOM SERVICE MANUAL TRANSMISSION Remove ball and main shaft(center)bearing by using hydraulic press． NOTICE： In the state as showl3 below，there is a ball in washer which is located under bearing．Be sure to prevent it from falling off and getting 1ost．...
  • Page 141 CHANGHE FREEDOM SERVICE MANUAL TRANSMISSION Removing Shift Forks and Shafts Fig.．13-21 1．Reverse gear shift shaft 2．Low speed gear shift shaft 3．High speed gear shift shaft 4．Reverse gear shift fork 5．Low speed gear shift fork 6．High speed gear shift fork 7．Shift yoke pin 【Gear shift fork and shaft】...
  • Page 142 CHANGHE FREEDOM SERVICE MANUAL TRANSMISSION Using spring pin remover(C)(special tool)，d rive out yoke pin on low speed gear shift fork．and pull out shift shaft．During this work，be careful not to let locating ball，interlock ball and spring fly away． CAUTI ON： when removing yoke pin，be sure not to I drive it out s0 far as to contact case．Or it will cause damage to case．...

  • Page 143: Inspection Of Components

    CHANGHE FREEDOM SERVICE MANUAL TRANSMISSION Fig.．13-28 INSPECTION OF COMPONENTS Gears Check each part for wear．damage or discoloration．Replace if found defective． Fig.13-29 Synchronizer Hubs，Sleeves and Keys Check each part for wear or damage Replace if found defective． Fig.．13-30...
  • Page 144 CHANGHE FREEDOM SERVICE MANUAL TRANSMISSION Shift Forks and Sleeves Check contact surfaces for wear or damage Measure clearance between fork and sleeve． Maximum clearance 1.0 mm (0.039 in.) Fig.．13-31 Main Shaft Check each part Of shaft for wear．Discoloration or damage．Replace shaft if any part is found Defective.．...
  • Page 145 CHANGHE FREEDOM SERVICE MANUAL TRANSMISSION Combination of Gear and Synchronizer Ring Fit ring to cone of each gear, and measure clearance between the two at peripheral teeth, as shown in Fig.．13-35．If clearance exceeds service limit, replacement is necessary． Clearance between gear and ring...
  • Page 146 CHANGHE FREEDOM SERVICE MANUAL TRANSMISSION those of the ring．When sleeve advances and slides into ring，ring will be rotating nearly with the speed of gear，so that sleeve is enabled smoothly t0 slide over into clutch teeth of gear． The initial contactor mesh between sleeve and ring is determined by widths of key and s1ot or，in other words，key clearance in the slot．and is prescribed to extend at least a third(1／3)0f chamfer．...
  • Page 147 CHANGHE FREEDOM SERVICE MANUAL TRANSMISSION Fork Shaft Locating Springs If “gears slipping out 0f mesh’’ has been complained， check these springs for strength by measuring their free length，and replace them if their free lengths are less than service limit． Standard Service limit 25.5 mm...

  • Page 148: Important Steps In Installation

    CHANGHE FREEDOM SERVICE MANUAL TRANSMISSION IMPORTANT STEPS IN INSTALLATION NOTICE： Before installation，wash each part and apply specified gear oil to sliding faces of bearing and gear． Use new circlips on shaft for reinstallation．Don’t reuse used circlips． Tighten each fastening b0It and nut according to specified torque data listed OR the last page of this section．...
  • Page 149 CHANGHE FREEDOM SERVICE MANUAL TRANSMISSION Install 2nd gear bearing， 2nd gear， synchronizer ring and IOW speed synchronizer hub／sleeve onto main shaft，using care for installing direction of synchronizer sleeve． After putting on each synchronizer，be sure that 3 keys mounted on hub fit snugly into slots cut in ring．...
  • Page 150 CHANGHE FREEDOM SERVICE MANUAL TRANSMISSION Press-fit center bearing with bearing installer (special tool)using care for its installing direction． Bearing installer (D) (09925-18010) Fig.13-45 Install bal and washer． As Figure shows，install washer s0 that its circumference chamfered side faces center bearing ①...
  • Page 151 CHANGHE FREEDOM SERVICE MANUAL TRANSMISSION Install reverse gear bearing，reverse gear and reverse synchronizer hub／sleeve．For proper direction．make sure to install hub so that the side whose inside boss ① is smaller in diameter and longer is directed to main shaft rear bearing，and sleeve so that the side whose inside is stepped ②...
  • Page 152 CHANGHE FREEDOM SERVICE MANUAL TRANSMISSION Press．fit main shaft rear bearing and circlip into groove in main shaft． Bearing installer (D) (09925·1 801 0) Fig.13-52 Fig.13-53 Install 3rd gear bearing，3rd gear，high speed synchronizer ring and hub／sleeve．When installing hub，direct the side with larger outer diameter boss to 3rd gear side．Then fit circlip into groove in main shaft．...
  • Page 153 CHANGHE FREEDOM SERVICE MANUAL TRANSMISSION Install speed meter drive gear on main shaft 12) Install synchronizer ring，needle bearing and input shaft． Fig.．13-56 Counter Shaft and Reverse idle Gear Drive counter shaft front bearing into lower case． Then using plastic hammer， drive counter shaft into front bearing a little．...
  • Page 154 CHANGHE FREEDOM SERVICE MANUAL TRANSMISSION Fit counter shaft front circlip into groove in shaft． Fig.．13-58 Install counter shaft reverse gear and 5th gear onto counter shaft． And then drive counter shaft rear bearing onto it． Fig.．13-59 Install idle gear and washer onto revere gear shaft and Din into it．install above as assembled ①...
  • Page 155 CHANGHE FREEDOM SERVICE MANUAL TRANSMISSION Shifter Forks，Shafts and Yokes 【Forks and Shafts】 ① High speed gear shift shaft ② Low speed gear shift shaft ③ Reverse gear shift shaft Fig. 3-62 ④ High speed gear shift fork ⑤ Low speed gear shift fork ⑥...
  • Page 156 CHANGHE FREEDOM SERVICE MANUAL TRANSMISSION Install high，low and reverse shafts in that order ① ．13-64) on top of Install 3 locating springs into 3 holes in upper case．Fit locating ball( in Fig. locating sprin9 in hole． Fig.．13-65 Insert high speed gear shift shaft into upper case．...
  • Page 157 CHANGHE FREEDOM SERVICE MANUAL TRANSMISSION Fig.．13-67 ② ③ 13-64)in upper case ． After Install interlock ball( in Fig. 13-64)and locating ball( in Fig. ④ installing interlock roller( in Fig. 13-64)in low speed gear shift shaft and insert shaft into upper case as described in 2)and 3)．...
  • Page 158 CHANGHE FREEDOM SERVICE MANUAL TRANSMISSION Transmission Lower Case and Upper Case With counter shaft assy.， reverse idle gear and reverse gear shaft installed in lower case， check ① ． to ensure that 2 knock pins ( are fitted in both sides of lower case as shown below Fig.13—73...
  • Page 159 CHANGHE FREEDOM SERVICE MANUAL TRANSMISSION Fig.13-76 Uniformly apply sealant(BOND NO．1215，99000-31110) t0 mating surface lower case． Fig.．13-77 Install upper case to lower case by matching 3 shift forks with 3 grooves in synchronizer sleeve on main shaft respectively． ① Shift forks Fig.13-78...
  • Page 160 CHANGHE FREEDOM SERVICE MANUAL TRANSMISSION Extension Case ① ． Check to ensure that knock pins are fitted Fig.．13-79 Apply grease(SUPER GREASE A 99000-25010)to 0il seal lip． Clean surface of extension case to mate with transmission case and uniformly apply sealant(BOND N0.1215 99000—31110)．...

  • Page 161: Maintenance Service

    CHANGHE FREEDOM SERVICE MANUAL TRANSMISSION Fig.．13-81 Apply grease(SUPER GREASE A 99000-2501 0)to speed meter driven gear and inside of its case． ① Install speed meter driven gear and case with driven gear case hole and extension case bolt hole ②...
  • Page 162 CHANGHE FREEDOM SERVICE MANUAL TRANSMISSION ① Oil filler plug ② Oil drain plug Fig.13-84 Fig.．13-81-1 NOTICE： Whenever car was hoisted for any other service work than oil change，also be sure to check for oil leakage． Input Shaft Bearing Retainer Apply grease(SUPER GREASE A 99000-25010)to oil seal lip．...
  • Page 163 CHANGHE FREEDOM SERVICE MANUAL TRANSMISSION Tighten retainer bolts to specification 1 8—28 N．m Tightening torque for (1.8—2.8 kgf．m) retainer bolts (13.5—20.0 Ib—ft) Check transmission input shaft for easy rotation by hand． Check each select and shift shaft for operation． Clutch Release Bearing Before installing bearing，apply grease(SUPER GREASE A 99000—25010)to inner surface of...

  • Page 164: Recommended Torque Specification

    CHANGHE FREEDOM SERVICE MANUAL TRANSMISSION RECOMMENDED TORQUE SPECIFICATION Be sure to torque each bolt and nut according to specification given below，whenever loosened. If specified torque for particular bolt or nut is not included in the list．refer to page 0-13． Tightening torque...
  • Page 165 CHANGHE FREEDOM SERVICE MANUAL GEAR SHIFTING CONTROL SECTION 10 GEAR SHIFTING CONTROL CONTENTS GENERAL DESCRIPTION ........................162 REMOVAL ..............................163 GEAR SHIFT CONTROL LEVER ......................163 GEAR SHIFT CABLE AND SELECT CABLE ..................163 GEAR SHIFT LEVER CASE ........................163 INSPECTION OF COMPONENTS ...

  • Page 166: General Description

    CHANGHE FREEDOM SERVICE MANUAL GEAR SHIFTING CONTROL G ENERAL DESCRIPTION The gear shifting control system consists of following main parts. The gear shift control lever is connected with the gear shift shaft and select shaft levers on the transmission case by means of two cables (gear shift cable and select cable).

  • Page 167: Removal

    CHANGHE FREEDOM SERVICE MANUAL GEAR SHIFTING CONTROL REMOVAL Gear Shift Control Lever 1）Remove center console box. 2）Disconnect gear shift cable from gear shift control lever and remove shift control lever by Gear Shift Lever Case 1）Make sure that gear shift control lever is in neutral position and disconnect gear shift and 1.Gear Shift Cable...
  • Page 168 CHANGHE FREEDOM SERVICE MANUAL GEAR SHIFTING CONTROL 3）Remove select shaft lever and shaft. removed. 7）Remove reverse shift limit dog. 4）Remove reverse check screw, coil spring and reverse check ball from case. 5）Pull out shift lever case pin from case. 6）Pull out gear shift shaft from case.

  • Page 169: Inspection Of Components

    CHANGHE FREEDOM SERVICE MANUAL GEAR SHIFTING CONTROL INSPECTION OF COMPONENTS Check each gear shift fork shaft(High, Low Gear Shift Lever and Select Lever and Reverse) where gear shift lever contacts, Check each lever end for wear and replace if ④,for wear, worn shaft must be replace.

  • Page 170: Installation

    CHANGHE FREEDOM SERVICE MANUAL GEAR SHIFTING CONTROL INSTALLATION Gear shift lever is installed by reversing removal procedure. Some important steps will be explained in detail. NOTICE： Be sure to apply gear oil to all parts before installing them into gar shift lever case.
  • Page 171 CHANGHE FREEDOM SERVICE MANUAL GEAR SHIFTING CONTROL 4） Install gear select shaft and tighten. Select 6）Check select shaft lever and shift shaft shaft nut to specified torque. lever for smooth and correct movement into each 13—20 N.m rang position. Tightening torque for （1.8—2.8 kg-m）...

  • Page 172: Gear Shift Control Cable And Lever

    CHANGHE FREEDOM SERVICE MANUAL GEAR SHIFTING CONTROL Gear Shift Control Cable and Lever Install by reversing procedure. Also, use care for the following. Washer and Bush Be sure to install washer and bush in correct installation position and apply SUPER GEARSE A （99000-25010）...
  • Page 173 CHANGHE FREEDOM SERVICE MANUAL GEAR SHIFTING CONTROL 图 1 Gear shift and select cables...

  • Page 174: Maintenance Service

    CHANGHE FREEDOM SERVICE MANUAL GEAR SHIFTING CONTROL MAINTENANCE SERVICE Select Cable Adjustment NOTICE： ●Before adjustment, check to make sure that each greasing point as indicated in p. 5-8 of this section is greased properly and that bush and other parts are not worn. Correct as necessary.
  • Page 175 CHANGHE FREEDOM SERVICE MANUAL PROPELLER SHAFT SECTION 11 PROPELLER SHAFT CONTENTS GENERAL DESCRIPTION ........................172 REMOVAL ..............................173 INSTALLATION ............................173 DISASSEMBLY ............................174 REASSEMBLY ............................175 MAINTENANCE SERVICES ......................... 176 TIGHTENING TORQUE SPECIFICATIONS ................... 176 NOTICE: The propeller shaft should not be welded, dropped or heated intentionally, or possibly some related part will be damaged or the shaft will be eccentric, resulting in the car vibration during driving.

  • Page 176: General Description

    CHANGHE FREEDOM SERVICE MANUAL PROPELLER SHAFT GENERAL DESCRIPTION The propeller shaft is a three-part combination consisting of a shaft and two universal joints, It is connected to the differential pinion through flanged connection and to the transmission output (main) shaft through a sliding spline joint．...

  • Page 177: Removal

    CHANGHE FREEDOM SERVICE MANUAL PROPELLER SHAFT REMOVAL 1） Hoist vehicle． 2） Loose propeller shaft nut and bolt． 3） Remove propeller shaft． Transmission-side end of propeller shaft has no flange piece, this end is splined to driving shaft inside extension case． All you have to do there is to pull propeller shaft off extension case．...

  • Page 178: Disassembly

    CHANGHE FREEDOM SERVICE MANUAL PROPELLER SHAFT DISASSEMBLY Disassemble on propeller shaft fork side 1) Remove circlips by using snap ring pliers （special tool） ． 2) Using universal joint assembler (Special tool 09926-48010), push spider bearing race out 3-4 mm (0.12-0.16 in) from shaft yoke race．...

  • Page 179: Reassembly

    CHANGHE FREEDOM SERVICE MANUAL PROPELLER SHAFT NOTICE: ● Take care not to lose rollers in spider bearing race when removing it． ● Fit removed bearings temporarily in spider so that they can be reinstalled in their original positions． REASSEMBLY NOTICE: ●...

  • Page 180: Maintenance Services

    CHANGHE FREEDOM SERVICE MANUAL PROPELLER SHAFT 3) Insert bearing races on the flange yoke side in the same way as described in 1) and 2) above． 4) Place a metal plate on bearing races when tapping them in to avoid damaging yoke．...
  • Page 181 CHANGHE FREEDOM SERVICE MANUAL DIFFERENTIAL SECTION 12 DIFFERENTIAL CONTENTS DESCRIPTION ............................... 178 REMOVAL ............................... 178 DISASSEMBLY ............................. 179 MAINTENANCE SERVICES ........................181 REASSEMBLY ..............................188 INSTALLATION .............................. 190...

  • Page 182: Description

    CHANGHE FREEDOM SERVICE MANUAL DIFFERENTIAL DESCRIPTION The components of the differential are shown in the exploded view, below. The bevel gear drive is of hypoid design; pinion and gear have hypoid gear teeth. This means that the pinion is locater slightly below the center of the bevel gear to permit the car body to be lowered in design, and that some wiping or sliding action occurs in tooth meshing between pinion and gear.

  • Page 183: Disassembly

    CHANGHE FREEDOM SERVICE MANUAL DIFFERENTIAL DISASSEMBLY 1） Lock the flange immovable, and remove the nut from the end of the bevel pinion shank. 2） Scribe marks on each cap bolted to the saddle portion of the carrier case and holding down the side bearing: The marks are to identify the cap ①.
  • Page 184 CHANGHE FREEDOM SERVICE MANUAL DIFFERENTIAL 4） Using the special tools indicated below, extract the right side bearing from the differential case. 1. Right side bearing 2. Bearing puller （09913-60910） 3. Side bearing removing jig （09913-85230） 5） Remove the bolts fastening bevel gear to differential case, and take off bevel gear.

  • Page 185: Maintenance Services

    CHANGHE FREEDOM SERVICE MANUAL DIFFERENTIAL 7） Using special tools indicated below, extract left side bearing from differential case. Left side bearing. MAINTENANCE SERVICES Bearing puller 09913-60910 Side bearing removing jig 09913-85230 Side gear backlash Side gear backlash 0.05-0.8mm （0.002-0.006in） specification Available thrust 0.9，1.0，1.1 and 1.2mm...
  • Page 186 CHANGHE FREEDOM SERVICE MANUAL DIFFERENTIAL Determination of shim thickness of bevel pinion The amount of shims to be used on the bevel pinion varies from one machine to another on account of a number of factors involved in machining and assembling. Thus, for each...
  • Page 187 CHANGHE FREEDOM SERVICE MANUAL DIFFERENTIAL With dummy now secured, dial indicator hand may have deflected from the "0" mark to show a certain value; read this value, which is value "b". Add this reading to 85 mm (= "a" + "c") and, from the sum, subtract the value marked on the bevel pinion.
  • Page 188 CHANGHE FREEDOM SERVICE MANUAL DIFFERENTIAL Bevel pinion bearing preload adjustment The bevel pinion, as installed in the normal manner in the carrier, is required to offer a certain torque resistance when checked with the use of a prescribed torquing pulley (special tool ○ A ) as shown in the following figure.
  • Page 189 CHANGHE FREEDOM SERVICE MANUAL DIFFERENTIAL Bevel gear backlash adjustment The backlash between bevel gear and pinion is checked in the manner shown in the below figure. Note that the differential case assembly is mounted in the normal manner, and fastened down by tightening the side bearing cap nuts to the specified torque.
  • Page 190 CHANGHE FREEDOM SERVICE MANUAL DIFFERENTIAL Pinion-to-gear Tooth Contact Pattern Check and Adjustment In addition to proper backlash, proper tooth contact must be secured in the mesh of bevel pinion and gear, so that there will be no “gear noise” coming from the axle and that the hypoid teeth will not be overstressed in transmitting drive.
  • Page 191 CHANGHE FREEDOM SERVICE MANUAL DIFFERENTIAL Contact patterns Diagnosis, and what to do High contact: Contact is on heel (drive side ) and on toe (coast side).This condition means that the pinion is too far back and must be brought forward by increasing its shim thickness used in “mounting distance”...

  • Page 192: Reassembly

    CHANGHE FREEDOM SERVICE MANUAL DIFFERENTIAL REASSEMBLY Tightening torque Reverse disassembly procedure for N•m kg-m (lb-ft) reassembly, noting the following. Side bearing 3.0-3.7 30—37 NOTICE: （22.0-26.5） cap nut Bevel pinion and bevel gear are supplied Drive bevel gear 8.0-9.0 80—90 as a set. Even when only bevel pinion or bevel （58.0-65.0）...
  • Page 193 CHANGHE FREEDOM SERVICE MANUAL DIFFERENTIAL 2） For outer race of rear bearing( gear side)： 3） For inner races, use this special tool. Differential side bearings Press-fit these bearings into differential case by using special tool. Driving bearing into the case is not permitted.

  • Page 194: Installation

    CHANGHE FREEDOM SERVICE MANUAL DIFFERENTIAL INSTALLATION Tightening torque Reverse removal procedure for installation, N•m kg-m (lb-ft) noting the following. Differential 1.8-2.8 18—28 Tightening torque （13.0-20.2） carrier bolt As left table show Propeller shaft 1.8-2.8 18—28 （13.0-20.2） flange nut Differential 3.5-5.0 Oil filler plug 35—50...
  • Page 195 CHANGHE FREEDOM SERVICE MANUAL SUSPENSION THE FOURTH PART SUSPENSION STEERING BRAKE SECTION 13 SUSPENSION CONTENTS ........................192 GENERAL DESCRIPTION Front Suspension ............................ 192 Front Suspension Strut........................... 193 Rear Suspension ............................. 194 ..........................195 FRONT SUSPENSION INSPECTION ............................195 REMOVAL AND INSTALLATION ......................

  • Page 196: General Description

    CHANGHE FREEDOM SERVICE MANUAL SUSPENSION NOTICE： All suspension fasteners are an important attaching part in that it could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary.

  • Page 197: Front Suspension Strut

    CHANGHE FREEDOM SERVICE MANUAL SUSPENSION Front Suspension Strut.

  • Page 198: Rear Suspension

    CHANGHE FREEDOM SERVICE MANUAL SUSPENSION Rear Suspension There is rebound stopper in the vehicle frame. Between the vehicle body and rear axle there is bidirectional telescopic shock absorber, which is used to absorb vehicle body shocks.

  • Page 199: Front Suspension

    CHANGHE FREEDOM SERVICE MANUAL SUSPENSION FRONT SUSPENSION INSPECTION Stabilizer Bar and/or Bushing Stabilizer Bar Inspect for damage deformation. defective, replace. Bushing Inspect for damage, wear or deterioration. If defective, replace. Tension Rod Inspect for damage deformation. defective, replace. Strut Assembly 1）...
  • Page 200 CHANGHE FREEDOM SERVICE MANUAL SUSPENSION Suspension Control Arm and Knuckle Inspect for cracks, deformation or damage. Suspension Control Arm Bushing Inspect for damage, wear or deterioration. Suspension Control Arm Ball Stud 1） Check for smooth rotation. 2） Inspect ball stud for damage.

  • Page 201: Removal And Installation

    CHANGHE FREEDOM SERVICE MANUAL SUSPENSION REMOVAL AND INSTALLATION Lateral Stabilizer Bar and Bushing Removal 1） Hoist the vehicle, allowing front suspension to hang free. 2） Remove stabilizer bar mount brackets nuts, washer and pad. 3） Remove stabilizer bar installation bushing bracket bolts.
  • Page 202 CHANGHE FREEDOM SERVICE MANUAL SUSPENSION Front Strut Assembly Removal 1） Hoist vehicle, allowing front suspension to hang free. 2） Remove wheel. 3） Remove E ring securing brake flexible hose and take brake flexible hose off strut bracket as shown. 4） For disc brake caliper，as shown in the left figure, remove caliper pin bolt and incline caliper.
  • Page 203 CHANGHE FREEDOM SERVICE MANUAL SUSPENSION 2） Using a spring compressor, compress the strut spring till its force pressing the spring seat is released. CAUTION： Use a commercially available spring compressor follow operation procedure described in the Instruction Manual supplied with that spring compressor.
  • Page 204 CHANGHE FREEDOM SERVICE MANUAL SUSPENSION Tightening torque： Strut support nut 73±7.5N.m Strut bracket nut 95±10N.m NOTE： Don't twist brake hose when installing it. Install E ring as far as it fits to bracket as shown. Wheel Hub and Wheel Bearing Removal 1）...
  • Page 205 CHANGHE FREEDOM SERVICE MANUAL SUSPENSION 7） Pool out wheel hub with special tool (Brake drum remover) and (Sliding hammer). 8） Remove circlip and wheel bearing. NOTE： Make sure to fit circlip into wheel hub groove securely. Installation ● Install brake disc to wheel hub. Tighten disc bolts only lightly as shown.
  • Page 206 CHANGHE FREEDOM SERVICE MANUAL SUSPENSION Install pad and caliper. Tighten steering knuckle castle nut to specified torque. Tighten caliper nuts to specified torque（55±5.5N.m）. Depress foot brake pedal and hold it there. Tighten brake disc bolts to specified torque （77-93N.m）. ●...
  • Page 207 CHANGHE FREEDOM SERVICE MANUAL SUSPENSION condition when tightening them to specified torque（68±7N.M）. 6） Check toe-in setting, adjust as required Knuckle Removal 1） Hoist vehicle and remove wheel. 2） Remove wheel hub. 3） Disconnect tie-rod end from knuckle with remover. 4） Remove ball stub bolt from knuckle, then remove strut bracket bolts from strut bracket.

  • Page 208: Rear Suspension

    CHANGHE FREEDOM SERVICE MANUAL SUSPENSION Front Suspension Frame Jointing Assembly Removal 1） Hoist vehicle and remove wheel. 2） Remove suspension arm. 3） Remove steering mount bolt. 4） Remove suspension bolts and front suspension frame jointing assembly. Installation 1） Install front suspension frame jointing assembly.
  • Page 209 CHANGHE FREEDOM SERVICE MANUAL SUSPENSION REMOVAL AND INSTALLATION Rear Shock Absorber Removal 1） Hoist vehicle. 2） Remove lower mounting bolt. 3） Remove upper mounting bolt and nut. Then remove shock absorber. Installation 1) Install shock absorber. 2) Tighten bolts. 3) Lower hoist.
  • Page 210 CHANGHE FREEDOM SERVICE MANUAL SUSPENSION Wheel Bearing and Rear Axle Shaft Removal 1） Check to ensure that parking brake lever is not pulled up. 2）Hoist car and remove rear wheel. 3） Drain oil from axle housing loosening drain plug. 4) Loose parking brake cable.
  • Page 211 CHANGHE FREEDOM SERVICE MANUAL SUSPENSION 7 ） Disconnect parking brake cable from parking brake shoe lever and remove brake shoes. 8）Remove parking brake cable securing clip and disconnect brake cable from brake back plate. 9）Take out fluid with a syringe or such and disconnect brake pipe from wheel cylinder.
  • Page 212 CHANGHE FREEDOM SERVICE MANUAL SUSPENSION 12) In order to remove the retainer ring from the shaft, grind with a grinder two parts of the bearing retainer ring as illustrated till it become thin. 13 ） Break with a chisel the thin ground retainer ring, and it can be removed.
  • Page 213 CHANGHE FREEDOM SERVICE MANUAL SUSPENSION 1）Press in a new bearing and retainer ring in order by using an oil hydraulic press. NOTICE： At this time, protect the outer surface of the retainer ring from any damage. A damage on the outer surface of the...

  • Page 214: Tires And Wheels

    CHANGHE FREEDOM SERVICE MANUAL SUSPENSION 9）Install brake drum. 10）Pour specified amount of specified gear oil into rear axle housing (differential gear) and tighten filler and drain plug to specified torque. 11）Bleed air from brake circuit. Refill tank with fluid. 12）Install rear wheel and tighten wheel nuts to specified torque.
  • Page 215 CHANGHE FREEDOM SERVICE MANUAL SUSPENSION Replacement Wheels Wheels must be replaced if they are bent, dented, have excessive lateral or radial runout, leak air through welds, have elongated bolt holes, if lug nuts won't stay tight, or if they are heavily rusted.
  • Page 216 CHANGHE FREEDOM SERVICE MANUAL SUSPENSION WHEEL Wheel Removal 1） Loosen wheel nuts by approximately 180 ° (half a rotation). 2） Hoist vehicle. 3） Remove wheel. CAUTION: 5 WHEEL ROTATION 5 WHEEL ROTATION Never use heat to loosen tight wheel （Radial Tires）...
  • Page 217 CHANGHE FREEDOM SERVICE MANUAL SUSPENSION WARNING: Do not exceed specified pressure when inflating. If specified pressure will not seat beads, deflate, re-lubricate and reinflate. Over inflation may cause bead to break and cause serious personal injury. Wheel Maintenance Wheel repairs that use welding, heating, or peening are not approved.
  • Page 218 CHANGHE FREEDOM SERVICE MANUAL MANUAL RACK AND PINION SECTION 14 MANUAL RACK AND PINION CONTENTS ........................215 GENERAL DESCRIPTION ................... 216 MANUAL RACK AND PINION ASSEMBLY ..........................219 STEERING WHEEL COMBINATION SWITCH ASSEMBLY ................. 219 STEERING COLUMN AND LOWER SHAFT ........................

  • Page 219: General Description

    CHANGHE FREEDOM SERVICE MANUAL MANUAL RACK AND PINION GENERAL DESCRIPTION The rack and pinion steering system consists of two components, the rack and the pinion. When the steering wheel is turned, the motion is transmitted to the steering shaft joint and then to the pinion.

  • Page 220: Manual Rack And Pinion Assembly

    CHANGHE FREEDOM SERVICE MANUAL MANUAL RACK AND PINION MANUAL RACK AND PINION ASSEMBLY REMOVAL 1) Remove steering shaft lower joint bolt. 2) Remove steering shaft joint cover from dash board, and disconnect steering shaft lower joint. 3) Hoist vehicle and remove both wheels.
  • Page 221 CHANGHE FREEDOM SERVICE MANUAL MANUAL RACK AND PINION Steering Shaft Joint Check shaft joint for wear, breakage and other damage and replace if any defect exists. Tie Rod End 1) Inspect for play in ball joint. 2) Inspect for play in rack end ball joint.
  • Page 222 CHANGHE FREEDOM SERVICE MANUAL MANUAL RACK AND PINION 8) Remove steering gear cover. 9) Remove bearing plug with special tool. 10) Tap on position as shown with plastic hammer to separate pinion assembly from housing. 11) Remove pinion assembly. 12) Remove rack from gear case. Direction for rack removal is as shown.

  • Page 223: Steering Wheel

    CHANGHE FREEDOM SERVICE MANUAL MANUAL RACK AND PINION STEERING WHEEL REMOVAL 1） Disconnected the negative cable from the battery. 2） Remove steering wheel upper cover. 3） Remove steering shaft nut. Remove steering wheel with special tools. CAUTION： Do not hammer the end of the shaft.
  • Page 224 CHANGHE FREEDOM SERVICE MANUAL MANUAL RACK AND PINION 4) Removal steering column upper cover. 5) Removal combination switch assembly screw ， and removal steering column lower cover. Disconnect connectors combination switch and ignition switch wire harness. 7) Removal combination switch screw and combination switch assembly.
  • Page 225 CHANGHE FREEDOM SERVICE MANUAL MANUAL RACK AND PINION INSTALLATION 1) Be sure that front wheels and steering wheel are in straight forward state and insert lower joint into steering pinion shafts 2) Tighten steering shaft lower joint bolts to specified torque.
  • Page 226 CHANGHE FREEDOM SERVICE MANUAL MANUAL RACK AND PINION SERVICE Check steering column for any damages, if abnormity fault is found hereinafter, replace as column assembly. 1) Check steering shaft for smooth rotation, If found defective, replace as column assembly. 2) Check steering shaft and column for bend, crack or deformation.

  • Page 227: Front End Alignment

    CHANGHE FREEDOM SERVICE MANUAL MANUAL RACK AND PINION FRONT END ALIGNMENT Front alignment refers to the angular relationship between the front wheels, the front suspension attaching parts and the ground. Generally, the only adjustment required for front alignments is toe setting. Camber and caster can’t be adjusted.
  • Page 228 CHANGHE FREEDOM SERVICE MANUAL MANUAL RACK AND PINION load is normally carried in vehicle, it should NOTE： remain in vehicle during alignment checks. If tie-rod lengths were changed to adjust 5） Regardless of equipment used to steering angle, reinspect toe-in.
  • Page 229 CHANGHE FREEDOM SERVICE MANUAL BRAKES SECTION 15 BRAKES CONTENTS ........................226 GENERAL DESCRIPTION Master Cylinder Assembly ........................227 Front Disc Brake Caliper Assembly ...................... 228 Rear Drum Brake Assembly ........................230 Booster Assembly ............................ 232 .................. 235 FRONT DISC BRAKE CALIPER ASSEMBLY Removal ..

  • Page 230: General Description

    CHANGHE FREEDOM SERVICE MANUAL BRAKES GENERAL DESCRIPTION When the foot brake pedal is depressed, hydraulic pressure is developed in the master cylinder to actuate pistons (front wheel brakes and rear wheel brakes). The master cylinder is a tandem master cylinder. Two brake pipes are connected to the master cylinder and each of these pipes has its own circuit independently.

  • Page 231: Master Cylinder Assembly

    CHANGHE FREEDOM SERVICE MANUAL BRAKES MASTER CYLINDER ASSEMBLY General Description The master cylinder has two pistons and three piston cups. Its hydraulic pressure is produced in the primary (“a” in the below figure) and secondary (“b”) chambers. The hydraulic pressure produced in the primary chamber （“a”）...

  • Page 232: Front Disc Brake Caliper Assembly

    CHANGHE FREEDOM SERVICE MANUAL BRAKES [One-circuit operation （Secondary chamber “b” circuit failure ）] In this case，the leftward movement of the piston “A” has but little effect in causing the fluid pressure to rise in the chamber “a”in the beginning, because the initial rise of the fluid pressure causes the piston “B”...
  • Page 233 CHANGHE FREEDOM SERVICE MANUAL BRAKES [Caliper Operation] Single piston floating caliper type The single piston floating caliper type brake Caliper body is employed in this model. One cylinder and one piston are used for this type. (The cylinder is constructed as a monoblock with the caliper.).

  • Page 234: Rear Drum Brake Assembly

    CHANGHE FREEDOM SERVICE MANUAL BRAKES REAR DRUM BRAKE ASSEMBLY [GENERAL DESCRIPTION] The drum brake assemb ly has a self shoe clea rance maintained appropriate at all times. For details, refer to OPERATION in the next page. OTICE： Replac e all components included in repair kits used to service this drum brake.
  • Page 235 CHANGHE FREEDOM SERVICE MANUAL BRAKES At this time, the distance the brake shoe moves is “B”, tha t is, the distance that “A” (the end of th e long hole made in the brake shoes web) moves till it contacts the lever (1) which is fitted in the long hole.

  • Page 236: Booster Assembly

    CHANGHE FREEDOM SERVICE MANUAL BRAKES BOOSTER ASSEMBLY ENERAL DESCRIPTION] The booster is located between the master cylinder and the brake pedal. It is so designed that the force created when the brake pe dal is depressed is mechanically increased combined with the engine acuum.
  • Page 237 CHANGHE FREEDOM SERVICE MANUAL BRAKES （BOOSTER OPERATION） Vacuum Booster Assembly When the brake pedal is depressed, the force is transmitted to the piston of the master cylinder through the valve operating rod, booster air valve, reaction disc and piston rod. At the same time, the force of the booster piston developed due to the pressure difference between the two chambers "A"...
  • Page 238 CHANGHE FREEDOM SERVICE MANUAL BRAKES When foot brake pedal is depressed eing pushed by the operating rod, the booster air valve moves to the left as shown. Then the control valve is pushed against the booster piston seat closely by the valve spring force. Thus the vacuum valve (control valve C) is closed to cut off between the chambers "A"...

  • Page 239: Front Disc Brake Caliper Assembly

    CHANGHE FREEDOM SERVICE MANUAL BRAKES When foot brake pedal is released When the brake pedal is released, the booster ir valve returns to the right by the master cylinder iston return force and the air valve spring force as hown. Then the vacuum valve (control valve "C") pens and causes negative pressure in the hamber "B".
  • Page 240 CHANGHE FREEDOM SERVICE MANUAL BRAKES 3) Remove caliper pin bolts (2 pc s.). 4) Remove cliper. OTICE: During removal, be careful not to damage brak e flexible hose. Also, don’t depress brake pedal. 5) Remove pads. Caliper, Piston & Piston Seal...
  • Page 241 CHANGHE FREEDOM SERVICE MANUAL BRAKES ) Remove caliper pin bolts (2 pcs). 4) Blo w compressed air into cylinder through bolt hole where flexible hose was fitted. With this air pressure, piston ca n be pushed out of cylinder. WA NING:...

  • Page 242: Inspection Of Components

    CHANGHE FREEDOM SERVICE MANUAL BRAKES SPECTION OF COMPONENTS ke Pad Check pad lining for wear. When wear xceeds its limit, replace with new one. Timing for ad replacement can be determined with the line f the groove which is provided on each pad ning .When it has disappeared, replace with a...

  • Page 243: Installation

    CHANGHE FREEDOM SERVICE MANUAL BRAKES Piston Seal Excessive or uneven wear of pad lining may indicate unsm ooth return of piston. In such a case, repl ace rubber seal. ake Disc Check disc surface for scratches in wearing rts. Scratches on disc surface noticed at the...
  • Page 244 CHANGHE FREEDOM SERVICE MANUAL BRAKES CAUTION: ● Wash each part cleanly before installation in the same fluid as the one used in master cylinder reservoir. ● Never use other fluid or thinner, ● Before installing piston and piston seal to cylinder, apply fluid to them.
  • Page 245 CHANGHE FREEDOM SERVICE MANUAL BRAKES 3) Insert piston into cylinder by hand and put boot in boot groove in piston. 4) To confirm that boot is fitted in its groove in cylinder properly, pull piston out of cylinder a little but do not take it all out.
  • Page 246 CHANGHE FREEDOM SERVICE MANUAL BRAKES Tightening torque Fastening parts kg.m 1. Disc bolt 4.0-6.0 2. Steering knuckle castle 15.0-25.0 3. Flexible hose bolt 2.0-2.5 4. Caliper bolt 7.0-10.0 5. Caliper pin bolt 3.0-3.8 6. Caliper pin 5.0-6.0 7. Wheel nut 5.0-8.0...

  • Page 247: Rear Drum Brake Assembly

    CHANGHE FREEDOM SERVICE MANUAL BRAKES If tire rotation is heavy, check the following: Wheel beari ngs for breakage. Disc for flatness (Improper flatness bring s disc into cont act with lining during rotation and m akes rotation heav To check this, measure disc lection.
  • Page 248 CHANGHE FREEDOM SERVICE MANUAL BRAKES 5) Remove shoe hold down spring by turning shoe hold down pins as shown. 6) Disconnect parking brake cable from parking brake shoe leve r and remove brake hoes. el Cylinders 1）Carry out steps 1）through 6）of Brake rums and Brake Shoes .

  • Page 249: Inspection

    CHANGHE FREEDOM SERVICE MANUAL BRAKES 3) Remove wheel cylinder mounting bolts. And put wheel cylinder breather plug cap(s) onto pipe(s) to prevent fluid from spilling. SPECTION OF COMPONENTS ke Drum Inspect drum for cleanliness. Check its braking surface for wear by measuring its inside diameter.
  • Page 250 CHANGHE FREEDOM SERVICE MANUAL BRAKES rake Shoe and Rim If lining is worn out beyond service limit, replace shoe. rake Lining Standard Service Limit Thickness 7.0mm 3.0mm （lining+shoe rim） (0.28 in.) (0.12in.) If one of brake linings is worn to or beyond ervice limit, all linings must be replaced at the ame time.

  • Page 251: Installation

    CHANGHE FREEDOM SERVICE MANUAL BRAKES INSTALLATION Wheel Cylinde Apply water tight sealant 366E (990 00-31090) to joint s eam of whe cylinder and brake back plate. 2) Tighten wheel linder to b rake back plate to specified torque. 3) Tighten flare nut(s) of brake pipe to specified torque.
  • Page 252 CHANGHE FREEDOM SERVICE MANUAL BRAKES 2) Assemble parts as shown in the reverse rder of removal. ICE: When installing shoes, don't cause damage to wheel cy linder boots. 3) Install shoe hold down springs by pushing em down in place and turning hold down pins.

  • Page 253: Master Cylinder

    CHANGHE FREEDOM SERVICE MANUAL BRAKES 5) Install brake drum after making sun，that inside of brake dr um and brake shoes are free om dirt and oil. 6) Tor que wheel nuts to specification. NOTICE: If brake pipe was disconnected from wheel ylinder.
  • Page 254 CHANGHE FREEDOM SERVICE MANUAL BRAKES 7) Remove plate "A" from pedal braket and dash panel. For t his removal, remove bolts first ① and loosen screw ② a little(Don't r emove crews.). 8) Remove meter panel assembly. 9) Disc onnect booster vacuum hose from floor side pipe.
  • Page 255 CHANGHE FREEDOM SERVICE MANUAL BRAKES 13) Disconnect clutch cable from clutch pedal pedal bracket. 14) Disconnect stop lamp switch lead wire at e switch. 15) Check pedal bracket for anything left onnected. If any disconnect. 16) Remove pedal bracket with booster and master cylin der installed as they are.

  • Page 256: Booster Assembly

    CHANGHE FREEDOM SERVICE MANUAL BRAKES BRAKE BOOSTER REMOVAL 1） Remove brake booster from body. 2） Remove master cylinder assembly. 3） Disconnect vacuum hose from booster. 4） Disconnect push rod clevis from brake edal arm. 5） Remove attaching nuts and then booster...

  • Page 257: Inspection & Adjustment

    CHANGHE FREEDOM SERVICE MANUAL BRAKES PECTION AND ADJUS TMENT The length of booster piston rod is adjusted to prov ide specifie d clearance between piston rod and master cylinder piston. Before measuring clearance, push piston d several times so as to make sure reaction disc is in place.

  • Page 258: Installation

    CHANGHE FREEDOM SERVICE MANUAL BRAKES INSTALLATION NOTICE： See NOTICE at the be ginning of this section。 Adjust clearance between booster piston rod and master cylinder piston with special tool. 1） Check length of push rod clevis, torque uts to specification.

  • Page 259: Brake Pipe And Brake Hose

    CHANGHE FREEDOM SERVICE MANUAL BRAKES 5） Install va cuum hose to booster. 6） With booster master cylinder installed to ped al bracket, install them to car body. But before installation check to ensure that rvoir hose connector of master cylinder is...

  • Page 260: Lspv

    CHANGHE FREEDOM SERVICE MANUAL BRAKES ICE: Be sure to inst ll brake flexible hose E-ring into hose groove. Upon completion of installation, check each joint for fluid leakage with brake pedal depressed. LSPV（Load Sen sing Proportioning Valve） CAUTION： LSPV assembly must disassembled.

  • Page 261: Brake Pipe Configuration

    CHANGHE FREEDOM SERVICE MANUAL BRAKES BRAKE PIPE CONFIGURATION...

  • Page 262: Repair

    CHANGHE FREEDOM SERVICE MANUAL BRAKES MAINTENANCE SERVICE ROAD TESTING BRAKES Brakes should be tested on dry, clean, smooth and reasonable level roadway which is not crowned. Road test brakes by making brake applications with both light and heavy pedal forces at various speeds to determine if the car stops evenly and effectively.

  • Page 263: Brake Pedal Free Height Adjustment

    CHANGHE FREEDOM SERVICE MANUAL BRAKES BRAKE PEDAL FREE HEIGHT ADJUSTMENT Brake pedal height is normal if brake pedal is as high as clutch pedal. 1） When booster push rod clevis has been reinstalled, it is important that measurement between booster mounting surface and the center of clevis pin hole is adjusted within 103.5-...

  • Page 264: Brake Hose And Pipe Inspection

    CHANGHE FREEDOM SERVICE MANUAL BRAKES KE HOSE AND PIPE INSPECTION The flexible hydraulic brake hose, which transmits hydraulic pressure from steel brake line on the body to rear cylinders and to front cylinders, should be inspected at least twice a year. The...

  • Page 265: Parking Brake Inspection And Adjustment

    CHANGHE FREEDOM SERVICE MANUAL BRAKES PARKING BRAKE INSPECTION AND ADJUSTMENT 1) Parking brake lever inspection. Hold the center of parking brake lever, grip pull it up slowly with about 20 kg force until brake is fully applied. While pulling it up, listen to clicking sounds ratchet makes.

  • Page 266: Brake Pedal Play Inspection

    CHANGHE FREEDOM SERVICE MANUAL BRAKES BRAKE PEDAL PLAY INSPECTION Pedal play should within below spec ification. If out of specification, c heck stop light switch for proper installation position and adjust if necessary. Also check pedal shaft bolt and master cylinder pin installation for looseness and replace if defective.
  • Page 267 CHANGHE FREEDOM SERVICE MANUAL BRAKES On the other hand, if brake pipe or hose is disc onnected on rear wheel brake line or wheel cylinder is dissembled, bleed air at rear left side brake (wheel cylinder). In following cas e, however, bleed air from hydr aulic brake system at all 4 positions, “A”, “B”,...

  • Page 268: Inspect Booster Operation

    CHANGHE FREEDOM SERVICE MANUAL BRAKES 6) When bubbles stop, depress and hold brake pedal and tighten bleeder plug. 7) Then attach bleeder plug cap. 8) After completing bleeding operation, apply fluid pressure to pipe line and check for leakage. 9) Replenish fluid into reserv...
  • Page 269 CHANGHE FREEDOM SERVICE MANUAL BRAKES Check Operation 1） With engine stopped, dep ress brake edal several times with the same load and make ure that pedal travel doesn’t change. 2） Start engine while depre ssing brake peda l. If p increases a little, operation is satisfactory.
  • Page 270 CHANGHE FREEDOM SERVICE MANUAL ELECTRICAL SYSTEM THE FIFTH PART BODY AND ELECTRICAL SERVICE SECTION 16 ELECTRICAL SYSTEM CONTENTS GENERAL DESCRIPTION ......................... 267 Maintenance Notice ..........................267 Wire Color Symbols ..........................270 Connector ..............................271 POWER SUPPLY DIAGRAM ........................272 Power Supply Diagram .......................... 272 JUNCTION BOX ............................

  • Page 271: General Description

    CHANGHE FREEDOM SERVICE MANUAL ELECTRICAL SYSTEM GENERAL DESCRIPTION Electrical System depicts all kinds of the fixing position, ground point and power supply condition of single parts. Section Illuminate The fixing position single The fixing position of car’s fuse relay and control unit...
  • Page 272 CHANGHE FREEDOM SERVICE MANUAL ELECTRICAL SYSTEM When connecting connectors, also hold connectors and put them together until they securely (a lick is heard). When installing the wiring harness, fix it with clamps so that no slack is left. When installing vehicle parts, be careful so that wiring harness is not interfered with or caught by any other parts.
  • Page 273 CHANGHE FREEDOM SERVICE MANUAL ELECTRICAL SYSTEM Always be careful not to handle electrical parts (computer, relay, etc.) in a rough manner or drop them. When performing a work that produces a heat exceeding 800C (1760F) in the heat sensitive electrical part(s) beforehand.

  • Page 274: Wire Color Symbols

    CHANGHE FREEDOM SERVICE MANUAL ELECTRICAL SYSTEM WIRE COLOR SYMBOLS The initial alphabet(s) of color name is used to represent each color as listed at the left. Abbreviations Each item shows abbreviation and full term of using. Wire/connector Wire/connector symbol symbol...

  • Page 275: Connector

    CHANGHE FREEDOM SERVICE MANUAL ELECTRICAL SYSTEM CONNECTOR...

  • Page 276: Power Supply Diagram

    CHANGHE FREEDOM SERVICE MANUAL ELECTRICAL SYSTEM POWER SUPPLY DIAGRAM Power Supply Diagram...

  • Page 277: Junction Box

    CHANGHE FREEDOM SERVICE MANUAL ELECTRICAL SYSTEM JUNCTION BOX...
  • Page 278 CHANGHE FREEDOM SERVICE MANUAL ELECTRICAL SYSTEM...

  • Page 279: System Circuit Diagram

    CHANGHE FREEDOM SERVICE MANUAL ELECTRICAL SYSTEM SYSTEM CIRCUIT DIAGRAM STARTING SYSTEM CHARGING SYSTEM...

  • Page 280: Electronic Fuel Injection (Cadillac)

    CHANGHE FREEDOM SERVICE MANUAL ELECTRICAL SYSTEM Electronic fuel injection system...

  • Page 281: Body

    CHANGHE FREEDOM SERVICE MANUAL ELECTRICAL SYSTEM BODY Windshield washer and wiper Power Central Locking System...

  • Page 282: Power Window Control System

    CHANGHE FREEDOM SERVICE MANUAL ELECTRICAL SYSTEM Power Window Control System...

  • Page 283: Combination Meter

    CHANGHE FREEDOM SERVICE MANUAL ELECTRICAL SYSTEM Combination Meter...

  • Page 284: Light System

    CHANGHE FREEDOM SERVICE MANUAL ELECTRICAL SYSTEM Lighting system Signal system...

  • Page 285: Radio 、Cigar Lighter And Electric Lock

    CHANGHE FREEDOM SERVICE MANUAL ELECTRICAL SYSTEM RADIO 、CIGAR LIGHTER AND ELECTRONIC LOCK...
  • Page 286 CHANGHE FREEDOM SERVICE MANUAL ELECTRICAL SYSTEM SECTION 17 BODY ELECTRICAL SYSTEM CONTENTS INSTRUMENTS AND GAUGES ......................283 Combination Meter Wiring ......................... 283 Trouble Diagnosis ..........................285 Fuel Level Meter and Gauges Unit ....................286 Engine Coolant temperature Meter and Sensor Unit ..............287 Oil Pressure Light .

  • Page 287: Instruments And Gauges

    CHANGHE FREEDOM SERVICE MANUAL ELECTRICAL SYSTEM INSTRUMENTS AND GAUGES COMBINATION METER CIRCUIT 1) THE FRONT OF COMBINATION METER 1. Speedometer and Odometer 2. Right turning light 3. Fuel level meter 4. Coolant (Water) temp. meter 5. Engine failure lamp 6.Brake warning light 7.
  • Page 288 CHANGHE FREEDOM SERVICE MANUAL ELECTRICAL SYSTEM 3) The connectors of Combination meter 4) Vehicle speed sensor...

  • Page 289: Trouble Diagnosis

    CHANGHE FREEDOM SERVICE MANUAL ELECTRICAL SYSTEM TROUBLE DIAGNOSIS Trouble Possible cause Correction Speedometer shows no IG fuse blown Replace fuse to check operation. Check speed sensor. Speed sensor faulty Replace speedometer. Speedometer faulty Repair. Wiring or grounding faulty Fuel level meter shows...

  • Page 290: Fuel Level Meter And Gauges Unit

    CHANGHE FREEDOM SERVICE MANUAL ELECTRICAL SYSTEM REMOVAL 1) Disconnect negative cable at battery. 2) Remove column hole cover. 3) Remove instrument cluster panel. 4) Disconnect couplers from combination meter. 5) Remove combination meter. INSTALLATION Reverse removal procedure for installation, noting the following.

  • Page 291: Engine Coolant Temperature Meter And Sensor Unit

    CHANGHE FREEDOM SERVICE MANUAL ELECTRICAL SYSTEM FUEL SENDER GAUGE INSPECTION Remove fuel pump assembly referring to Section 6C of this manual. Use an ohmmeter to confirm that resistance of sender gauge unit changes with change of float position. Float Position Resistance（Ω）...

  • Page 292: Oil Pressure Light

    CHANGHE FREEDOM SERVICE MANUAL ELECTRICAL SYSTEM ENGINE COOLANT TEMPERATURE SENSOR REMOVAL WARNING: Make sure that engine coolant temperature is cold before removing any part of cooling system. Also be sure to disconnect negative cable from battery terminal before removing any part.

  • Page 293: Brake Warning Light

    CHANGHE FREEDOM SERVICE MANUAL ELECTRICAL SYSTEM BRAKE WARNING LIGHT DESCRIPTION OF CIRCUIT The brake warning light circuit consists of a brake fluid level switch Installed In the master cylinder reservoir, and the light (brake warning light) in the gauge cluster.

  • Page 294: Combination Switch

    CHANGHE FREEDOM SERVICE MANUAL ELECTRICAL SYSTEM COMBINATION SWITCH DESCRIPTION Combination switch incorporates lighting, turn signal, hazard warning light, dimmer, passing light and wiper/washer switches. INSPECTION 1) Disconnect negative (-) cable at battery. 2) Disconnect combination switch lead wire couplers from junction/fuse block.
  • Page 295 CHANGHE FREEDOM SERVICE MANUAL ELECTRICAL SYSTEM Dimmer & Passing light...
  • Page 296 CHANGHE FREEDOM SERVICE MANUAL ELECTRICAL SYSTEM Turn & Hazard Wiper and washer...

  • Page 297: Lighting Systems

    CHANGHE FREEDOM SERVICE MANUAL ELECTRICAL SYSTEM LIGHTING SYSTEMS HEADLIGHTS WIRING CIRCUIT Refer to “BODY ELECTRICAL SYSTEM” in section 16. TROUBLE DIAGNOSIS Trouble Possible cause Correction Bulb burnt out Replace bulb. Only one light does not Fuse blown Replace fuse. light.
  • Page 298 CHANGHE FREEDOM SERVICE MANUAL ELECTRICAL SYSTEM INSPECTION CIRCULT CONTINUITY 1) Headlight is grounded as J/B. 2) Check lighting and dimmer switch for each terminal-to-terminal continuity. Refer to “COMBINATION SWITCH” in this section. REMOVAL 1) Disconnect negative (-) cable at battery.

  • Page 299: Turn Signal And Hazard Warning

    CHANGHE FREEDOM SERVICE MANUAL ELECTRICAL SYSTEM TURN SIGNAL AND HAZARD WARNING LITHTS WIRING CIRCUIT Refer to “BODY ELECTRICAL SYSTEM” in section 16. TROUBLE DIAGNOSIS Trouble Possible cause Correction Flash rate high or one Faulty ground Repair as necessary. side only flashes.

  • Page 300: Clearance, Tail And Licence Light

    CHANGHE FREEDOM SERVICE MANUAL ELECTRICAL SYSTEM LICENCE、REAR COMBINATION LIGHT AND HIGH –MOUNTED STOP LIGHT PARKING LIGHT AND LICENCE LIGHTS WIRING CIRCUIT Refer to “BODY ELECTRICAL SYSTEM” in section 16. TROUBLE DIAGNOSIS Trouble Possible cause Correction Light do not light. ( Main fuse and/or fuses blown Replace fuses to check for short.

  • Page 301: Rear Fog Light

    CHANGHE FREEDOM SERVICE MANUAL ELECTRICAL SYSTEM TROUBLE DIAGNOSIS Trouble Possible cause Correction Stop lights do not Fuse blown Replace fuse to check for light. Bulb burnt out short. Stop light switch faulty Replace. Wiring or grounding faulty Adjust or replace switch.

  • Page 302: Front Fog Light

    CHANGHE FREEDOM SERVICE MANUAL ELECTRICAL SYSTEM INSPECTION Rear Fog Light switch FRONT FOG LIGHT WIRING CIRCUIT Refer to “BODY ELECTRICAL SYSTEM” in section 16. TROUBLE DIAGNOSIS Trouble Possible cause Correction Front light Main fuse and/or fuses blown Replace main fuse and/or fuses to does not come on.

  • Page 303: Cigarette Lighter

    CHANGHE FREEDOM SERVICE MANUAL ELECTRICAL SYSTEM CIGARETTE LIGHTER WIRING CIRCUIT Refer to “BODY ELECTRICAL SYSTEM” in section 16. TROUBLE DIAGNOSIS Trouble Possible cause Correction Cigarette lighter does Fuse blown Replace fuse to check for short. not work. Main switch faulty Check switch.

  • Page 304: Windshield Wipers

    CHANGHE FREEDOM SERVICE MANUAL ELECTRICAL SYSTEM WINDSHIELD WIPERS FRONT WIPER AND WASHER The windshield woper is 3-speed type and the windshield washer is equipped with a separate- type washer pump. DESCRIPTION OF CIRCUIT WINDSHIELD WIPER CIRCUIT The circuit is designed so that when the wiper switch is turned OFF the wiper blades automatically return to their specified level rest positions.
  • Page 305 CHANGHE FREEDOM SERVICE MANUAL ELECTRICAL SYSTEM When wiper switch is turned OFF with the blades When switch is turned OFF with the positioned other than at the rest position. blades positioned at the rest position. 1. Battery 2. Main fuse 3.
  • Page 306 CHANGHE FREEDOM SERVICE MANUAL ELECTRICAL SYSTEM INSPECTION A. Wiper/Washer Switch Use a circuit tester to check switch for each terminal-to- terminal continuity, referring to "COMBINATION SWITCH" in this section. B. Wiper Motor REMOVAL 1) Disconnect wiper motor coupler. 2) Remove wiper motor assembly mounting bolt, and remove wiper motor assembly from wiper link.
  • Page 307 CHANGHE FREEDOM SERVICE MANUAL ELECTRICAL SYSTEM C. Washer Pump REMOVAL 1) Disconnect battery (-) cable. 2) Remove front fender lining (LH). 3) Remove washer tank fitting nuts and clip. 1. Front washer pump 2. Rear washer pump 4) Disconnect pump lead wires and hoses.
  • Page 308 CHANGHE FREEDOM SERVICE MANUAL ELECTRICAL SYSTEM REAR WIPER AND WASHER The rear window wiper is of the one-speed type, and its washer is equipped with a separate-type washer pump. 1. Wiper motor assembly 2. Washer nozzle 3. Wiper arm 4. Wiper blade WIRING CIRCUIT Refer to “BODY ELECTRICAL SYSTEM”...
  • Page 309 CHANGHE FREEDOM SERVICE MANUAL ELECTRICAL SYSTEM B．Washer Pump Refer FRONT WIPERAND WASHER INSPECTION in this section. C．Wiper Motor 1) TESTING WIPER MOTOR As illustrated left, use a 12V battery to connect its (+) and (-) terminals to terminal "G" and Black lead wire 1.

  • Page 310: Power Window Control System (If Equipped)

    CHANGHE FREEDOM SERVICE MANUAL ELECTRICAL SYSTEM POWER WINDOW CONTROL SYSTEM (If equipped) The power window control system is so designed that it electrically controls up & down movement of side door window glass by means of the motor which is installed to the window regulator.

  • Page 311: Power Door Lock Control System (If Equipped)

    CHANGHE FREEDOM SERVICE MANUAL ELECTRICAL SYSTEM POWER DOOR LOCK CONTROL SYSTEM (If equipped) The power door lock control system consists of the power door lock controller, door knob switch, door lock actuator and related wiring harness. WIRING CIRCUIT Refer to Wiring Diagram Manual mentioned In FOREWORD of this manual.
  • Page 312 CHANGHE FREEDOM SERVICE MANUAL ELECTRICAL SYSTEM Power Door Look Actuator 1) Disconnect power door lock actuator coupler. 2) Connect (+) cord and (-) cord of 12V battery to coupler terminal "1" and "2". 3) Actuator is proved to be operating properly if (-) cord connection to terminal "1"...

  • Page 313: Telecontrol Door Lock Control System (If Equipped)

    CHANGHE FREEDOM SERVICE MANUAL ELECTRICAL SYSTEM TELECONTROL DOOR LOCK CONTROL SYSTEM (If equipped) Push the telecontrol emitter’s button，the signal will send to the acceptor。Then control power door lock or unlock. WIRING CIRCUIT Refer to Wiring Diagram Manual mentioned In FOREWORD of this manual.
  • Page 314 CHANGHE FREEDOM SERVICE MANUAL BODY SERVICE SECTION 18 BODY SERVICE CONTENTS .................................... WINDSHIELD ..................................FRONT FENDER ......................... FRONT DOOR AND BACK DOOR ..................................... DOOR LOCK...

  • Page 315: Windshield

    CHANGHE FREEDOM SERVICE MANUAL BODY SERVICE WINDSHIED The windshield is installed by using a special type of adhesive (that is, one component urethane adhesive used with primer). For the Windshield replacement, it is important to use an adhesive which provides sufficient adhesion strength and follow the proper procedure.
  • Page 316 CHANGHE FREEDOM SERVICE MANUAL BODY SERVICE 7) Cut adhesive all around windshield with piano string. 8) Using knife, smoothen adhesive remaining on body side so that it is 1 – 2 mm thick all around. 9) When reusing windshield, remove the adhesive from it, using care not to damage primer coated surface.

  • Page 317: Front Fender

    CHANGHE FREEDOM SERVICE MANUAL BODY SERVICE 4) Using new brush, apply sufficient amount of primer onto glass along glass edge. 5) Apply adhesive for windshield 6) Peel off the paper on the adhesive. 7) Holding rubber sucker grips, place glass onto body by aligning mating marks marked in step and presses it.

  • Page 318: Front Door And Back Door

    CHANGHE FREEDOM SERVICE MANUAL BODY SERVICE FRONT DOOR AND REAR DOOR FRONT DOOR GLASS AND REGULATOR REMOVAL 1) Remove inside handle bezel. 2) Remove inside handle. 3) Remove handle of regulator. Put a piece of cloth in, remove the clamp spring, then remove the handle of regulator.
  • Page 319 CHANGHE FREEDOM SERVICE MANUAL BODY SERVICE 8) Remove door glass while tilting it as shown. 9) Remove door glass from front glass bottom channel. 10) Remove the regulator screws. Ease off the screw, take the regulator out. CHECK a. Check whether the gear of regulator is damaged or not.

  • Page 320: Door Lock

    CHANGHE FREEDOM SERVICE MANUAL BODY SERVICE DOOR LOCK LOCK OF FRONT DOOR REMOVAL Remove inside handle bezel. Remove inside handle Remove handle of regulator, put a piece of cloth in, remove the clamp spring, then remove the handle of regulator.
  • Page 321 CHANGHE FREEDOM SERVICE MANUAL BODY SERVICE REAR DOOR REMOVAL Remove the trim near the guide rail. Relax the screw on low bracket then remove rear door. INASTALLATION Reverse removal procedure to install rear door noting the following instruction. If the weather-strip is indurate, it may make water leakage.
  • Page 322 CHANGHE FREEDOM SERVICE MANUAL BODY SERVICE 2) Support door panel using a jack with rags and a piece of wood placed between jack and panel as shown. 3) Remove door assembly by loosening hinge mounting bolts. INSTALLATION Reverse removal procedure to install door assembly noting the following instructions.
  • Page 323 CHANGHE FREEDOM SERVICE MANUAL HEATER AND AIR CONDITIONING THE SIXTH PART HEATER AND AIR CONDITIONING SECTION 19 HEATER AND COOLING CONTENTS ................................320 HEATER GENERAL DESCRIPTION ........................320 WIRING CIRCUIT ............................323 REMOVAL ..............................323 INSPECTION .............................. 324 ......................325 AIR CONDITIONING (OPTION) GENERAL DESCRIPTION ........................

  • Page 324: Heater

    CHANGHE FREEDOM SERVICE MANUAL HEATER AND AIR CONDITIONING HEATER GENERAL DESCRIPTION HEATER AND VENTILATION The heater and ventilation of this vehicle consist of such main components as control levers, blower motor, heater core and air ducts. The blower motor runs on electricity to send air inside.
  • Page 325 CHANGHE FREEDOM SERVICE MANUAL HEATER AND AIR CONDITIONING HEATER CONTROL OPERATION A: Air control lever B: Fresh air control C: Temperature control lever D: Blower motor speed selection lever COOL (1)Air flows from center and side outlets. (2)Air flows from center, side and floor outlets.
  • Page 326 CHANGHE FREEDOM SERVICE MANUAL HEATER AND AIR CONDITIONING Side demister Defroster Side demister HEATING Side outlet Center outlet Floor outlet Side outlet VENTILATION HEATING Side demister Defroster Side demister Center outlet Side outlet Floor outlet Side outlet outside air Inside air 、...

  • Page 327: Wiring Circuit

    CHANGHE FREEDOM SERVICE MANUAL HEATER AND AIR CONDITIONING WIRING CIRCUIT Battery Ignition switch Resistor Heater fan switch Top evapmotor motor Heater motor Resistor Heater fan switch A/C switch Ignition sys REMOVAL FAN MOTOR RESISTOR 1）Disconnect battery(-)cable at battery. 2）Disconnect blower motor resistor lead wire at coupler.

  • Page 328: Inspection

    CHANGHE FREEDOM SERVICE MANUAL HEATER AND AIR CONDITIONING HEATER BLOWER FAN MOTOR 1）Disconnect battery(-)cable at battery. 2）Disconnect blower motor lead wire at coupler. 3）Remove heater blower motor. 1.Coupler 2.Resistor 3.Screw 4.Motor 1. Coupler 2.Screw 3.Motor Check circuit of heater fan switch by Ⅲ...

  • Page 329: Air Conditioning (Option)

    CHANGHE FREEDOM SERVICE MANUAL HEATER AND AIR CONDITIONING AIR CONDITIONING (OPTIONAL) GENERAL DESCRIPTION Air conditioning for this vehicle is available as an optional equipment. This section describes function of its main components, installation, servicing etc. COOLING LOCATION 1.Condenser 2.Receiver/dryer 3.Top evap drainpipe 4.Front evap 5.Compressor...

  • Page 330: Top Evaporator Control And Inspection

    CHANGHE FREEDOM SERVICE MANUAL HEATER AND AIR CONDITIONING TOP EVAPORATOR CONTROL AND INSPECTION Run engine. Operate air conditioning, push A/C switch. Set temperature lever at “COOL”. Set top evaporator blower switch at LO、.、HI，wind speed change larger more. Cooling air flows backward from top evaporator.

  • Page 331: Evacuation Charging And Test

    CHANGHE FREEDOM SERVICE MANUAL HEATER AND AIR CONDITIONING EVACUATION CHARGING AND TEST EVACUATING SYSTEM 1）Whenever opened (exposed to atmospheric air), air conditioning system must be evacuated by using a vacuum pump. The A/C system should be attached with a manifold gauge set, and should be evacuated for approx 15 minutes.

  • Page 332: Check Charge Of Refrigerant

    CHANGHE FREEDOM SERVICE MANUAL HEATER AND AIR CONDITIONING LIQUID LEAK DETECTORS 1) There are a number of fittings and places throughout the air conditioning system where a liquid liad detector solution may be used to pinpoint refrigerant leaks. 2) By merely applying the solution to the area in question with a swab, bubbles will form within seconds if there is a leak .For confined areas, such as sections of the evaporator and condenser, an...

  • Page 333: Performance Test

    CHANGHE FREEDOM SERVICE MANUAL HEATER AND AIR CONDITIONING PERFORMANCE TEST PROCEDURE 1）Connect high and low side charging hose of manifold gauge set to hose fittings of compressor. 2）Run engine, and keep compressor speed at 2000rpm. 3）Operate air conditioning, and set blower switch at “HI”, temperature lever at “COOL”.
  • Page 334 CHANGHE FREEDOM SERVICE MANUAL SEAT BELT AND AIR BAG SYSTEM SECTION 20 SEAT BELT AND AIR BAG SYSTEM CONTENTS ........................331 AIR BAG SYSTEM General Description ......................... 331 Installation ..........................332 The Condition Of Air Bag Start ....................333 Removal ........................... 334 Deployed Air Bag (Inflator) Modules ....

  • Page 335: Air Bag System

    CHANGHE FREEDOM SERVICE MANUAL SEAT BELT AND AIR BAG SYSTEM AIR BAG SYSTEM GENERAL DESCRIPTION The additional passenger's air bag device of automobile is by increasing the security from turning to the protective measure offered of a air bag that central authorities launched , it cooperates with safety belt of the automobile and uses, can save driver's life effectively when the automobile accident happens .

  • Page 336: Installation

    CHANGHE FREEDOM SERVICE MANUAL SEAT BELT AND AIR BAG SYSTEM INSTALLATION ● INSTALL STEERING WHEEL OF SRS-40 1） Take down the right and left panel. 2） After installation steering wheel in the steering column is in charge of, need to guarantee that the position is just in the front, fit it of the axle.

  • Page 337: The Condition Of Air Bag Start

    CHANGHE FREEDOM SERVICE MANUAL SEAT BELT AND AIR BAG SYSTEM THE CONDITION OF AIR BAG START SRS-40 air bag system is in bumping into 30 degrees of ranges of contained angle of centre line of vehicle (namely shaded area), and there is enough intensity that will just work.

  • Page 338: Removal

    CHANGHE FREEDOM SERVICE MANUAL SEAT BELT AND AIR BAG SYSTEM REMOVAL WARNING： The maintenance of the air bag system should be dealt with by the designated franchiser, if need to dismantle, should operate according to the following procedure. Never attempt disassembly of the air bag (inflator) modules.,...

  • Page 339: Deployed Air Bag (Inflator)Modules

    CHANGHE FREEDOM SERVICE MANUAL SEAT BELT AND AIR BAG SYSTEM DEPLOYED AIR BAG (INFLATOR)MODULES WARNING： ● The air bag (inflator) module immediately after deployment is very hot.Wait fot at least 30 minutes to cool it off before proceeding the work.

  • Page 340: Seat Belt

    CHANGHE FREEDOM SERVICE MANUAL SEAT BELT AND AIR BAG SYSTEM SEAT BELT GENERAL DESCRIPTION The seat belt for driver’s and front passenger’s seats is provided with an Emergency Locking Retractor(ELR)，the following picture shows. WARNING： If replacing seat belt is necessary,replace buckle and ELR(or webbing)together as a set.This is for the reason of ensuring locking of...

  • Page 341: Inspection

    CHANGHE FREEDOM SERVICE MANUAL SEAT BELT AND AIR BAG SYSTEM INSPECTION Seat belts and attaching parts can affect the bital components and systems of a vehicle. Therefore,they should be inspected carefully and replaced with genuine parts only. 1） Seat belt Its webbing or strap should be free from damage.

Table of Contents