LIFAN 1022 Service Manual (LF-20150819)

LIFAN 1022 Service Manual
Chongqing LIFAN Industry(Group) Imp.&Exp.Co.,Ltd.
第 1 页共 221 页
Chapter I Complete Vehicle
Section I Overview
I. Vehicle identification
1. Vehicle identification number (VIN)
(1) Description
The VIN is posted at three locations on the vehicle:

1. On the upper plate of the lower metal sheet of the sub-cab seat, as shown in Fig.1-1-1;
2. On the name plate of the vehicle
3. On the upper left of the dash board at the driver side, as shown in Fig.1-1-2;
Fig. 1-1-1 Vehicle identification number Fig. 1-1-2 Vehicle identification number
(2) Name plate
Fig. 1-1-3 Name plate
2. Location of the engine identification code
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LF479Q5
Fig. 1-1-4 Location of LF479Q5 engine identification code
II. Notes for vehicle lifting
The vehicle should be lifted partially or entirely during certain maintenance. A correct supporting
point should be selected during lifting to ensure safety. Notes for lifting of Lifan minivan as below:
1) Pit. Park the vehicle right above the pit for the serviceman to check and repair it, as shown in Fig.
1-1-4.
2) Pit bridge. Park the vehicle right above the pit for the serviceman to check and repair it, as shown
in Fig. 1-1-5.
3) Lift. Park the vehicle on the hydraulic lift. Start the lift to lift the vehicle to a proper height for the
serviceman to check and repair it, as shown in Fig. 1-1-6
Fig. 1-1-4 Pit Fig. 1-1-5 Pit bridge
Fig. 1-1-6 Hydraulic lift
3) For lifting of the axle, use a jack to uphold the lower part of the lower swing arm and place the
holding surface of the jack between the retaining nut and V-shaped angle clip as shown in Fig. 1-1-7.
For lifting of the rear axle, use a jack to uphold the lower part of the steel plate spring, as shown in Fig.
第 3 页共 221 页
1-1-8.
内端内端
内端
（b ）（e ）
Fig. 1-1-7 Lifting of the front axle Fig. 1-1-8 Lifting of the rear axle
第 4 页共 221 页
Section II Techinical Performance Parameters
For technical parameters of LF1022, please see Fig. 1-2-1 and Table 1-2-1.
Fig. 1-2-1 The overall dimension of Lifan minivan
Table 1-2-1 The overall dimension of Lifan minivan

Model LF1022
Overall 4580 4015

dimension 1615 1595
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1892 1900
Wheel base mm (millimeter) 2800
1310 1310
Track
1320 1320
Curb weight kg (kilogram) 1000
Full load weight kg (kilogram) 1930
Approach angle ° (degree) 33
Tire specs 175/70R14
Departure angle ° (degree) 25
Front suspension mm (millimeter) 620
Rear suspension mm (millimeter) 1160
Seats 2
Maximum speed km/h (kilometer/hour) 120
Engine model LF479Q5-1
Four-stroke, water-cooled, straight-4-cylinder,
Type dual overhead camshaft, multi-point electronic
injection and 16 valves (L4 DOHC 16V)
Displacement ml (milliliter) 1342/1299
Maximum power Kw (kilowatt) 65
Maximum torque N·m (Newton meter) 110
Idle speed r/min (revolution/minute) 800±50
Fuel consumption of comprehensive 7.7
operation mode L/100 km
Maximum grade ability % ≥30
Emission standard Euro IV
Section III Use and Maintenance

I. Maintenance categories and basic contents
During the use, the technical performance of the vehicle will change with the increase of travel
distance and various factors, which may cause the degrading of the dynamic property, economical
efficiency and safety & reliability and the rise of exhaust pollution, noise and failure rate. Therefore,
maintenance in time during the use of vehicle can eliminate hidden risks and avoid faults, improve the
completeness and technical performance of the vehicle, and effectively extend the service life of the
vehicle.
The maintenance for Lifan minivan can be divided into several categories according to the
technical requirements and use of the vehicle.
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1. The first maintenance
The first maintenance is also called break-in period maintenance which refers to the
maintenance carried out for the first time on a new or an overhauled vehicle after reaching a mileage
of 1,500-2,500km. It should be carried out at the specified Lifan minivan service station, with contents
as below:
1) Check all locations of the engine, transmission and differential for leakage; if yes, please
eliminate it.
2) Replace the engine oil filter and the oil.
3) Check the level of coolant, brake fluid, windshield detergent and battery electrolyte (except
maintenance-free battery), power steering fluid (models with power steering) and check if there is
leakage. If the level is too low, please fill the fluid; if there is leakage, please repair it.
4) Check the triangular arm & ball pin, the connecting ball head and the flexible hinge of
triangular arm for damage and the ball head for looseness. If yes, please repair or replace it.
5) Check the drive shaft dustproof cover for breakage; if so, replace it.
6) Check the steering mechanism, front and rear shock dampers for oil leakage; if so, repair it.
7) Check the tire pressure. For the front tires, the standard pressure is 240KPa and the highest
pressure is 260KPa; for the rear tires, the standard pressure is 240KPa and the highest pressure is
300KPa.
8) Check if there is a DTC stored in the self-diagnostic system (model with an electronic injection
engine and model with an automatic transmission). If yes, eliminate the faults according to the DTC
and then delete the DTC.
2. Regular maintenance
The vehicle enters the normal period for use after the first maintenance. During the normal use,
a regular maintenance should be carried out according to the actual application conditions of the
vehicle.
(1) Regular maintenance for vehicles operating in severe conditions. Severe conditions are as
below:
1) Frequent starting.
2) The vehicle always runs in dusty environment.
3) The vehicle runs in hot areas (such as in summer of the south).
4) The vehicle always runs in low-temperature environment (the vehicle always drives for short
distance; and the temperature of the engine does always not reach the normal working temperature).
(1) The vehicle operating in severe conditions should be regularly maintained for every 5,000km.
(2) The vehicle operating in normal conditions (except in severe conditions) should be regularly
maintained for every 7,500km.
The regular maintenance should be carried out at Lifan minivan service station.
The contents of the regular maintenance are shown in Table 1-3-1.
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① Meaning of I, R and C:
I---Check these items and related parts. Do calibration, cleaning, filling, adjustment or replacement as
necessary;
R---Replacement;
C=Cleaning;
② For vehicles operating in severe conditions, for short distance and always driving at idle speed or
in dusty environment, shorten the period for replacing the engine oil and filter as necessary;
③ For vehicles driving in dusty environment, the air cleaning elements should be checked every
5,000Km; clean or replace it as necessary;
④ For vehicles driving in hill or mountain area or under trailering, the brake/clutch fluid should be
replaced every 20,000km.
⑤ Only use 93 or above unleaded gasoline.
① For vehicles driving less than 7,500km, replace the engine oil at least once a year.
② As per the vehicle model.

Odometer Readings Or Months, Whichever Is First
NO Maintenance 3,000k 8,000k 13,000k 18,000k 23,000k 28,000k 33 ,000k 38 ,000k 43 ,000k 48,000 53,000k 58,000k
. Item m m m m m m m m m km m m
3Month 9Month 15Month 21Month 27Month 33Month 57 63Month 69Month

39Months 45Months 51Months
s s s s s s Months s s
Replacing the
oil or fluid
Replacing the
1.1 engine oil & R R R R R R R R R R R R
engine oil filter
Replacing the
1.2 R R R R R
fuel filter
Replacing the
1.3 brake fluid
It must be replaced every 40,000 km or 2 years
Replacing the
1.4 coolant
It must be replaced every 40,000 km or 2 years
Replacing the
transmission(M
1.5 T) oil & rear axle
R It must be replaced every 40,000 km or 2 years
gear oil
Fluid Level
Check
Add As The Case May Be
Inspecting the
fluid level & add
(including brake
1.6 fluid, coolant, I I I I I I I I I I I I
glass cleaning
fluid, etc.) to the
proper level
Check &
Adjustment
Adjust As Necessary
Inspecting the
lighting system
1.7 I I I I I I I I I I I I
of the whole
vehicle
Inspecting the
clutch pedal &
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its position as
well as the
parking brake
handle position
Check the ABS
system
Inspecting the
1.10 tire pressure I I I I I I I I I I I I
Rotate the tires

and check the
1.11 parameter of I I I I I
four wheel
alignment
Inspecting the
parking brake
1.12 mechanism I I I I I I I I I I I I
working
performance
Inspecting the
brake system
1.13 working I I I I I I I I I I I I
performance
Inspecting the
steering system
performance
Inspecting the
A/C & HVAC
condition
Cleaning throttle
1.16 & injection C C C C C
nozzle
1.17 Inspecting the I
exhaust
I I I I I I I I I I I
emission
condition
Inspecting &
Replacement
Replace As Necessary
Inspecting the
glass cleaning
1.18 system & I I I I I I I I I I I I
windshield
wiper system
Inspecting or
replacing
1.19 the high-tension I It must be replaced every 40,000km or 2 years
cable
Replacing the
drive belt
1.20 (generator, A/C It must be replaced every 80,000 km or 2 years
compressor)
Inspecting or I I I I I I
replacing the
1.21 engine timing
belt It must be replaced every 60,000 km or 3 years
Replacing the
three-way
1.22 catalytic It must be replaced every 80,000 km
converter
第 9 页共 221 页

Cleaning or
1.23 replacing the air C C R C R C R C R C R C
filter
Cleaning or
replacing the
1.24 interior C C R C R C R C R C R C
ventilation
system air filter
Inspecting if
1.25 there is oil I I I I I I I I I I I I
leakage
Inspecting the
1.26 radio, CD or I I I I I I I I I I I I
DVD
Inspecting the
instrument
1.27 cluster I I I I I I I I I I I
&
speaker
Inspecting or
1.28 replacing the I I I R I I I R I I I R
spark plug
Inspecting the
1.29 suspension I I I I I I I I I I I I
system
Inspecting the
brake system
condition
(including pipe
line leakage,
mechanism
1.30 performance, I I I I I I I I I I I I
friction condition
of brake pads or
brake shoes),
dust boot &n
rubber boot
condition
Inspecting the
dust boot & the
rubber boot
1.31 condition I I I I I I I I I I I I
(leakage &
damage) of the
whole vehicle
Inspecting the
cooling system
1.32 & fuel system I I I I I I I I I I I I
(leakage &
damage)
Inspecting the
related control
units (ECU,
immobilizer
control unit, A/C
1.33 control I I I I I I I I I I I I
unit,
ABS control
unit, etc.)
working
condition
Inspecting the
vehicle body
1.34 (dent, paint off, I I I I I I I I I I I I
discoloration,
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etc. )
Inspecting the
lubrication of
1.35 the lock, hinge, I I I I I I I I I I I I
etc.
Road Test
Carrying out the

1.36 road test T T T T T T T T T T T T
Notes：
1. Some maintenance items in the table are determined by specific vehicle configuration.
2. The definition of I,R,C,T in the LIFAN Commercial Vehicle Maintenance Plan Table
I: Inspecting,
R: Replacing,
C: Cleaning,
T: Testing.
II. Routine maintenance of Lifan minivan
Routine maintenance refers to operations such as check, cleaning, tightening and refilling
carried out according to the utilization and condition of the vehicle so as to ensure a good condition. It
should be carried out by the driver or professional vehicle serviceman during the normal operation.
But some items must be maintained by professional vehicle servicemen at Lifan service station.
1. Maintenance of the air cleaner
The air cleaner is to filter the air entering the engine cylinder for the first time. The filtered dust
and other impurities are accumulated in the filter element. The air cleaner can filter many dust and
impurities, thus they must be removed immediately.
Dismantle the air cleaner to remove the dust and impurities in the filter element. For the structure
of the air cleaner, please refer to Fig. 1-3-1. Generally speaking, it should be cleaned for every driving
of 3,000km. If the vehicle runs on a dusty road, it should be cleaned for every three days.
2. Maintenance of the air cleaner
The air cleaner is to filter the dust and impurities in the air, as well as ensure the smooth flow of
air. The condition of the air cleaner directly influences the economical efficiency and dynamic
property; therefore, it must be checked and maintained in time.
Within the replacement period for the filter element of the air cleaner, please decide the
frequency of maintaining the air cleaner according to the cleanness of the road. During maintenance,
dismantle the filter element, blow away the dust on the filter element by compressed air and remove
the impurities in the air cleaner housing.
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7 7
7
6 7
4
6 1-1
9
8 5
1-4
8
1-3
2
3
1-2
1-5
1 1-5
1-5
Fig. 1-3-1 Cleaning the air cleaner of Lifan minivan

1-air cleaner assembly, 1-1-upper cover of air cleaner, 1-2-filter element assembly, 1-3-lower cover of air cleaner,
1-4-bush, 1-5-shock pad, 2-intake pipe of air cleaner, 3-type A worm drive hose clamp, 4-intake pipe of engine,
5-crankshaft ventiduct, 6-clamp, 7-hexangular flange head with a cross slot bolt, 8-steel band type flexible ring clamp
Note: Do not use a wet cloth to clean the filter element. Make sure that the connection is sealed
well during restoring the filter element.
3. Maintenance of battery
Battery is the power supply for vehicle starting and electrical appliances. Its condition directly
influences the normal use of the vehicle, especially the one with electronic control devices. It’s very
important to maintain the sound condition and reliable connection of the battery. For daily use, the
battery should be checked and maintained as below:
(1) Outer cleaning: regularly check if the housing and cover surface of the battery is dirty; in
case of dust, oil stain or other dirties, please clean them immediately and keep the cover surface dry
to avoid electricity leakage.
(2) Check of the battery connection: the poor contact at the joint between the battery terminal
post and cable may cause a hard or failing starting of engine; the drop of the battery connecting wire
may cause damage to the electrical parts on the vehicle; and may lose the fault code and other
information in the RAM memory of the computer system. Therefore, please always check if the
connector of cable on the battery terminal post is fixed.
(3) Check of the peep hole on the battery housing: if it’s green, it’s normal; if it’s black, it
requires charging; and if it’s colorless, the battery has been damaged.
4. Maintenance of tires
It is very important for the fuel consumption and driving safety to keep the good condition of the
tires. Thus they should be always checked and maintained.
(1) Tire pressure: always check the tire pressure. Inflate the tires as necessary to make it always
keep the standard pressure.
(2) Damage of the tires: visually inspect if the tire is abnormally worn, cracking and bulging. If yes,
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please repair or replace the tire immediately; if there is a hard impurity on the tire, please remove it in
time to avoid damage to the tire.
(3) Tire rotation: the front wheels of Lifan minivan function as both driving wheels and steering
wheels. The front axle load is bigger than that of the rear axle, which may cause too fast abrasion of
the front wheel tire and eccentric wear. Please carry out the tire rotation for every driving of
15,000-20,000km to ensure the performance and service life of the tires. For methods, please see Fig.
1-3-2.
Front
Fig. 1-3-2 Tire rotation
(4) Standard for normal wear of tires: the tire may be worn in the normal driving of the vehicle.
The tires should be replaced when the wheel tread is less than 1.6mm in depth or wear is found in the
groove between two or among more neighboring treads. Please see Fig. 1-3-3.
Fig. 1-3-3 Wear mark of tires
5. Maintenance of wiper and washer
The condition of wiper and washer directly influences the sight of the driver and the service life of
the windshield. Therefore, please pay attention to the maintenance of wiper and washer during daily
use.
(1) Wiper: Check if the wiper is damaged or deformed, it influences the sound contact between
the wiper blade and the windshield and the wiper is in normal operation. In case of poor contact
between the wiper blade and the windshield or bad operation of wiper, please repair or replace them
in time.
(2) Washer: Check the storage of the washer reservoir and refill detergent in time. Please use
the specified detergent to ensure the best effect. Slowly fill the detergent and no impurity should enter
the reservoir. Add suitable alcohol to the detergent to avoid freezing in winter.
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6. Check and adjustment of headlamp
The incorrect beam of headlamp will influence the safety of driving at night. Thus, it should be
always checked and adjusted, if necessary. For the check and adjustment of headlamp, please refer
to Chapter IV.
7. Interior maintenance
Interior maintenance mainly refers to cleaning to keep the inside of vehicle clean and offer a
pleasant environment for driver and passengers. Key points are stated below:
(1) Method for dirt removal: firstly remove the dust, and then clean the dirt by a proper
detergent, and repeatedly wipe the surface with a clean, soft and not very damp cloth.
(2) Detergent: use liquid solution with soap solution and surface active agent to remove the dirt
on a fabric or synthetic leather as possible as you can. Solutions may corrupt the synthetic materials
for interior decoration to a certain extent, so please pay special attention.
Mark of ballpoint and lipstick can be cleaned by alcohol, oil or grease by gasoline with a low
number, chocolate and sugar stain by commodity hartshorn and asphaltum stain by a special
solution.
(3) A long time exposure under the sun may damage the interior decorations. Therefore, the
upper part of seat back pad exposed to sunshine and rear baffle plate should be sheltered by a cover.
8. Exterior maintenance
Exterior maintenance is to keep the exterior surface clean and shining, offer a pleasant
appearance and avoid the vehicle body becoming rusty and paint falling abnormally. Key points are
as below:
(1) Washing the vehicle body. The methods are as follows:
1) Wash away the dirt on the surface by pressure water and then wipe the body by a soft cloth or
sponge from the top to bottom.
2) Dry the surface by high-quality white gauze, step down the brake pedal for several times during
driving after washing to drain the water in the friction pair.
If detergent is used, it should be washed away by clear water.
(2) Cleaning the windshield: silicon-copper-based product can not be used. For a better cleaning
effect, you’d better use the special detergent provided by the technical service station of our
company.
(3) Removing the asphaltum: the asphaltum on the vehicle body and bumper should not be
scraped but wiped by a special material.
(4) Repairing paint: repair the paint scratches or slight damages with a special paint repairing
spray tank. (The auto technical service station may provide various colors of paint repairing spray
tanks.) After repairing, keep the paint in air for drying.
(5) Polishing and waxing: it can not only beautify the vehicle body, but also protect the paint.
1) Paint polishing should be carried out at the end of winter. The vehicle body should be clean
and dry before polishing. Liquid or emulsus polishing agent is used.
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2) Before waxing, the painted surface should be absolutely dry and clean. Spray the wax on the
painted surface evenly by a waxing tool (or by a soft napkin or soft but lint-free cotton fabric). Check
the waxing by water droplet testing: spray a little water on the painted surface to be tested; if there are
droplets, wax layer has been formed; otherwise, clean the surface and repeat waxing. Note: waxing
should not be carried out under direct sunshine or in a cold day.
第 15 页共 221 页
Section IV Maintenance Data
I. Common parameters for check and adjustment
For convenient lookup, the common parameters for check and adjustment are listed in Table 1-4-1.
Table 1-4-1 Common parameters for check and adjustment

Item Normal parameter
Front wheel 240Kpa (no load) 260Kpa (full load)
Tire pressure
Rear wheel 240Kpa (no load) 300Kpa (full load)
High pressure: 1.30-1.60 Mpa
Working pressure of A/C system
Low pressure: 0.15-0.20 Mpa
Front wheel toe-in (no load) （0.0±1）mm
Front wheel camber angle 1°18′±30′
Master pin caster angle 30°24′±30′
Master pin inclination angle 9°47′±30′
II. Parameters for oils and fuels
Proper oils and fuels should be used during maintenance to ensure the normal operation of the
vehicle. The model and amount of oils and fuels for Lifan minivan are listed in Table 1-4-2.
Table 1-4-2 Model and amount of oils and fuels for Lifan minivan
Item Model Amount
Above 10W/30 or 15W/40SF (according
Engine oil 3.2L
to different regions)
Gear oil of gear box SAE 80W/90 GL-4 1.5L
Brake fluid (for brake without DOT4 0.45L
ABS)
Coolant Antifreezer G11 8.5L
Gasoline RON 93﹟ and above unleaded 40L
gasoline
Windshield cleaning agent NFC-60 1.4
A/C refrigerant R134a 420g
Gear oil of rear axle GL 80W/90 1.3L
III. Parameters for bulbs

The bulbs for lighting and signal are listed in Table 1-4-3.
Table 1-4-3 Parameters for lighting and signal bulbs

High beam light White 55W 2
Lightin
signal
g and
syste
Front group lamp Low beam light White 55W 2

m
Front position light White 5W 2

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Front steering light Amber 21W 2
Rear steering light Amber 21W 2
Rear position light White 5W 2
Rear group lamp Reverse light White 21W 1
Rear fog light White 21W 1
Brake lamp White 21W 2
High-mounted brake lamp Red (optional)
License plate lamp White 5W 2
Side steering light Amber 5W 2
Instrument illuminating light White 2W 5
Front fog light White (optional)
Front interior light White 8W 1
Front interior light
Front reading light White 5W 2
Rear interior light White 8W 1
Reflex reflector Red 2
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Section V Notes for Use and Maintenance
I. Notes for the safety of maintenance
1. Notes for removal and installation
Most of the parts, components and assemblies are tightened by bolts and nuts. Please pay
attention to the following notes during removal and installation to ensure the safe operation and
completeness of parts, and guarantee the normal connection of parts after maintenance:
1) For the removal of fasteners such as bolts and nuts, use a wrench or sleeve of the specific
specification rather than an adjustable wrench for convenience to prevent damage to parts or
personal injury due to removal.
2) If the bolt or nut is too rusty to be loosed, dip it in gasoline for 1h and then remove it. Do not
apply excessive force to avoid damage to parts or accident due to the unbalanced bearing (during
raising the vehicle by a jack).
3) Some parts are mated closely, so do not pry or knock them by an improper tool during
removal and installation so as to avoid damage to parts.
4) For the removal and installation of bearing or oil seal, use a proper tension and compression
tool to prevent damage to bearing, oil seal and their mating and sealing with the related parts.
5) Bolts and nuts must be tightened according to the specified torque. If too loose, the vehicle
may be loosen and cause fault or damage in the driving; if too tight, the spare parts may be damaged
easily.
2. Others
1) Pay attention to the reliability of the bearing when maintaining the vehicle during lifting.
2) The maintenance workshop should be reasonably arranged; the removed parts should be
placed according to regulations and the oil stain on the ground should be cleaned immediately to
avoid being stumbled or sliding by parts during maintenance.
3) No smoking to prevent a fire.
4) The maintenance workshop should be ventilated to prevent the harmful materials in the
exhaust gas from the engine from causing injury to human body.
5) The maintenance should be carried out after the engine stops and the temperature decreases
so as to prevent being scalded by hot parts such as cylinder body or exhaust pipe. Some thin-plate
metal parts should be dismantled under normal temperature, otherwise they will be distorted. If
maintenance is required while the engine is operating, please do not contact the surfaces of the
engine body or the exhaust pipe, etc.
6) During maintenance, the skin should not contact the oils and fuels directly for a long time,
otherwise it will be hurt. When the painting surface is with brake fluid, antifreeze and electrolyte, wash
them immediately to avoid damage to the painting.
7) Open fire is prohibited when checking the electrolyte level. Flame or spark is not allowed to be
close to the battery when the engine is working so as to avoid battery explosion due to igniting the
hydrogen and oxygen accumulated when the battery is being charged.
II. Notes for use and maintenance of electrical system
1. Notes for maintenance of electrical system

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1) Disconnection or connection of the connectors of electronic devices, electrical equipment or
circuits must be carried out when the power is cut off, to avoid damage to the electronic elements by
the transient voltage produced when the circuit is cut off or energized.
2) After the ignition switch is turned off, electrical appliances such as motor and computer,
electronic system components and circuits of power supplies directly connected to battery should not
be switched off from the power. For necessary disconnection with the battery, the negative cable of
battery must be dismantled.
3) Do not check the continuity of circuit by a spark test to avoid damage to the electronic
elements by the transient voltage pulse produced from the spark test.
4) Do not check the continuity of circuit by piercing the lead insulation to prevent poor connection
or insulation of the circuit.
5) When pulling out the connector of harness or electrical components, do not directly pull the
lead to avoid broken lead or connection within the lead.
6) For checking the voltage or resistance of electronic control circuits like computer, a digital
multimeter with internal resistance no less than 10MΩ should be used.
7) Checking the continuity of circuits and resistance of electrical appliances and electronic
components by the ohms range of the multimeter should be carried out when the circuit is cut off to
avoid a burnt-out meter.
2. Notes for use and maintenance of battery

(1) Notes for use:
1) The electrolyte of battery is featured by strong corrosivity. Please protect your eyes and face
during the disassembly, assembly and handling of the battery. Once your face contacts the
electrolyte, wash it immediately with large amount of clear water.
2). If the starting rotation speed decreases evidently (insufficient battery charging), recharge the
battery in time by a charging equipment to avoid that the long-time insufficient power condition of
battery will easily vulcanize the polar plate and further impact the service life.
3) Always check the level of the electrolyte. If it is too low, fill distilled water.
4) Ensure that the battery cable clamp is installed fixedly, to prevent its loosing or falling off
during driving which may cause damage to the electronic equipment due to the overvoltage from the
electrical system.
5) The terminal post, cable clamp and cover surface of battery should keep clean to avoid poor
contact or electricity leakage.
6) Disconnect the negative cable of battery if the vehicle stops for over one month.
(2) Notes for disassembly and assembly:
1) Make sure that the electrical equipment on the vehicle are cut off when disassembling the
battery.
2) Firstly disconnect the negative cable lamp, and then the positive cable lamp, so as to prevent
the short circuit because the tool contacts the neighboring components; for assembly, reverse the
order for the same reason.
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3) The connectors of positive and negative cables must not be connected incorrectly; otherwise,
the commutation diode of the generator will be burnt out.
(3) Notes for recharging:
1) For recharging, disconnect the connectors of positive and negative cables.
2) For charging, connect the cable first and then turn on the power switch; turn off the power first
to stop charging.
3) The cable clamp of charging equipment and the terminal post of the battery must be reliably
connected to prevent that the hydrogen and oxygen produced by charging are ignited by the spark
due to the sudden disconnection and further brings about an accident.
4) For constant-voltage charging, the charging voltage should not be over 15.5V, and the current
not over 20% of the mark value of the battery (e.g. the maximum charging current of L2 300A battery
should not exceed 60A). Otherwise, that will cause overcharging or damage to the polar plate.
(4) Notes for use in winter
In winter with low temperature, the capacity of battery decreases; the internal resistance
increases; and the electrolyte may be frozen. In case of a frozen electrolyte, the battery can not be
used any more and the active materials on the polar plate will fall off and the container will break.
Therefore, attention must be paid in winter in the cold region:
1) Adjust the density of electrolyte higher properly. The electrolyte with a low density easily gets
frozen in winter. Therefore, properly adjust the electrolyte to the density that it will not cause freezing
in that area in winter.
2) Keep the battery with sufficient power. After discharging, the density of the electrolyte will
decrease and thus the risk of being frozen will increase. Therefore, in winter, it's quite necessary to
keep the battery with sufficient power.
3) Filling distilled water during charging can make water blend with the electrolyte fast and then
decrease the risk of being frozen.
4) Pay attention to the heat preservation and pre-heating of battery. In the cold region in winter,
the battery should be pre-heated when the cold engine starts, to enlarge the capacity of the battery,
decrease the resistance and further make the engine start easily.
(5) Notes for starting by an emergency battery: when the battery is too insufficient in power and
the engine can not be started by a starter, the engine maybe also can not be started by pushing the
vehicle, because the insufficient power of battery will cause the engine ECU not to work normally. If
starting is badly needed, the engine must be started by another battery or a spare one. For starting
and its safety, follow the operation methods and motes as below:
1) Connect the emergency battery as per the order shown in Fig. 1-5-1. The clamp should be
tight to avoid spark produced due to the loose clamp.
第 20 页共 221 页
Fig.1-5-1 Starting by an emergency battery
2) If using the battery from another vehicle, start the engine of the rescue vehicle first after
connecting the two batteries, and make the engine run at a relatively high rotation speed for 1min,
and then start the vehicle engine with an insufficient battery.
3) The rescue vehicle should not contact the vehicle with an insufficient battery. During
connecting the clamp, the engine must stop. During starting, do not touch the clamp and do not lean
on the battery.
4) Reverse the order to remove the clamp.
3. Notes for use and maintenance of generator
1) When the generator is not being charged or has not been charged sufficiently, check if the
tension of the drive belt is proper, as the slipping of the drive belt forms one of the causes for the
generator being not charged or not charged sufficiently.
2) When the engine and the generator are working, do not disconnect the battery; otherwise
overvoltage will be caused and then burn out the commutation diode within the generator and
damage other electronic elements on the vehicle.
3) When the generator is working, do not check if the generator generates power by a spark test,
because that will easily burn out the commutation diode and other electronic elements on the vehicle.
4) When checking the insulation performance of the armature winding by a 220v AC test lamp or
a megger, the connection between the commutation diode and armature winding must be
disconnected firstly; otherwise the commutation diode will be burnt out.
5) When the engine stops, the ignition switch should be disconnected immediately, because the
battery will continue supplying power to the generator magnetic field winding if the ignition switch is
connected. That will not only consume the capacity of the battery, but burn out the magnetic field
winding.
4. Notes for use and maintenance of starter
1) When the starter is hard to be started, the time for each starting should not be too long
(always not over 5s). Another starting must be carried out 15s later. That will not only give enough
time for the battery electrolyte to infiltrate into the inside of the polar plate and make the electromotive
force recover, which is helpful for starting, but also prevent the starter from being burn out due to the
continuous work of generator for a long time.
2) Do not drive the vehicle to move by a starter to avoid damage to the starter due to too large
load.
3) After the engine starts, release the ignition switch in time and make it return to the ignition
position automatically so as to avoid wear of one-way clutch and prevent the generator starting from
第 21 页共 221 页
being accelerated as the engine runs at a high speed for a long time after starting.
4) When the engine is working, the ignition switch should not be turned to the starting position,
so as to prevent the driving gear of starter and the gear ring of engine flywheel (model with automatic
transmission) from contacting each other and being damaged.
5) During maintenance, the time for performance test (no load test and brake test) of starter should
not exceed 5s; otherwise the starter will be damaged.
III. Notes for use and maintenance of engine and vehicle
1. Notes for vehicle driving
The following points should be paid attention to for the normal operation of engine and other
systems and the safety of driving:
1) Always observe the indicators on the instrument and the instrument cluster. If the indicator
illuminates, stop the vehicle immediately and eliminate the fault.
2) Ensure the radiator cover is screwed down to guarantee the normal operation of the engine
cooling system. (The radiator cover flange should be parallel to the radiator surface after being
screwed down.)
3) Start at the first gear. Coasting is not allowed.
4) When the electronic injection engine starts, the injection system is controlled by computer
according to the starting switch signal. Thus there is no need to step down the acceleration pedal.
5) After the engine starts, the vehicle can start without need of warm-up. However, accident
acceleration should not be applied. The vehicle should run stably for a distance. Before the engine
stops, make the engine run at an idle speed first so as to make its temperature decrease smoothly.
6) A hard starting may be caused by the over storage of the engine intake manifold. Step the
acceleration pedal to the end slowly and keep that for 30s to evaporate the gasoline in the intake
manifold. Then start the engine.
7) The electronic injection engine is equipped with an inertia switch which can automatically cut
off the fuel in case of collision. If the engine couldn't start up and there is no other fault, check the
inertia switch for close (press down the switch).
8) Regularly check the level of engine coolant, brake fluid, windshield cleaning solution and
engine oil. As for the vehicle of power steering model, check the liquid level of power steering fluid.
Without fluid, driving is prohibited.
9) Always check and keep the normal idle speed of the engine that will be helpful for the
performance of the engine.
10) The spark plugs of the electronic injection engine and the carburetor engine can not be
exchanged.
2. Notes for use of tires
1) Always check the tire pressure to make tires keep a normal pressure. Too low tire pressure
easily causes tire side with cracks at an early stage, crown with abnormal wear and shoulder with too
early wear; besides, the rolling resistance will increase and the oil consumption will rise. Too high tire
第 22 页共 221 页
pressure easily causes tire surface with too early wear, decreasing adhesion performance, and
extended brake distance. Besides, sideslipping always happens, and even seriously, the tire may
explode when the vehicle runs at a high speed.
2) The tire should be removed and installed by a special tire changer, and tested by a wheel
balancer. Wrong assembly or disassembly always causes the tire bead to be distorted or damaged,
influences the air tightness or brings about a bulge, and even more seriously results in fracture of
carcass cord and a discarded tire. If the wheels have not been adjusted by a balancer, the vehicle will
vibrate during running, and the noise will become louder and the tire may be abnormally worn and
then the service life of the tire will be reduced.
3) Pay attention to the regular tire rotation to decrease the wear of tires, ensure the performance
of vehicle and extend the service life of the tires.
4) Use the special tires for Lifan minivan. On the same vehicle, tires with different specifications
and treads are not allowed.
5) Wash away the mud and sand stone on the tire in time to avoid wheel vibration and damage
when the vehicle runs at a high speed.
6) During installation of wheel, be noted that the side with a red point mark should face outside.
3. Notes for vehicle washing
Do not dry rub the vehicle body, nor wash the painting and organic glass by gasoline, kerosene,
trichloroethylene, strong lye and alcohol to avoid damage to the surface.
After the vehicle runs on the road defrosted by salt, wash the lower engine compartment and the
vehicle bottom to avoid corrosion.
IV. Notes for use and maintenance of vehicle with a three-way catalytic converter
Impure fuel may cause deposit of lead, zinc, sulphur and phosphor on the three-way catalytic
converter. Thus it may react excessively (due to over high HC content in exhaust gas) and age or be
damaged for overheat, and then it may lose effect. For the normal working of the three-way catalytic
converter and extend the service life, the content of lead, zinc, sulphur, phosphor and hydrocarbon
exhausted into the three-way catalytic converter should be reduced during use and maintenance.
1. Notes for use
1) Only use unleaded gasoline of 93 or above.
2) Do not use gasoline additive and engine oil additive not accepted or recommended by Lifan.
3) Do not move the vehicle by a starter.
4) Do not drive or stop vehicle on the road and place with flammable materials (e.g. hay,
gasoline, alcohol and organic solvent) to avoid that the three-way catalytic converter with a too high
temperature ignites the flammable materials and causes a fire.
5) In case of a hard cold starting of engine, it should be checked and maintained in time to
eliminate the fault of hard cold starting, so as to prevent the unburnt gasoline in the cylinder started
for several times from being discharged into the three-way catalytic converter and causing damage
due to its excessive reaction.
6) When the warning lamp illuminates due to over low fuel level, refill the oil tank with fuel, so as
to prevent the enlarged load of the three-way catalytic converter due to poor combustion of engine
第 23 页共 221 页
and abnormal oil supply caused by the too low fuel level.
2. Notes for maintenance
During maintenance, excessive HC exhausted into the three-way catalytic converter should be
avoided. Please pay attention to:
1) Do not judge the working condition of each cylinder by the method of cutoff for each cylinder
one by one.
2) When using a starter to start the engine to measure the cylinder pressure, the plug of the
injector must be pulled out.
3) Regularly check and clean the injectors, and in time eliminate faults like oil drop, channel
blockage and surface carbon deposit of injectors.
4) Regularly check the ignition system and in time eliminate faults like high-tension line falling off
or poor contact, carbon deposit in spark plug or burntout spark plug, bad ignition coil or circuit.
第 24 页共 221 页
Chapter II Electronic Injection System
Section I Overview
I. Introduction to engine control system
1. Composition of electronic control system (1.3L displacement DELPHI and 1.0L

displacement SUNNY TEK)
The electronic control system of Lifan minivan is composed of the following three parts:
(1) Sensor---converting the non electric physical quantity of engine to electric quantity and
meanwhile sending information to ECU. Sensors for the electronic control system of LF6401 include:
① intake pressure and temperature sensor; ② throttle position sensor; ③ coolant temperature
sensor; ④ front heated oxygen sensor; ⑤ knock sensor; ⑥ crankshaft position sensor; ⑦ weak
acceleration sensor (G III with OBD and G VI configuration); ⑧ rear heated oxygen sensor;
(2) Electronic control unit---ECU, the brain of the whole electronic control system. It analyzes
and processes information from sensors and then sends the result to the actuators in form of order to
make the engine operate in a good condition.
(3) Actuator---carrying out the orders from ECU. Actuator is the hand and foot of the electric
control system. Actuators for the electronic control system of LF6401 include:
① injector; ② ignition coil; ③ idle speed stepper motor; ④ canister solenoid; ⑤ relay (fan, A/C,
oil pump and A/C compressor, etc.)
II. Introduction to parts and components of electronic injection system

i. Intake pressure temperature sensor
1. Sketch and foot circuit

(1) Sketch
Fig. 2-1-1 Sketch of pressure temperature sensor
(2) Foot definition
No. ECU Function and definition

pin
1 J1-42 Output voltage terminal
2 J1-04 System signal earthing
3 J1-27 5V reference voltage input terminal
4 J1-21 Intake temperature resistance output
terminal
2-1-1 Feet of pressure temperature sensor
第 25 页共 221 页
1 2 3 4
Fig. 2-1-2 Feet of pressure temperature sensor
(3) Foot circuit
Fig. 2-1-3 Circuit of intake pressure temperature sensor
2. Installation position
This sensor is composed of the intake manifold absolute pressure sensor and the intake
temperature sensor. It is installed on the intake manifold.
3. Working principle
The element of the intake manifold absolute pressure sensor consists of a silicon chip. A
pressure diaphragm is etched on the silicon chip. There are 4 piezoresistances on the pressure
diaphragm. As strain elements, the four piezoresistances form a wheatstone bridge. Apart from the
pressure diaphragm, a signal processing circuit is also integrated on the silicon chip. The silicon chip
and a metal housing compose an enclosed reference space in which the air absolute pressure is
nearly zero, thus a microelectro mechanical system is formed. The active surface of the silicon chip
bears a pressure nearly zero and the back with an intake manifold absolute pressure to be tested and
introduced by a connection pipe. The silicon chip is a few μm in depth, so the change of the intake
manifold absolute pressure will deformate the silicon chip, and the four piezoresistances will also be
distorted with changing resistance. Voltage signals with a linear relation with the pressure are formed
after the signal and circuit processing of the silicon chip.
The intake temperature sensor element is a NTC resistance which will vary according to the
intake temperature. This sensor sends a voltage expressing the change of intake temperature to the
controller.
4. The intake temperature sensor element is a NTC resistance which will vary according
to the intake temperature. This sensor sends a voltage expressing the change of intake
temperature to the controller.
① Faults: misfire, poor idle speed, increased oil consumption and discharge.
② Common causes: 1. Abnormal high pressure or reverse large current during use; 2. vacuum
element damaged during maintenance.
③ Notes for maintenance: do not use high-pressure gas to impact the vacuum element during
maintenance; if there is need to replace the sensor for fault, check if the output voltage and
current of generator are normal.
第 26 页共 221 页
④ Measuring methods: refer to related content in Section II and Section III.
ii. Throttle position sensor

1. Sketch and foot
(1) Sketch
Fig. 2-1-4 Throttle position sensor
(2) Foot definition
A B
Fig. 2-1-5 Definition of feet of the throttle position sensor
Table 2-1-2 Definition of feet of the throttle position sensor

No. ECU pin Function and definition
A J1-20 5V+
B J1-05 5V-
C J1-24 Throttle position signal output
(3) Foot circuit
第 27 页共 221 页
Fig. 2-1-6 Circuit diagram of the throttle position sensor
On the throttle body
This is an angle sensor with linear output and consists of two circular slide resistances and two
slide arms. The spindle of the slide arm and the throttle spindle are connected on the same axis. The
two ends of the slide resistance are added with a 5V power voltage US. When the throttle rotates, the
slide arm revolves also and moves on the slide resistance, and then transfers the potential UP of the
contact as output voltage. Therefore it is actually an angle potentiometer which outputs a voltage
signal in proportion to the throttle position.
4. Fault and judgement
1) Faults: engine without idle speed or unstable idle speed, hard acceleration or acceleration
failure, increased oil consumption and exhaust pollution.
2) Common causes:
① The poor contact between the sensor slip sheet and resistance results in that the signal is
interrupted or intermittent.
② Open circuit or short circuit in the sensor resistance or inner circuit causes no signal voltage
output or incorrect signal voltage.
③ The sensor slip sheet, resistance and other related parts are loose and distorted, causing an
incorrect signal voltage.
3) Notes for maintenance: pay attention to the installation position.
4) Measuring methods: refer to related content in Section II and Section III.
iii. Coolant temperature sensor
1. Sketch and foot
(1) Sketch
Fig. 2-1-7 Sketch of the coolant temperature sensor
(2) Foot definition
第 28 页共 221 页
Fig. 2-1-8 Feet of the coolant temperature sensor
Table 2-1-3 Definition of feet of the coolant temperature sensor

Function and
No. ECU pin
definition
1 J1-05 Earthing
2 Meter output
3 J1-43 Signal output
(3) Foot circuit
Fig. 2-1-9 Circuit diagram of the coolant temperature sensor
On the engine water outlet
This sensor is a NTC thermistor. The resistance will decrease with the rise of the coolant
temperature, but is not in a linear relation with that. The NTC thermistor is installed on the copper
surface, see Fig. 2-1-10.
Fig. 2-1-10 Profile of the coolant temperature sensor
4 故障现象及判断方法
第 29 页共 221 页
1) Faults: increased engine oil consumption and exhaust pollution, hard cold starting or starting
failure, intermittent misfire of engine and unstable idle speed
2) Common causes:
① Poor contact in the inner circuit of coolant temperature sensor causes no signal or abnormal
signal.
② The thermal element of coolant temperature sensor is aging, causing abnormal signal.
Measuring methods: refer to related content in Section II and Section III.
iv. Knock sensor
1. Sketch and foot
(1) Sketch
Fig. 2-1-11 Knock sensor Fig. 2-1-12 Profile of the knock sensor
1-knock pad, 2-housing, 3-piezoelectric ceramic body,
4-contact terminal, 5-electrical connector
(2) Foot definition
Fig. 2-1-13 Feet of the knock sensor
Table 2-1-4 Definition of feet of the knock sensor

1 J1-69 Signal +
2 J1-05 Signal -
第 30 页共 221 页
(3) Foot circuit
Fig. 2-1-14 Circuit diagram of the knock sensor
On the cylinder block between cylinder 2 and cylinder 3.
The knock sensor is a vibration acceleration sensor installed on the cylinder block. One or more
such sensors can be installed. The sensitive element of the sensor is a piezoelectric element. The
vibration of the engine cylinder block is transmitted to the piezoelectric crystal by the mass block in
the sensor. Because of the pressure from the vibration of the mass block, voltage is produced on the
two polar fronts and the piezoelectric crystal converts the vibration signal into alternate voltage signal
for output. The frequency of the vibration signal caused by engine knock is much higher than that of
the normal vibration signal of engine, so the ECU can distinguish knock signal or non knock signal
after the processing of signal from the knock sensor.
4. Notes
Do not let liquids like engine oil, coolant, brake fluid and water contact the sensor for a long time.
① Faults: poor acceleration
② Common cause: liquids like engine oil, coolant, brake fluid and water contact the sensor for a
long time, so the sensor is corrosive.
③ Measuring methods:
Refer to related content in Section II and Section III.
Fig. 2-1-15 Oxygen sensor

第 31 页共 221 页
v. Oxygen sensor
1. Sketch and foot
(1) Sketch
Fig. 2-1-16 Profile of the oxygen sensor

1-protection sleeve with a groove, 2-tube socket of oxygen sensor, 3-housing, 4-insulator,
5-electrode, 6-power terminal of heating resistor of sensor, 7-leaf spring, 8-heating resistor, 9-ceramic body,
10-multi-hole ceramic and plate electrode
(2) Foot definition

4 3 2 1
Fig. 2-1-17 Feet of the oxygen sensor
Warning: the positive and negative poles of the heating element of OPS+ oxygen sensor can not be
connected incorrectly.
Table 2-1-5 Definition of feet of the oxygen sensor

Terminal No. Terminal definition Lead color
1 Signal output low level Grey
2 Signal output high level Black
3 Negative pole of heating White
element
4 Positive pole of heating element Purple
(3) Foot circuit
第 32 页共 221 页
Fig. 2-1-18 Circuit diagram of the oxygen sensor
At the front end of the exhaust pipe.
The sensing element of the oxygen sensor is a ceramic tube with holes. The outside of the tube
wall is surrounded by the exhaust of engine and inside with air. The ceramic tube wall is a solid
electrolyte within which there is an electric heating tube as shown in Fig.3-17. The oxygen sensor
works by transforming the oxygen ion concentration difference inside and outside the ceramic tube to
voltage signal output. When the ceramic tube reaches 350℃, it will enjoy the feature of solid
electrolyte. The special material can make the oxygen ions freely pass the ceramic tube. And the
sensor just uses this feature to transform the concentration difference to potential difference and then
the voltage signal output is produced. If the concentration of the gas mixture is relatively high, that of
the oxygen ions inside and outside the ceramic tube will be higher and also the potential difference,
and then a large amount of oxygen ions move from the inside to the outside and the output voltage is
higher (nearly 800mV-1,000mV); if the concentration of the gas mixture is relatively low, that of the
oxygen ions inside and outside the ceramic tube will be lower and also the potential difference, and
then only a few oxygen ions move from the inside to the outside and the output voltage is lower
(nearly 100mV). The signal voltage will suddenly change at stoichiometric ratio (λ=1), see the above
figure.
4. Notes
① Do not make the cable metal buckle beside the oxygen sensor heated improperly, especially
after the engine stops.
② Do not use cleaning detergent, oil liquid or volatile solid during maintenance.
1) Faults: increased engine oil consumption and exhaust pollution, unstable idle speed, misfiring
and hesitation.
第 33 页共 221 页
Common causes:
① Lead poisoning due to use of leaded gasoline. Under a high temperature, the lead is attached
to the surface of the oxygen sensor, which results in that the sensor can not produce normal
signals.
② Carbon deposit. The carbon deposit on the platinum sheet of the oxygen sensor results in that
it can not produce normal voltage signals.
③ Poor contact or open circuit in the interior circuit in the oxygen sensor causes no output of
signal voltage.
④ Damage to the ceramic elements of oxygen sensor causes no normal signal voltage.
⑤ The burnout resistance wire of the oxygen sensor heater or its open circuit results in that the
oxygen sensor can not rapidly reach the normal working temperature.
2) Measuring methods:
Refer to Section II.
vi. Crankshaft position sensor
1. Sketch and foot
(1) Sketch
Fig. 2-1-19 Crankshaft position sensor Fig. 2-1-20 Profile of the crankshaft position
sensor
1-shielding line, 2-permanent magnet, 3-sensor

housing,
4-installation bracket, 5-soft magnet core, 6-coil, 7-air
gap, 8-gear ring
(2) Foot definition
第 34 页共 221 页
Fig. 2-1-21 Feet of the crankshaft position sensor
Table 2-1-6 Definition of feet of the crankshaft position sensor
1 Shielding line
2 J1-28 Signal low
3 J1-12 Signal high
(3) Foot circuit
Fig. 2-1-22 Circuit diagram of the crankshaft position sensor
On the plane of the fly wheel of the engine rear part。
The inductive speed sensor cooperates with the pulse wheel to offer information about engine
rotation speed and crankshaft upper dead center in distributorless ignition system. It is composed of a
permanent magnet and coil around it. The pulse wheel is a fluted disc installed on the crankshaft and
rotating with it. When the tooth top passes the end of the inductive speed sensor, the pulse wheel
made of ferromagnetic materials will cut the magnetic line of force of the permanent magnet in the
inductive speed sensor and then produce the induced voltage in the coil which is then output as
rotation speed signal.
第 35 页共 221 页
Fig. 2-1-23 Composition of the crankshaft position sensor
4. Notes for installation
The inductive speed sensor is installed by pressing in instead of hammering.
1) Faults: the engine can not start, or stops immediately after starting.
2) Common causes:
① Poor contact or open circuit of the sensor connector or interior circuit causes weak signal or
no signal output.
② Short circuit or earthing of the sensor induction coil causes weak signal or no signal output.
③ Loose installation of sensor or improper clearance causes weak signal or no signal output.
3) Notes for maintenance: it should be installed by pressing in instead of hammering.
vii. Electronic controller unit
1. Sketch and foot
(1) Sketch
Fig. 2-1-24 Engine ECU
(2) Foot definition
Fig. 2-1-25 Sketch of electronic injection ECU feet and definition of feet of the engine controller
Side of engine compartment
第 36 页共 221 页
ECU is the core of the engine electronic control system. The sensor offers signals for ECU
electronic control, and then the ECU controls the action of injector and ignition coil after interior
calculation so as to control the working of engine.
4 故障现象及判断方法
表 2-1-7 电喷 ECU 针脚定义

管脚号定义管脚号定义管脚号定义
J1-01 点火开关 J1-02 未使用 J1-03 车速
J1-04 2号5伏电源正 J1-05 1号5伏电源负 J1-06 氧传感器信号低
J1-07 未使用 J1-08 未使用 J1-09 中压开关信号
J1-10 未使用 J1-11 串口通讯 J1-12 曲轴58齿信号高
J1-13 未使用 J1-14 CAN线负端 J1-15 CAN线正端
J1-16 未使用 J1-17 电瓶电源1 J1-18 电瓶电源2
J1-19 未使用 J1-20 1号5伏电源正 J1-21 2号5伏电源负
J1-22 未使用 J1-23 未使用 J1-24 节气门位置信号
J1-25 冷却液温度计 J1-26 前蒸发器温度传感器 J1-27 进气温度
J1-28 曲轴58齿信号低 J1-29 维修灯 J1-30 未使用
J1-31 发动机故障诊断灯 J1-32 点火线圈A J1-33 怠速B相输出正
J1-34 怠速A相输出负 J1-35 加速度信号 J1-36 未使用
J1-37 未使用 J1-38 后氧传感器信号高 J1-39 空调请求开关
J1-40 未使用 J1-41 未使用 J1-42 进气压力
J1-43 冷却液温度 J1-44 未使用 J1-45 转速表
J1-46 空调压缩机离合器继电
J1-47 油泵继电器控制 J1-48 未使用
器控制
J1-49 未使用 J1-50 高速风扇继电器控制 J1-51 未使用
J1-52 点火线圈B J1-53 怠速A相输出负（低） J1-54 怠速A相输出正（高）
J1-55 1缸喷油嘴 J1-56 3缸喷油嘴 J1-57 未使用
J1-58 主继电器控制 J1-59 未使用 J1-60 未使用
J1-61 前氧传感器加热控制 J1-62 前氧传感器信号高 J1-63 碳罐电磁阀控制
J1-64 后氧传感器加热控制 J1-65 未使用 J1-66 未使用
J1-67 低速风扇继电器控制 J1-68 未使用 J1-69 爆震信号
J1-70 2缸喷油嘴 J1-71 4缸喷油嘴 J1-72 未使用
J1-73 系统地线
Table 2-1-7 Definition of feet of the electronic injection ECU

Pin
Definition Pin No. Definition Pin No. Definition
No.
J1-01 Ignition switch J1-02 Not used J1-03 Vehicle speed
#2 5V power supply #1 5V power supply Oxygen sensor
J1-04 J1-05 J1-06
(positive) (negative) signal low
Middle pressure
J1-07 Not used J1-08 Not used J1-09
switch signal
第 37 页共 221 页
Crankshaft 58
J1-10 Not used J1-11 Serial communication J1-12
tooth signal high
J1-13 Not used J1-14 CAN cable negative J1-15 CAN cable positive
Battery power
J1-16 Not used J1-17 Battery power supply 1 J1-18
supply 2
#1 5V power supply #2 5V power
J1-19 Not used J1-20 J1-21
(positive) supply (negative)
Throttle position
J1-22 Not used J1-23 Not used J1-24
signal
Front evaporator
J1-25 Coolant thermometer J1-26 J1-27 Intake temperature
temperature sensor
Crankshaft 58 tooth
J1-28 J1-29 Service lamp J1-30 Not used
signal low
Idle speed B
Engine fault diagnostic
J1-31 J1-32 Ignition coil A J1-33 phase output
lamp
positive
Idle speed A phase
J1-34 J1-35 Acceleration signal J1-36 Not used
output negative
Rear oxygen sensor
J1-37 Not used J1-38 J1-39 A/C request switch
signal high
J1-40 Not used J1-41 Not used J1-42 Intake pressure
J1-43 Coolant temperature J1-44 Not used J1-45 Tachometer
A/C compressor clutch
J1-46 J1-47 Oil pump relay control J1-48 Not used
relay control
High-speed fan relay
J1-49 Not used J1-50 J1-51 Not used
control
Idle speed A phase
Idle speed A phase
J1-52 Ignition coil B J1-53 J1-54 output positive
output negative (low)
(high)
Injection nozzle of Injection nozzle of
J1-55 J1-56 J1-57 Not used
cylinder 1 cylinder 3
J1-58 Main relay control J1-59 Not used J1-60 Not used
Front oxygen sensor Front oxygen sensor Canister solenoid
J1-61 J1-62 J1-63
heating control signal high valve control
Rear oxygen sensor
J1-64 J1-65 Not used J1-66 Not used
heating control
Low-speed fan relay
J1-67 J1-68 Not used J1-69 Knock signal
control
Injection nozzle of Injection nozzle of
J1-70 J1-71 J1-72 Not used
cylinder 2 cylinder 4
J1-73 System earth wire
① Faults: unstable idle speed, poor acceleration, failure of starting, too high idle speed, exhaust
gas out of limit, hard starting, invalid A/C, ineffective injector control and engine stop.
② Common causes: 1. The electrical overload of the externally connected device makes the
interior parts of the ECU burnout and ineffective; 2. Water entering the ECU causes a rusty circuit
board.
5. Notes for maintenance:
第 38 页共 221 页
① Do not dismantle ECU at will during maintenance;
② Firstly dismantle the battery harness connector more than 1 minute prior to removal of ECU;
③ Do not attach additional circuit to the connecting line of ECU.
④ Measuring methods: refer to related content in Section II and Section III.
viii. Electric fuel pump
1. Sketch and foot
(1) Sketch
Fig. 2-1-26 Electric fuel pump
(2) Foot definition
Fig. 2-1-27 Feet of the electric fuel pump
Table 2-1-8 Feet of the electric fuel pump

Pin Definition
1 Instrument cluster 24
2 Signal ground
3 Fuel pump relay 87
4 Ground
（3） Foot circuit
第 39 页共 221 页
Fig. 2-1-28 Circuit of the electric fuel pump
In the fuel tank
The electric fuel pump is composed of DC motor, vane pump and end cap (integrating check
valve, relief valve and anti-electromagnetic interference elements). The pump and the motor are
installed on the same axle and enclosed in the same housing. The pump and the motor are
surrounded by gasoline, and use fuel for heat emission and lubrication. The battery supplies power to
the electric fuel pump through the relay which only makes the circuit of electric fuel pump connected
when the engine is started and running. When the engine stops due to an accident, the fuel pump will
automatically stop operation.
The maximum pressure at the outlet of the electric fuel pump is decided by relief valve and is
always at 450-650kPa. The system adopts a no oil return system, thus the pressure of the whole fuel
system is decided by the fuel pressure regulator, always at 380kPa.
According to the demand of the engine, the electric fuel pump has different flows. For convenient
production, the electric fuel pump of the same structure adjusts the rotation speed of the motor by
adjusting the number of the turns of the coils and then further changes the flow. Thus please do not
install the electric fuel pump of a vehicle model to another model.
① The fuel pump should be taken out from the plastic packaging only during installation. The
protective cap can only be removed when the fuel pump is to be installed. The filter screen at the fuel
port must not be removed. Foreign materials entering the port or filter screen may cause damage to
the fuel pump. Please keep clean when installing the oil pipe.
②According to the demand of the engine, the electric fuel pump has different flows. Electric fuel
pump that is of the same appearance and can be installed is not necessarily proper. The part number
of the fuel pump used for maintenance must be the same with the original one; wrong replacement is
not allowed;
③ Do not operate the fuel pump in a dry state to avoid an accidental damage；
④ Pay attention to cleaning the fuel tank and pipeline and replace the fuel filter when the fuel
pump is needed to be replaced.
① Faults: loud noise during operation, poor acceleration, failure of starting (hard starting)
第 40 页共 221 页
② Common causes: use of low-quality fuel
ix. Electromagnetic fuel injector
1. Sketch and foot
(1) Sketch
Fig. 2-1-29 Electromagnetic nozzle
7 5 3 4 2 8
6
Fig. 2-1-30 Profile of fuel injector

1-nozzle body, 2-needle valve, 3-spring, 4-core, 5-solenoid coil, 6- wiring plug, 7- filter screen, 8-baffle plate
(2) Foot definition
Fig. 2-1-31 Feet of the electromagnetic nozzle
Table 2-1-8 Feet of the electromagnetic nozzle

Type No. ECU pin Function and definition
1 J1-02 Main relay output
Fuel injector 1
2 J1-55 Control signal of cylinder 1
Fuel injector 2
Fuel injector 3
Fuel injector 4
第 41 页共 221 页
(3) Foot circuit
Fig. 2-1-32 Circuit diagram of the electromagnetic fuel injector
On the intake manifold close to the intake valve。
ECU sends electric pulse to the coil of the fuel injector, forming magnetic force. When the
magnetic force increases enough to overcome the resultant force of return spring pressure, needle
valve gravity and friction, the needle valve will begin to go up and then the fuel injection will start.
When the injection pulse ends, the return spring pressure will make the needle valve close again.
1) Confirm trademark and product number.
2) Each fuel injector must be equipped with a specific plug which can not be mixed for use.
3) To be convenient for installation, clean non-silicon engine oil should be coated on the surface
of the upper O-ring connected with the fuel distribution pipe. Don’t let engine oil contaminate the inner
fuel injector and the injection orifice.
4) In the direction vertical to the fuel injector seat, the fuel injector should be installed into the
seat and should be fixed on the seat by clamp. Please pay attention to:
① Based on the locating method, the fuel injector clamp should be divided into the axial located
clamp and the axial-radial located clamp. Misuse should be avoided.
② During the installation for the axial located fuel injector, the mouth in the middle of the clamp
should be completely inserted into the slot of the fuel injector and the slots at the two sides of the
clamp should be completely inserted into the outer edge flanging of the fuel injector seat.
③ During the installation for the axial and radial located fuel injector, the axial-radial located
clamp should be used and the locating set of the fuel injector and the locating pin of the fuel injector
seat should be respectively placed at the corresponding slot on the locating clamp.
④ If the fuel injector has two clamp slots, they cannot be misused. The installation position
should follow the original. The fuel injector should be installed by hand and the use of tools like
hammer for knocking the fuel injector should be forbidden. When the fuel injector is removed or
re-installed, the O-ring should be replaced without damaging the seal face of the fuel injector. The
第 42 页共 221 页
supporting washer of the O-ring should not be pulled out of the fuel injector. The inlet end, O-ring,
supporting ring, injection orifice plate and electric plug should not be damaged during the installation.
Any one broken shouldn’t be used. After the installation for the fuel injector is finished, leakage test
should be done for the fuel distribution pipe assembly. The one without leakage should be qualified.
5) The part out of work should be removed by hand. The clamp of the fuel injector should be
removed first and then the fuel injector should be pulled out of the seat. And the seat should be kept
clean after removal.
Faults: poor idle speed, bad acceleration, failing to start (hard to start), etc.
Common causes: lacking of maintenance causes gum deposit in the inner fuel injector and then
the injector is out of work.
x. Fuel pressure regulator
1. Sketch
Fig. 2-1-33 Sketch of fuel pressure regulator Fig. 2-1-34 Fuel pressure regulator
1-to intake manifold, 2-spring, 3-valve, 4-fuel feed hole, 5-spill port,
6-diaphragm
On the fuel pump assembly
The fuel pressure regulator is separated into the upper chamber and the lower chamber by a
piece of flexible diaphragm made of rubber-fibre. The upper chamber, leading to the air, is equipped
with spring inside. The lower chamber is full of fuel from the fuel feed holes around the bottom of the
pressure regulator. The part under the diaphragm receives the fuel pressure while the part above
receives air pressure and spring pressure. The diaphragm can be distorted to drive the valve seat,
opening or closing the valve. However, the distortion is very small and the force of the spring can be
considered to remain unchanged, therefore, the opening and closing of the valve is mainly decided by
difference between the fuel pressure of the lower chamber and the air pressure of the upper chamber.
For example, at first the valve is closed, and along with the increase of the fuel pressure, the pressure
difference between the upper chamber and the lower chamber increases, finally causing the
diaphragm to be jacked up by the fuel pressure, and then the valve opens. The fuel flows back to the
第 43 页共 221 页
fuel tank through the spill port at the center of the pressure regulator and the fuel pressure decreases
until the valve is closed. In such a way, the difference between the pressure of the fuel system and
the air pressure can remain unchanged on the whole even if the working condition of the engine is
changed.
During the repair, the following should be noticed: ① high-pressure gas cannot be used for
impacting the diaphragm element; ② strongly corrosive liquid cannot be used for cleaning; ③
external force cannot be applied to it to avoid distortion.
1) Faults: difficulty in starting, unstable idle speed of the engine, increased pollution to the air
2) Common causes:
① Dirty valve or leakage caused by loose or broken pipe connection
② Short circuit or open circuit of the solenoid valve coil or inside it, making the solenoid valve
unable to open
3) Measuring methods:
xi. Steel fuel distribution pipe assembly
1. Sketch, as shown in Fig. 2-1-35
Fig. 2-1-35 Fuel distribution pipe assembly
On the intake manifold
Fuel distribution pipe assembly is composed of fuel distribution pipe, fuel injector and fuel
injector clamp, used for storing and distributing fuel.
1) The connection between intake pipe and rubber pipe should be tightened with clip, the model
of which should match the rubber pipe to ensure the seal for the connection between the intake pipe
and the rubber pipe.
2) There should be no crack, scar, groove, burr or rust on the intake pipe wall.
3) Clean lubricant should be used to lubricate the lower O-ring of the fuel injector before the fuel
第 44 页共 221 页
distribution pipe assembly is installed.
xii. Idle speed actuator stepper motor
1. Sketch and foot
(1) Sketch
Fig. 2-1-36 Idle speed actuator stepper motor
(2) Foot definition
Fig. 2-1-37 Feet of the idle speed actuator stepper motor
Table 2-1-9 Feet of the idle speed actuator stepper motor

Function and
No. ECU pin
definition
1 J1-34 B-
2 J1-33 B+
3 J1-53 A-
4 J1-54 A+
(3) Foot circuit
Fig. 2-1-38 Circuit diagram of the idle speed actuator stepper motor
On the throttle body
Stepper motor is a mini-motor, which consists of many steel stators in a circle and a rotor, as
第 45 页共 221 页
shown in the figure below. Each steel stator is wound with a coil and the rotor is a permanent magnet,
the center of which is a nut. All the stator coils are always electrified. Once the current direction of a
coil is changed, the rotor will pass by an angle. When each stator coil changes the current direction in
proper sequence, a rotating magnetic field will form to make the rotator made of permanent magnet
rotate according to some direction. If the sequence of the current direction is reversed, the rotating
direction of the rotator will be also reversed. The nut connected to the rotator center will drive a stem.
Designed not to rotate, the screw rod can only move at the axial direction, making another name,
linear axis, for itself. Therefore, the end of the stem, a choke plug, can be withdrawn or extended to
increase or decrease the sectional area of the bypass intake passage of the idle speed actuator until
it is blocked. When the current direction of a coil is changed, the rotator will pass by a certain angle
which is called step length with the numerical value equaling to 360°/the number of the stators or the
coils. The step length of this stepper motor rotator is 15°. Correspondingly, the distance of the step
the screw rod moves is fixed. ECU controls the steps the stepper motor moves through controlling the
number of times of changing the coil current direction, to adjust the sectional area of the bypass
passage and the air flow which has a linear relation with the step length on the whole. As shown in
the following figure, a spring is behind the choke plug of the screw rod end. The force which can be
used at the extending direction of the choke plug is the force of the stepper motor plus the spring
force. The force which can be used at the withdrawing direction of the choke plug is the force of the
stepper motor minus the spring force.
Fig. 2-1-39 Profile of the idle speed stepper motor

1-connector, 2-housing, 3-permanent magnet, 4-rotator
5-auxilliary air passage, 6-rotating valve
① No force can be exerted at the axial direction to press in or pull out the axis；
② Before the idle regulator with stepper motor is installed into the throttle body, its axis should
be completely withdrawn.
③ The bypass air passage should be cleaned regularly.
④ After accumulator or ECU is removed, self-learning should be done on the stepper motor. The
self-learning method of M7 system is: to open ignition switch and not to start engine at once which
should be started after 5s. If the idle speed of the engine is bad, the above processes should be
repeated.
① Faults: idle speed is too high or the engine stops at idle speed.
第 46 页共 221 页
② Common causes: part of the bypass air passage is blocked by dust or oil gas deposit,
resulting in abnormal idle speed adjustment of the stepper motor.
xiii. Two-spark ignition coil
1. Sketch and foot
(1) Sketch
Fig. 2-1-40 Ignition coil
(2) Foot definition
Fig. 2-1-41 Ignition coil feet
Table 2-1-10 Ignition coil feet

1 J1-32 Control signal of cylinder 1 and 4
2 J1-01 Ignition switch power +
3 J1-52 Control signal of cylinder 2 and 3
(3) Foot circuit
Fig. 2-1-42 Circuit diagram of the ignition coil
第 47 页共 221 页
On the engine
The ignition coil is composed of primary winding, secondary winding, core, housing, etc. When the
voltage of the battery is added to the primary winding, the primary winding will be electrified. If ECU
cuts off the circuit of the primary winding, electrification will be stopped and high voltage will be
induced in the secondary winding.
1) Faults: the idle speed of the engine is unstable, or the engine stops intermittently or can not
start.
2) Common causes:
① Short circuit, open circuit or earth of the ignition coil makes the ignition coil produce too low
voltage or not produce high voltage, causing that the ignition energy is not enough or the ignition
doesn’t happen.
② The aging of ignition coil insulation material weakens the insulation performance and then the
spark of the ignition system will become weak or the ignition system will not ignite because of the
leakage of the ignition coil.
3) Notes for repair: short-circuit spark test should be prohibited for testing the ignition during the
repair, to avoid damaging electronic control unit.
4) Measuring methods: refer to related content in Section II and Section III.
xv. CanCV canister control valve

1. Sketch and foot
(1) Sketch
Fig. 2-1-43 CanCV canister control valve
（2） Foot definition
第 48 页共 221 页
Fig. 2-1-44 Feet of CanCV canister control valve
Table 2-1-12 Feet definition of CanCV canister control valve

2 J1-63 Canister solenoid valve control
(3) Foot circuit
Fig. 2-1-45 Circuit diagram of the CanCV canister control valve
On the vacuum pipeline of the intake manifold
CanCV canister control valve consists of solenoid coil, armature, valve, etc. At the inlet is the
filter screen. On one hand the air flow through the CanCV canister control valve is connected with the
duty ratio of the electric pulse which ECU outputs to the CanCV canister control valve, and on the
other hand it is also connected with pressure difference between the inlet and the outlet of the CanCV
canister control valve. Without electric pulse, the CanCV canister control valve will be closed.
Fig. 2-1-46 Profile of the CanCV canister control valve

1-pipe connection, 2-valve, 3-core
4-return spring, 5-solenoid coil
第 49 页共 221 页
4. Notes for installation: see Fig. 2-1-47 for connection of CanCV canister control valve,
canister and intake manifold.
① The airflow direction should meet the requirement during the installation.
② When black particles are found in the valve body to make the control valve stop working and
the control valve needs replacing, please check the canister.
③ Do not make liquid like water, oil enter the valve during the repair.
④ To avoid the transmission of the solid-borne noise, CanCV canister control valve should be
installed on the hose in a hanging way.
① Faults: excessive accumulation of gasoline vapor in the charcoal canister with the function out
of work causes gasoline leakage, polluting the environment.
② Common causes: Foreign material entering the valve causes rusting or weakens tightness.
③ Measuring methods: refer to related content in Section II and Section III.
Fig. 2-1-47 Schematic diagram of CanCV canister control valve working

1-from fuel tank, 2-canister, 3-air, 4-CanCV canister control valve, 5-to intake manifold, 6-throttle, 7-engine
xvi. Charcoal canister
1. Sketch
第 50 页共 221 页
Fig. 2-1-48 Charcoal canister
At the lower left of engine compartment
The canister functions to absorb gasoline vapor produced in fuel tank and make the passing air,
under the vacuum suction of the intake manifold, take away the gasoline vapor into the intake
manifold for combustion when the engine works and the canister vent control valve is opened by the
computer.
1) Faults: vehicle fuel consumption and air pollution are increased.
2) Common causes: the common fault of the canister is that dirty or broken canister can not
absorb gasoline vapor or the vent is hindered, resulting in that the fuel vapor can not be retrieved.
3) Fault inspection and repair: the inspection and repair method for the canister is as follows:
① Remove the canister and check if it is broken.
② Unplug the canister air pipe;
③ Start the engine. If the engine temperature reaches 60℃ or above, properly increase the
rotation speed of the engine (about 3500 r/min) and check if there is vacuum at the canister air pipe
connection (if suction exists). And the normal condition is that vacuum exists.
Abnormal result indicates that the canister is blocked and needs replacing.
第 51 页共 221 页
Section II Fault Diagnosis
I. Basic principles of fault diagnosis for electronic injection system
1. Fault record
The electronic control unit keeps monitoring sensor, actuator, relevant circuit, malfunction
indicator lamp, battery voltage and even itself and does reliability inspection on output signal of
sensor, drive signal of actuator and inner signal (like oxygen closed-loop control, knock control, idle
rotation speed control and battery voltage control). Once the electronic control unit finds fault exists at
a certain circle or some signal value is unreliable, it will set fault record in the fault memory of RAM.
Fault record is stored in the form of DTC and is shown in the sequence in which fault appears. Based
on the appearing frequency of fault, fault can be divided into stable-state fault and random fault (for
example, the fault is caused by open circuit of harness for a short time or by bad contact of interface).
2. Fault status
If the duration of an identified fault exceeds the set stabilization time for the first time, ECU will
consider it as a stable fault and will store it as “stable-state fault”. If this fault disappears, ECU will
store it as “random fault” and “nonexistent”. If this fault is identified again, it should still be “random
fault” but the “existing” historical fault will not influence the normal operation of the engine.
3. Type of fault
In this system are following types of fault:
a. Short circuit to the positive pole of the power;
b. Short circuit to the ground;
c. Open circuit (at the situation that the input stage has pull-up or pull-down resistor, ECU will
identify the fault of open circuit at the input port as the fault of short circuit of the input port to the
positive pole of the power or the fault of short circuit to the ground);
d. Unreliable signal
4. Limping home
If the duration of some important identified faults exceeds the set stabilization time, ECU will
adopt proper software policy, such as closing some control functions like closed-loop control of
oxygen sensor, setting value to replace some data which is considered as unreliable one. And at this
moment, though the working status of the engine is relatively bad, the vehicle could drive. And then
the vehicle could limp home or to the service station for inspection and repair, to avoid the
embarrassment that the vehicle breaks down on the expressway or in the wild. Once the fault is
identified to have disappeared, the normal data should be used again.
5. Fault warning
The vehicle with this system is equipped with malfunction indicator lamp, through the light of
which, ECU will send out warning at the corresponding faulty locations when fault happens to some
important parts like ECU, manifold absolute pressure sensor, throttle position sensor, coolant
temperature sensor, knock sensor, oxygen sensor, fuel injector, two drive stages of idle speed
actuator stepper motor, canister solenoid valve and fan relay, until the fault is reset.
6. Reading fault
第 52 页共 221 页
Fault record could be called out from electronic control unit by diagnostic instrument. If the fault
involves the function of the regulator for the mixture proportion of fuel and air, the engine could read
the fault record only after rotating for some time.
After the fault is eliminated, the fault record in the memory should be cleared by means of:
a. Using diagnostic instrument to clear the fault record through the order “reset fault memory”;
b. Unpluging ECU connector or removing battery wire to clear the fault record in the external
RAM.
7. Finding fault:
After the fault record is gained through the above means, the part where the fault happens
could only be known roughly, which does not mean that the fault is found, because a fault could
be caused by a broken electronic unit (like sensor, actuator or ECU), or open circuit, short circuit
of the wire to ground or battery positive pole, or even the machinery fault. The fault appears
inside but it has all kinds of expressions outside. After the fault is found, the diagnostic
instrument should be used to check if there is fault record which could be also checked according
to the flash code and then the relevant fault should be eliminated based on the fault record.
II. Basic processes for fault diagnosis based on DTC
1. Throttle position sensor
Table 2-2-1 Throttle position sensor DTC and diagnosis procedure

DTC Position or type of fault
P0122 Low voltage of throttle position sensor
P0123 High voltage of throttle position sensor
Inspection Follow-up
S/N Operating steps
result steps
1 Place ignition switch at “ON”. Next step
Unplug the throttle position sensor connector on Yes Next step
harness and use multimeter to check if the voltage
2
value between foot (1) and foot (2) on the connector is No 5
about 5V.
Use multimeter to check if the resistance value between Yes Next step
3 foot (1) and foot (2) of the sensor is between 1.6 and 2.4 Replace
KΩ. No
sensor
Slowly move the throttle position sensor from one end to Replace
the other and at the same time use multimeter to check Yes
sensor
4 if there is open circuit or short circuit between foot (1)(-)
and foot (3) (+) of the throttle position sensor or if the No Replace ECU
resistance value between them jumps.
Connect adapter between ECU and harness and use Repair or
multimeter to check if there is open circuit or short circuit Yes replace
5
from foot J1-20, J1-05 and J1-24 of ECU respectively to harness
foot (1), (2) and (3) of the sensor connector. No Replace ECU
第 53 页共 221 页
2. Knock sensor
Table 2-2-2 Knock sensor DTC and diagnosis procedure

P0325 Circuit fault of knock sensor 1
Inspectio Follow-up
S/N Operating steps
n result steps
1 Close ignition switch and engine doesn’t rotate. Next step
Unplug the knock sensor connector on harness and use Yes Next step
2 multimeter to check if the resistance value between foot Replace
(1) and foot (2) of the knock sensor is higher than 1M. No
sensor
Gently hit the surrounding of the knock sensor with a Yes Next step
small hammer and use multimeter to check if there is
3 Replace
AC signal output between foot (1) and foot (2) of the No
sensor. sensor
4 Put through ignition switch and do not start engine. Next step
Repair or
Connect adapter between ECU and harness and use
Yes replace
multimeter to check if there is open circuit or short circuit
5 harness
from foot J1-05 and foot J1-69 of ECU respectively to
foot 1 and foot 2 of the sensor connector. No Replace ECU
3. Intake pressure and intake temperature sensor
Table 2-2-3 Intake pressure and intake temperature sensor DTC and diagnosis procedure
P0107 The voltage of the intake pressure part of the intake pressure and intake
temperature sensor is low.
P0108 The voltage of the intake pressure part of the intake pressure and intake
temperature sensor is high.
Inspection
S/N Operating steps Follow-up steps
result
Unplug the intake pressure and intake temperature sensor
Yes 4
connector on harness and use multimeter to check if the
2
voltage value between foot (1) and foot (3) of the
No Next step
connector is about 5V.
Check if there is open circuit or short circuit from foot Repair or replace
J1-21, J1-27 and J1-42 of ECU respectively to foot (1), (3) Yes
3 harness
and (4) of the sensor connector.
No Next step
4 Put through ignition switch and do not start engine. Next step
Apply the neutral position, start engine and make it
operate at idle speed. Step accelerator down to nearly the
Yes Replace ECU
full and at the same time, through adapter, use multimeter
5
to check if the voltage between foot (4) and foot (1) of the
sensor, namely, foot J1-42 and foot J1-21 of ECU, Replace ECU, replace
No
gradually increases to 4V or so. sensor

The voltage of the intake temperature part of the intake pressure and intake temperature
P0112
sensor is low.
The voltage of the intake temperature part of the intake pressure and intake temperature
P0113
sensor is high.
第 54 页共 221 页
Inspection
result
Connect diagnostic instrument and adapter and place ignition
1 Next step
switch at “ON”.
Observe if the term of data stream, “intake temperature”,
corresponds to the temperature in the intake pipe (specific Yes To step 5
2 numerical value is related to the engine temperature at that time).
Note: if the numerical value shown is always -40℃, there might
No Next step
be fault of open circuit.
Unplug the intake temperature sensor connector on harness and
use multimeter to check if the resistance value between foot 1# Yes Next step
3
and foot 2# of the sensor matches its temperature (please refer to
the relevant part in the workshop manual for details). No Replace sensor
Unplug the intake temperature sensor connector on harness and Yes To step 6
4 use multimeter to check if the voltage value between foot 1# and
foot 2# of the connector is about 5V. No Next step
Repair or replace
Yes
Check if the circuit from foot 21# and 27# of ECU respectively to harness
5
foot 1# and 2# of the sensor connector is short to the ground.
No Next step
Start engine and make it operate at idle speed. Observe the Diagnosis
numerical value change of the “intake temperature” on the Yes
assistance
6 diagnostic instrument and the numerical value shown at this
moment should increase with the rising of the engine intake No Replace sensor
temperature.
4. Oxygen sensor
Table 2-2-4 Oxygen sensor DTC and diagnosis procedure

P0133 Oxygen sensor responds slowly.
P0132 High voltage of oxygen sensor circuit (front)
P0134 Oxygen sensor is detected to be inactive (front).
P0135 Heating fault of oxygen sensor (front)
P0137 Short circuit of oxygen sensor (rear)
P0138 High voltage or short circuit of oxygen sensor
circuit (rear)
P0140 Oxygen sensor is detected to be inactive or
short circuit of oxygen sensor is detected. (rear)
P0141 Heating fault of oxygen sensor (rear)
Inspectio Follow-up
S/N Operating steps
n result steps
Unplug the oxygen sensor connector on harness and Yes Next step
use multimeter to check if there is battery voltage of
2
about 12V between foot (1) (+) and foot (2) (-) of the
No 4
connector.
Use multimeter to check if the resistance value between Replace
Yes
3 foot (1) and foot (2) of oxygen sensor is between 6 and sensor
25. No Next step
Check if the fuse in the heating circuit of oxygen sensor Yes Replace fuse
4
blows out. No Next step
Use multimeter to check if there is open circuit or short Repair or
circuit between foot (1) of the oxygen sensor connector Yes replace
5 and foot J1-02 of main relay, and between foot (2) of the harness
sensor connector and foot J1-61 (front)/foot J1-64 (rear)
No Next step
of ECU.
第 55 页共 221 页
Plug the oxygen sensor connector on harness, apply
the neutral position, start engine and make it operate at
6 Next step
idle speed until coolant temperature reaches normal
value.
Unplug the oxygen sensor connector on harness and Yes Next step
use multimeter to check if there is output voltage of
7 Replace
0.1-0.9V between foot (4) (+) and foot (3) (-) of the No
sensor. sensor
8 from foot J1-06 and foot J1-62 (front)/J1-38(rear) of harness
ECU respectively to foot (3) and foot (4) of the sensor.
No Replace ECU
5. Coolant temperature sensor
Table 2-2-5 Engine coolant temperature sensor DTC and diagnosis procedure
P0116 Engine coolant temperature circuit
range/performance
P0117 Low input of engine coolant temperature circuit
P0118 High input of engine coolant temperature circuit
P0119 Engine coolant temperature circuit input
interrupted intermittently
Inspectio
n result
Unplug the coolant temperature sensor connector on
Yes Next step
harness and use multimeter to check if the voltage
2
value between foot (1) (+) and foot (3) (-) of the
No 4
connector is about 5V.
Use multimeter to check if the resistance value Yes Replace ECU
between foot (1) and foot (3) of the sensor matches
3
its temperature (please refer to the relevant part in
No Replace sensor
the workshop manual for details).
Connect adapter between ECU and harness and use Repair or replace
Yes
multimeter to check if there is open circuit or short harness
4 circuit from foot J1-05 and foot J1-43 of ECU
respectively to foot (1) and foot (3) of the sensor No Replace ECU
connector.
第 56 页共 221 页
6. Fuel injector
Table 2-2-6 Fuel injector DTC and diagnosis procedure

P0261 The fuel injector circuit of cylinder 1 is low.
P0264 The fuel injector circuit of cylinder 2 is low
P0262 The fuel injector circuit of cylinder 1 is high
S/N Operating steps
result steps
1 Close ignition switch and engine doesn’t rotate.
Successively unplug all the electromagnetic fuel injector
connectors on harness and connect two feet of multimeter
2
respectively with foot (1) (+) of the connector and the
engine earth point.
Place ignition switch at “ON”. Observe if the battery Yes Yes
voltage shown on the multimeter is about 12V and lasts Yes for all Yes for all
3
about 1s at the moment when the ignition switch is got
through. No No
Use multimeter to check successively if there is open
Yes Yes
circuit or short circuit between foot J1-02 of main relay
4
output end and foot (1) of each electromagnetic fuel
No No
injector.
Repair or replace fuel pump relay and main relay and their Next step
5
circuits.
multimeter to successively check if there is open circuit or Yes replace
6 short circuit between foot J1-55, J1-70, J1-56, J1-71 of harness
ECU and foot (2) of each corresponding electromagnetic
No Next step
fuel injector connector on harness.
Yes Repeat 7
Use multimeter to check successively if the resistance Yes for all Next step
7 between foot (1) and foot (2) of the electromagnetic fuel
Replace
injector is between 12 and 16Ω at 20℃.
No electromagneti
c fuel injector
Plug all the electromagnetic fuel injector connectors again,
place gear at the neutral position, start engine and make it Yes Repeat 8
operate at idle speed. Successively unplug each
8
electromagnetic fuel injector connector on harness. And
observe if the vibration of the engine is intensified when No Replace ECU
each connector is unplugged.
Table 2-2-7 Fuel injector DTC and diagnosis procedure

第 57 页共 221 页
P0444 Open circuit of CanCV canister control valve of the evaporative emission control
system
P0445 Short circuit of CanCV canister control valve of the evaporative emission control
system
Inspectio
n result
Start engine and make it operate at idle speed until
1 the engine coolant temperature reaches normal Next step
value.
Unplug the CanCV canister control valve connector
Yes Next step
on harness and use multimeter to check if there is
2
battery voltage of about 12V between two feet of
No 5 (check live wire)
the connector.
Plug again the CanCV canister control valve
connector on harness and increase the rotation Yes Next step
3 speed of the engine to 1500 r/min. Touch the valve
body with hand and check if there is slight vibration No 7 (check earth wire)
and impact of the CanCV canister control valve.
4 between foot (1) and foot (2) of the CanCV canister
control valve is 22-30Ω. Replace CanCV
No
canister control valve
Use multimeter to check if there is open circuit or Repair or replace
Yes
5 short circuit between foot J1-02 of main relay and harness
foot (1) of CanCV canister control valve. No Next step
6 Repair or replace main relay and its circuit. Next step
Close engine, connect adapter between ECU and
Repair or replace
harness and use multimeter to check if there is Yes
harness
7 open circuit or short circuit between foot J1-63 of
ECU and foot (2) of CanCV canister control valve
No Replace ECU
connector.
7. CanCV canister control valve drive stage
Table 2-2-8 CanCV canister control valve DTC and diagnosis procedure
第 58 页共 221 页
P0444 Open circuit of CanCV canister control valve of the evaporative emission control
system
P0445 Short circuit of CanCV canister control valve of the evaporative emission control
system
Inspectio
n result
1 the engine coolant temperature reaches normal Next step
value.
Unplug the CanCV canister control valve connector Yes Next step
on harness and use multimeter to check if there is
2
battery voltage of about 12V between two feet of
No 5 (check live wire)
the connector.
Plug again the CanCV canister control valve
connector on harness and increase the rotation Yes Next step
3 speed of the engine to 1500 r/min. Touch the valve
body with hand and check if there is slight vibration No 7 (check earth wire)
and impact of the CanCV canister control valve.
4 between foot (1) and foot (2) of the CanCV canister
control valve is 22-30Ω. Replace CanCV
No
canister control valve
Use multimeter to check if there is open circuit or Repair or replace
Yes
5 short circuit between foot J1-02 of main relay and harness
foot (1) of CanCV canister control valve. No Next step
6 Repair or replace main relay and its circuit. Next step
Close engine, connect adapter between ECU and
Repair or replace
harness and use multimeter to check if there is Yes
harness
7 open circuit or short circuit between foot J1-63 of
ECU and foot (2) of CanCV canister control valve
No Replace ECU
connector.
8. Malfunction indicator lamp (MIL) drive stage
Table 2-2-9 Malfunction indicator lamp (MIL) drive stage DTC and diagnosis procedure

P0650 Malfunction indicator lamp (MIL) control circuit
Inspecti Follow-up
S/N Operating steps
on result steps
Remove instrument panel, pull out malfunction indicator Yes Next step
lamp bulb and use multimeter to check if there is battery
2
voltage of about 12V at the malfunction indicator lamp 5 (check live
No
socket. wire)
第 59 页共 221 页
Use multimeter to check if the instrument panel MIL bulb Yes Next step
3 works normally. No Replace bulb
Connect adapter between ECU and harness, and use Repair or
4
between foot J1-31 of ECU and the input connector of harness
malfunction indicator lamp. No Replace ECU
Check if the fuse in the heating circuit of the oxygen Yes Replace fuse
5
sensor circuit blows out. No Next step
Use multimeter to check if there is open circuit or short Repair or
circuit between foot 87 of main relay and foot (1) of Yes replace
6
malfunction indicator lamp socket. harness
No Next step
7 Repair or replace main relay and its circuit.
9. Drive stage of coil 1/2 of stepper motor
Table 2-2-10 Diagnosis procedure for drive stage of coil 1/2 of stepper motor
Inspectio Follow-up
S/N Operating steps
n result steps
1 Get through ignition switch and do not start engine. Next step
Unplug the idle speed actuator stepper motor Yes Next step
connector on harness and use multimeter to check if
Replace idle
2 there is resistance of 40～80Ω between foot 1 and
No speed
foot 2, and between foot 3 and foot 4 of the idle
actuator
speed actuator stepper motor.
Use multimeter to check if the resistance between Yes Next step
foot 1 and foot 2, and between foot 3 and foot 4 of Replace idle
3 the idle speed actuator stepper motor is infinite. No speed
actuator
Use multimeter to check if there is battery voltage of Replace idle
about 12V between foot 1 and foot 2, between foot 3 Yes speed
4
and foot 4 of the idle speed actuator stepper motor actuator
connector on harness is infinite. No Next step
Connect adapter between ECU and harness and Repair or
5 use multimeter to check if there is open circuit or Yes replace
short circuit from foot J1-34, J1-33, J1-53 and J1-54 harness
第 60 页共 221 页
of ECU respectively to foot 1, 2, 3, and 4 of the idle
No Replace ECU
speed actuator stepper motor connector on harness.
10. Crankshaft position sensor
Table 2-2-10 Crankshaft position sensor DTC and diagnosis procedure

P0335 Crankshaft position sensor fault
P0337 Improper singal fault of Crankshaft position
sensor
Inspection
result
Connect diagnostic instrument
1 and adapter, and place ignition Next step
switch at “OFF”.
Pull out the plug on the crankshaft Yes
position sensor and check the
Next step
2 resistance between foot 2# and
No Repalce sensor
3#for 770-950Ω at 20℃with a
multimeter.
Check if the circuit from connector Yes
2# and 3# of the crankshaft
Repair or replace harness
3 position sensor to 34# and 15# of
No Next step
ECU is open circuit or short to
power or to ground.
Check if the flywheel signal panel Yes
4 Diagnosis assistance
is OK. No
第 61 页共 221 页
11. Vehicle fuel system fault
Table 2-2-12 Vehicle fuel system DTC and diagnosis procedure
Air/fuel ratio closed-loop control
P0171
self-adaption exceeds the upper limit.
S/N Operating steps Inspection result Follow-up steps
Connect diagnostic instrument and adapter, and
1 Next step
place ignition switch at “ON”.
coolant temperature reaches normal value. Under Yes Next step
all working conditions, observe the numerical value
2 change of “oxygen sensor voltage” shown on
diagnostic instrument and check if the numerical Diagnosis
No
value is kept around 100mV for a long time under assistance
some working conditions.
Connect the intake pipe end of the fuel system with Yes Next step
fuel pressure indicator and observe if the fuel Check and
3
pressure is kept around 380kPa under all working No repair fuel
conditions. system
Check if the circuit from foot 62# and foot 38# of Repair or
Yes
ECU respectively to foot A# (relative to the grey replace harness
4 connecting line of oxygen sensor) and foot B#
(relative to the black connecting line of oxygen No Next step
sensor) is short to the ground.
A. Check if there is serious leakage in air intake Do check and
system; Yes repair based on
B. Check if fuel injector is blocked; diagnosis
5
C. Check if the clearance of spark plug is too big;
Diagnosis
D. Check if the distributor resistance is too large; No
assistance
E. Check if the valve clearance is too small.
Table 2-2-13 Vehicle fuel system DTC and diagnosis procedure
Air/fuel ratio closed-loop control
P0172 self-adaption exceeds the lower
limit.
Inspection
result
Connect diagnostic instrument and adapter, and
1 Next step
Start engine and make it operate at idle speed
until coolant temperature reaches normal value. Yes Next step
Under all working conditions, observe the
2 numerical value change of “oxygen sensor
voltage” shown on diagnostic instrument and
No Diagnosis assistance
check if the numerical value is kept around
900mV for a long time under some working
第 62 页共 221 页
conditions.
Connect the intake pipe end of the fuel system Yes Next step
with fuel pressure indicator and observe if the
3 Check and repair fuel
fuel pressure is kept around 350kPa under all No
the working conditions. system
Check if the circuit from foot 62# and foot 38# of Repair or replace
ECU respectively to foot A# (relative to the grey Yes
harness
4 connecting line of oxygen sensor) and foot B#
(relative to the black connecting line of oxygen No Next step
sensor) is short to the power.
A. If there is drop leak of fuel injector; Do check and repair
B. If there is leakage of exhaust pipe; Yes
based on diagnosis
5 C. If ignition timing is not correct;
D. If intake valve guide is broken; No Diagnosis assistance
E. If valve clearance is too small;
12. Vehicle speed sensor
Table 2-2-14 Vehicle speed sensor DTC and diagnosis procedure

P0500 Vehicle speed sensor fault (SUNNY
TEK electronic injection system)
P0502 Vehicle speed sensor fault (DELPHI
electronic injection system)
Inspection
result
1 Connect diagnostic instrument and adapter, and Next step
2 Check if the pointer of speedometer works Yes Next step
normally.
No Check instrument
circuit
3 Check if the voltage between the earth wire of Yes Next step
connecting plug of the vehicle speed sensor and No Check vehicle speed
the power supply line is at -14V. sensor harness
4 Check if the vehicle speed sensor works Yes Next step
normally. No Replace vehicle speed
sensor
5 Check if the circuit between the vehicle speed Yes Repair or replace
sensor signal line and foot 3 of ECU is open or if harness
it is a short circuit to the power or the ground. No Diagnosis assistance
Remarks: if DTCs of intake pressure and temperature sensor, CanCV canister control valve drive
circuit, oxygen sensor, etc. do not happen together, the above diagnosis procedure should apply. If
relevant DTCs exist together, please deal with the other faults first and then do check and repair
according to the above procedure.
第 63 页共 221 页
Section III Diagnosis Procedure for Fault Elimination Based on
Vehicle Fault Phenomenon
I. Preliminary inspection
Before starting the diagnosis procedure for fault elimination based on the engine fault
phenomenon, the preliminary inspection should be carried out first:
1. Ensure that the engine fault indicator is normal;
2. Confirm no fault information record through check by a diagnostic instrument;
3. Confirm the fault phenomenon complained by the vehicle owner exists and in which condition
the fault happens;
4. Check if there is leakage in the fuel pipeline;
5. Check if the vacuum pipeline is broken, twisted or correctly connected;
6. Check if the intake pipeline is blocked, leaking, flattened or damaged;
7. Check if the high-tension line of the ignition system is fractured and aged, and if the ignition
order is correct;
8. Check if the harness is well earthed;
9. Check if there is looseness or poor contact of all the connectors of sensors and actuators.
Important notes:
If the phenomenon mentioned above exist, carry out maintenance to the faults first, otherwise, the
subsequent fault diagnosis and maintenance will be affected.
Diagnosis assistance:
1. Confirm there is no fault records of the engine;
2. Confirm the phenomenon complained exists;
3. No abnormal conditions are found after inspection following the steps above;
4. Do not ignore the effects of vehicle maintenance, cylinder pressure, mechanical ignition timing,
fuel oil, and etc.
5. Replace the ECU and have a test.
If the fault can be eliminated now, the fault is in ECU, otherwise, replace back the original ECU,
repeat the process and carry out the check and repair again.
II. Fault diagnosis procedure
i. The engine doesn’t run or runs slowly during starting
General fault locations: 1. battery; 2. starting motor; 3. harness or ignition switch; 4. mechanical part
of engine.
General diagnosis procedure:
第 64 页共 221 页
Table 2-3-1 Diagnosis procedure for phenomenon that engine doesn’t run or runs slowly during
starting
Operating steps Inspectio Follow-up steps

S/N
n result
Check the voltage between the two terminals of the Yes Next step
1 battery with a multimeter to see if it is 8-12V when the Replace the
No
engine starts. battery
Keep the ignition switch at the starting position and Yes Next step
2 check the positive terminal of the starting motor with a Repair or replace
No
multimeter to see if the voltage is above 8V. the harness
Repair or replace
Dismantle the starting motor and check its working
Yes the starting
3 condition. Focus on checking if there is an open circuit
motor
or the starting motor is stuck due to poor lubrication.
No Next step
Replace with
If the fault happens in winter only, check if the
lubricant of
resistance of the starting motor is overlarge due to Yes
4 proper brand and
improper selection of the engine lubricants and gear box
number
oil.
No Next step
Check and repair
the internal
Check if the overlarge internal mechanical resistance of Yes
resistance of the
5 the engine leads to the failure of rotation or slow rotation
engine
of the starting motor.
Repeat the steps
No
above
ii. The engine can be drawn but not start successfully during starting
General fault locations: 1. no oil in the fuel tank; 2. fuel pump; 3. speed sensor; 4. ignition coil; 5.
mechanical part of engine.
Table 2-3-2 The engine can be drawn but not start successfully during starting
Inspection
result
Attach the fuel manometer (at the front end of the oil Yes Next step
inlet of the fuel rail assembly), start the engine, and
1 Check and repair
check if the fuel pressure is at about 380KPa under all
No the oil supply
conditions.
system
Yes Next step
Attach the diagnostic instrument for electronic injection
2 system, observe the data item of “engine speed”, start Check and repair
the engine and check for speed signal output. No the speed sensor
circuit
Pull out the connection wire of a cylinder and connect Yes Next step
the spark plug to make its electrode about 5mm away
3 Check and repair
from the engine body, and then start the engine to check No
the ignition system
for blue and white high pressure spark.
第 65 页共 221 页
Eliminate the
Check the pressure condition of each cylinder of the Yes mechanical fault of
4
engine, and observe if there is insufficient pressure. the engine
No Next step
Attach the adapter of the electronic injection system, Diagnosis
Yes
turn on the ignition switch, and check if the power of foot assistance
5
17#, 18#, 04# and 20# is normal and the earthing of foot Check and repair
No
05#, 21# and 73# is normal. the relevant circuit
iii. Hard warm-starting

General fault locations: 1. water in fuel; 2. fuel pump; 3. coolant temperature sensor; 4. vacuum tube
of fuel pressure regulator; 5. ignition coil.
Table 2-3-3 Diagnosis procedure for hard warm-starting
Inspection
result
inlet of the fuel rail assembly), start the engine, and Check and repair
1
check if the fuel pressure is at about 380KPa under all No the oil supply
conditions. system
Pull out the connection wire of a cylinder and connect Yes Next step
the spark plug to make its electrode about 5mm away
2 Check and repair
from the engine body, and then start the engine to No
check for blue and white high pressure spark. the ignition system
Take out the connector of the coolant temperature Check and repair
sensor, start the engine and observe if it can start Yes the circuit or
successfully now. (Or install a 300 ohm electric replace the sensor
3 resistance in series at the connector of the coolant
temperature sensor to replace the coolant temperature
No Next step
sensor, and observe if the engine starts successfully
now.)
Check and repair
Check if the vacuum tube of fuel pressure regulator is Yes
4 or replace
loose or leaks.
No Next step
Check the fuel and observe if the fault is caused by Yes Replace the fuel
5
fuel filling. No Next step
Attach the adapter of the electronic injection system, Diagnosis
Yes
turn on the ignition switch, and check if the power of assistance
6
foot 17#, 18#, 04# and 20# is normal and the earthing Check and repair
No
of foot 05#, 21# and 73# is normal. the relevant circuit
iv. Hard cold-starting
General fault locations: 1. water in fuel; 2. fuel pump; 3. coolant temperature sensor; 4. fuel injector; 5.
ignition coil; 6. throttle body and idle speed bypass air flue; 7. mechanical part of engine.
Table 2-3-4 Diagnosis procedure for hard cold-starting

Inspectio
n result
Yes Next step
Attach the fuel manometer (at the front end of the oil inlet of
Check and
1 the fuel rail assembly), start the engine, and check if the fuel
No repair the oil
pressure is at about 380KPa under all conditions.
supply system
第 66 页共 221 页
Pull out the connection wire of a cylinder and connect the Yes Next step
spark plug to make its electrode about 5mm away from the Check and
2
engine body, and then start the engine to check for blue and No repair the
white high pressure spark. ignition system
Take out the connector of the coolant temperature sensor, Check and
start the engine and observe if it can start successfully now. repair the circuit
Yes
(Or install a 2500 ohm electric resistance in series at the or replace the
3
connector of the coolant temperature sensor to replace the sensor
coolant temperature sensor, and observe if the engine
No Next step
starts successfully now.)
Clean the
Step down the accelerator petal lightly and observe if it is Yes throttle and idle
4
easy to start. speed air flue
No Next step
Replace the
Dismantle the fuel injector. Check by a special cleaning Yes
5 faulty part
analyzer if there is leakage or blockage in the fuel injector.
No Next step
Check the fuel and observe if the fault is caused by fuel Yes Replace the fuel
6
filling. No Next step
Eliminate the
Check the pressure of all cylinders and observe if there is Yes mechanical fault
7
insufficient pressure. of the engine
No Next step
Diagnosis
Attach the adapter of the electronic injection system, turn on Yes
assistance
the ignition switch, and check if the power of foot 17#, 18#,
8 Check and
04# and 20# is normal and the earthing of foot 05#, 21# and
No repair the
73# is normal.
relevant circuit
v. Hard starting at any time with normal speed
General fault locations: 1. water in fuel; 2. fuel pump; 3. coolant temperature sensor; 4. fuel injector; 5.
ignition coil; 6. throttle body and idle speed bypass air flue; 7. air inlet; 8. ignition timing; 9. spark plug;
10. mechanical part of engine.
Table 2-3-5 Diagnostic procedure for hard starting at any time with normal speed
Inspectio Follow-up
S/N Operating steps
n result steps
Check and
Check the air cleaner for blockage and the air inlet for Yes repair the air
1 intake system
leakage.
No Next step
2 Attach the fuel manometer (at the front end of the oil inlet Yes Next step
第 67 页共 221 页
of the fuel rail assembly), start the engine, and check if the Check and
fuel pressure is at about 380KPa under all conditions. No repair the oil
supply system
Pull out the connection wire of a cylinder and connect the Yes Next step
spark plug to make its electrode about 5mm away from Check and
3
the engine body, and then start the engine to check for No repair the
blue and white high pressure spark. ignition system
Yes Next step
Check the spark plug of each cylinder and observe if the
4 Adjust or
model and clearance within the regulations No
replace
Check and
repair the
Take out the connector of the coolant temperature sensor, Yes circuit or
5 start the engine and observe if it can start successfully replace the
now. sensor
No Next step
Clean the
Step down the accelerator petal lightly and observe if it is Yes throttle and
6
easy to start. idle air way
No Next step
Replace the
Dismantle the fuel injector. Check by a special cleaning Yes
7 faulty part
analyzer if there is leakage or blockage.
No Next step
Replace the
Check the fuel and observe if the fault is caused by fuel Yes
8 fuel
filling.
No Next step
Eliminate the
Check the pressure of all cylinders and observe if there is Yes mechanical
9
insufficient pressure. fault of engine
No Next step
Yes Next step
Check the ignition order and ignition timing to see if they Check and
10
are in accordance with the standards. No repair the
ignition timing
Diagnosis
Yes
assistance
Attach the adapter of the electronic injection system, turn
检修相应的线
on the ignition switch, and check if the power of foot 17#,
11 路
18#, 04# and 20# is normal and the earthing of foot 05#, 否
Check and
21# and 73# is normal. No
repair the
relevant circuit
vi. Normal starting, but unstable idle speed at any time
General fault locations: 1. fuel in water; 2. fuel injector; 3. spark plug; 4. throttle body and idle speed
bypass air flue; 5. air inlet; 6. idle speed adjuster; 7. ignition timing; 8. spark plug; 9. mechanical part
of engine.
Table 2-3-6 Normal starting, but unstable idle speed at any time
Inspectio Follow-up
S/N Operating steps
n result steps
Check and
Check the air cleaner for blockage and the air inlet for Yes repair the air
1 intake system
leakage.
No Next step
第 68 页共 221 页
Clean or
Yes
2 Check if the idle speed adjuster is stuck. replace
No Next step
Yes Next step
Check the spark plug of each cylinder and observe if the
3 Adjust or
model and clearance within the regulations No
replace
Check if there is carbon deposit at the throttle body and idle Yes Clean
4
speed bypass air flue. No Next step
Dismantle the fuel injector. Check by a special cleaning Replace the
Yes
5 analyzer if there is leakage, blockage or flow out of faulty part
tolerance in the fuel injector. No Next step
Replace the
Check the fuel and observe if the fault is caused by fuel Yes
6 fuel
filling.
No Next step
Eliminate the
Yes mechanical
7 Check the pressure of all cylinders and observe if there is a
fault of engine
big difference.
No Next step
Yes Next step
Check the ignition order and ignition timing to see if they are Check and
8
in accordance with the standards. No repair the
ignition timing
Diagnosis
Attach the adapter of the electronic injection system, turn on Yes
assistance
the ignition switch, and check if the power of foot 17#, 18#,
9 Check and
04# and 20# is normal and the earthing of foot 05#, 21# and
73# is normal. No repair the
relevant circuit
vii. Normal starting, but unstable idle speed in warm-up
General fault locations: 1. water in fuel; 2. coolant temperature sensor; 3. spark plug; 4. throttle body
and idle speed bypass air flue; 5. air inlet; 6. idle speed adjuster; 7. mechanical part of engine.
Table 2-3-7 Normal starting, but unstable idle speed in warm-up
Inspection
result
Check and repair the
Check the air cleaner for blockage and the air inlet Yes
1 air intake system
for leakage.
No Next step
Check the spark plug of each cylinder and observe Yes Next step
2
if the model and clearance within the regulations. No Adjust or replace
第 69 页共 221 页
Remove the idle speed adjuster, check if there is Clean related parts
Yes
3 carbon deposit at the throttle body, idle speed and components
adjuster and idle speed bypass air flue. No Next step
Take out the connector of the coolant temperature
Yes circuit or replace the
4 sensor, start the engine and observe if the idle
sensor
speed is unstable during warm-up.
No Next step
Dismantle the fuel injector. Check by a special Replace the faulty
Yes
5 cleaning analyzer if there is leakage, blockage or part
flow out of tolerance in the fuel injector. No Next step
6
Eliminate the
Check the pressure of all cylinders and observe if Yes mechanical fault of
7
there is a big difference. engine
No Next step
Attach the adapter of the electronic injection Yes Diagnosis assistance
system, turn on the ignition switch, and check if the
8 Check and repair the
power of foot 17#, 18#, 04# and 20# is normal and No
relevant circuit
the earthing of foot 05#, 21# and 73# is normal.
viii. Normal starting, but unstable idle speed after warm-up
General fault locations: 1. water in fuel; 2. coolant temperature sensor; 3. spark plug; 4. throttle body
and idle speed bypass air flue; 5. air inlet; 6. idle speed adjuster; 7. mechanical part of engine.
Table 2-3-8 Normal starting, but unstable idle speed after warm-up
Inspection
S/N Operation steps Follow-up steps
result
Check and repair the air
Check the air cleaner for blockage and the air inlet Yes
1 intake system
for leakage.
No Next step
Check the spark plug of each cylinder and observe if Yes Next step
2
the model and clearance within the regulations. No Adjust or replace
Remove the idle speed adjuster, check if there is Clean related parts and
Yes
3 carbon deposit at the throttle body, idle speed components
Yes circuit or replace the
sensor
speed is unstable during warm-up.
No Next step
5 Dismantle the fuel injector. Check by a special Yes Replace the faulty part
第 70 页共 221 页
cleaning analyzer if there is leakage, blockage or
No Next step
flow out of tolerance in the fuel injector.
6
Eliminate the
Check the pressure of all cylinders and observe if Yes mechanical fault of
7
there is a big difference. engine
No Next step
Attach the adapter of the electronic injection system, Yes Diagnosis assistance
turn on the ignition switch, and check if the power of
foot 17#, 18#, 04# and 20# is normal and the No
relevant circuit
earthing of foot 05#, 21# and 73# is normal.
ix. Normal starting, but unstable idle speed or misfire when with some load (e.g.
A/C on)
General fault locations: 1. A/C system; 2. idle speed adjuster; 3. fuel injector.
Table 2-3-9 Normal starting, but unstable idle speed or misfire when with some load (e.g. A/C on)
Inspectio
n result
Clean related
Remove the idle speed adjuster, check if there is carbon
Yes parts and
1 deposit at the throttle body, idle speed adjuster and idle
components
speed bypass air flue.
No Next step
Observe if the engine output power is increased when Yes Turn to step 4
A/C is on, i.e. use the diagnostic instrument for electronic
2
injection system to observe the change of ignition No Next step
advance angle, injection pulse width and air intake.
Attach the adapter of the electronic injection system, Yes Next step
disconnect the connection line of foot 75# of ECU, and Check and
3
check if there is high level signal at the harness end No repair the A/C
when A/C is on. system
Yes Next step
Check if the pressure of A/C system, electromagnetic
No Check and
4 clutch of compressor and A/C compressor pump are
repair the A/C
normal.
system
第 71 页共 221 页
Dismantle the fuel injector. Check by a special cleaning Replace the
Yes
5 analyzer if there is leakage, blockage or flow out of faulty part
tolerance in the fuel injector. No Next step
Diagnosis
Attach the adapter of the electronic injection system, turn Yes
assistance
on the ignition switch, and check if the power of foot 17#,
6 Check and
18#, 04# and 20# is normal and the earthing of foot 05#,
No repair the
21# and 73# is normal.
relevant circuit
x. Normal starting, too high idle speed
General fault locations: 1. throttle body and idle speed bypass air flue; 2. vacuum tube; 3. idle speed
adjuster; 4. coolant temperature sensor; 5. ignition timing.
Table 2-3-10 Normal starting, too high idle speed
Inspection
result
Check if the accelerator dragline is stuck or too Yes Adjust
1
tight. No Next step
Check and repair
Check if there is leakage in the intake system and Yes
2 the intake system
its vacuum tube.
No Next step
Clean related
Remove the idle speed adjuster, check if there is
Yes parts and
3 carbon deposit at the throttle body, idle speed
components
adjuster and idle speed bypass air flue.
No Next step
Check and repair
Yes the circuit or
replace the sensor
speed is too high.
No Next step
Yes Next step
Check if the ignition timing of engine conforms to
5 Check and repair
regulations. No
the ignition timing
第 72 页共 221 页
Attach the adapter of the electronic injection
Diagnosis
system, turn on the ignition switch, and check if Yes
assistance
6 the power of foot 17#, 18#, 04# and 20# is normal
and the earthing of foot 05#, 21# and 73# is Check and repair
No
normal. the relevant circuit
xi. Rotation speed can not increase or the engine misfires during acceleration
General fault locations: 1. water in fuel; 2. intake pressure sensor and throttle position sensor; 3.
spark plug; 4. throttle body and idle speed bypass air flue; 5. air inlet; 6. idle speed adjuster; 7. fuel
injector; 8. ignition timing; 9. exhaust pipe
Table 2-3-11 Rotation speed can not increase or the engine misfires during acceleration
S/N Operation steps
result steps
Check and
Yes repair the air
1 Check if the air cleaner is blocked. intake system
No Next step
2 Check and
check if the fuel pressure is at about 380KPa under all
No repair the oil
conditions.
supply system
Yes Next step
Check the spark plug of each cylinder and observe if
3 Adjust or
the model and clearance within the regulations. No
replace
Clean related
Remove the idle speed adjuster, check if there is
Yes parts and
4 carbon deposit at the throttle body, idle speed adjuster
components
and idle speed bypass air flue.
No Next step
Yes Next step
Check and
Check if the intake pressure sensor, throttle position repair the
5
sensor and their circuits are normal. No circuit or
replace the
sensor
Dismantle the fuel injector. Check by a special Replace the
6 Yes
cleaning analyzer if there is leakage or blockage in the faulty part
第 73 页共 221 页
fuel injector. No Next step
Replace the
Check the fuel and observe if the fault is caused by Yes
7 fuel
fuel filling.
No Next step
Yes Next step
Check if the ignition order and ignition timing conform Check and
8
to regulations. No repair the
ignition timing
Yes Next step
Repair or
9 Check if the exhaust pipe is smooth.
No replace the
exhaust pipe
Diagnosis
Attach the adapter of the electronic injection system, Yes
assistance
10 Check and
foot 17#, 18#, 04# and 20# is normal and the earthing
No repair the
of foot 05#, 21# and 73# is normal.
relevant circuit
xii. Slow response during acceleration
spark plug; 4. throttle body and idle speed bypass air flue; 5. air inlet; 6. idle speed adjuster; 7. fuel
injector; 8. ignition timing; 9. exhaust pipe
Table 2-3-12 Slow response during acceleration

Inspection
result
Check and
Yes repair the air
1 Check if the air cleaner is blocked. intake system
No Next step
Yes Next step

Attach the fuel manometer (at the front end of the oil
inlet of the fuel rail assembly), start the engine, and Check and
2
check if the fuel pressure is at about 380KPa under all No repair the oil
conditions. supply system
Yes Next step

3 Check the spark plug of each cylinder and observe if
Clean related
Remove the idle speed adjuster, check if there is Yes parts and
4 carbon deposit at the throttle body, idle speed adjuster components
and idle speed bypass air flue.
No Next step
Check if the intake pressure sensor, throttle position
5 Yes Next step
sensor and their circuits are normal.
第 74 页共 221 页
Check and
repair the circuit
No
or replace the
sensor
Dismantle the fuel injector. Check by a special Yes Replace
6 cleaning analyzer if there is leakage or blockage in the
fuel injector. No Next step
Yes Replace the fuel
Check the fuel and observe if the fault is caused by
7
Yes Next step
Check if the ignition order and ignition timing conform Check and
8
to regulations. No repair the
ignition timing
Yes Next step
Repair or
9 Check if the exhaust pipe is smooth.
No replace the
exhaust pipe
Diagnosis
Attach the adapter of the electronic injection system, Yes
assistance
10 Check and
foot 17#, 18#, 04# and 20# is normal and the earthing
of foot 05#, 21# and 73# is normal. No repair the
relevant circuit
xiii. Poor acceleration and performance
spark plug; 4. ignition coil; 5. throttle body and idle speed bypass air flue; 6. air inlet; 7. idle speed
adjuster; 8. fuel injector; 9. ignition timing; 10. exhaust pipe
Table 2-3-13 Poor acceleration and performance
Inspection
result
Check if there are faults like clutch slipping, low tire Yes Repair
1 pressure, braking dragging, wrong tire dimensions
No Next step
and wrong four tires positioning.
Yes
2 Check if the air cleaner is blocked. air intake system
No Next step
check if the fuel pressure is at about 380KPa under No
oil supply system
all conditions.
Pull out the connection wire of a cylinder and Yes Next step
connect the spark plug to make its electrode about
4 5mm away from the engine body, and then start the Check and repair the
engine to check if the strength of high pressure No
ignition system
spark is normal.
Check the spark plug of each cylinder and observe if Yes Next step
5
Remove the idle speed adjuster, check if there is Clean related parts
Yes
6 carbon deposit at the throttle body, idle speed and components
第 75 页共 221 页
Yes Next step
Check if the intake pressure sensor, throttle position Check and repair the
7
sensor and their circuits are normal. No circuit or replace the
sensor
Dismantle the fuel injector. Check by a special Replace the faulty
Yes
8 cleaning analyzer if there is leakage or blockage in part
the fuel injector. No Next step
9
Yes Next step
Check if the ignition order and ignition timing
conform to regulations. No
ignition timing
Yes Next step
11 Check if the exhaust pipe is smooth. Repair or replace the
No
exhaust pipe
Attach the adapter of the electronic injection system, Yes Diagnosis assistance
foot 17#, 18#, 04# and 20# is normal and the No
relevant circuit
earthing of foot 05#, 21# and 73# is normal.
xiv. A/C system fault
General fault locations: 1. A/C pressure switch; 2. A/C switch request signal; 3. A/C compressor relay;
4. A/C system pipeline pressure; 5. A/C controller
Table 2-3-14 A/C system fault
Inspection
result
Check if there is sufficient refrigerant in the system, Yes Next step
1 and if A/C belt, A/C clutch and pressure switch are Eliminate the
normal. No
fault
Operate the engine at idle speed and connect the A/C Eliminate the
Yes
2 switch. Check by a diagnostic instrument if there is displayed fault
fault in the A/C thermistor. No Next step
Connect the A/C switch and attach an adapter Yes Next step
between ECU and harness, and measure if there is
3 Check the
signal input at foot J1-09 and J1-39 (A/C switch) of No
harness
ECU.
Replace the bulb
For vehicle controlled by low level, check if the A/C Yes or repair the
4
still works when it is off. harness
No Next step
Repair the A/C
Check if there is low level output at foot J1-46 of ECU Yes relay and
5
(earth end to connect the A/C relay operating coil) harness
No Replace ECU
第 76 页共 221 页
xv. Check of the three-way catalytic converter
General fault locations: 1. leakage in engine exhaust manifold; 2. leakage in three-way catalytic
converter and muffler; 3. fault in fuel injector; 4. connecting lead from ignition coil to spark plug; 5.
fault in fuel injector; 6. engine cylinder pressure
Table 2-3-15 Check of the three-way catalytic converter
Inspection
result
Yes Next step
Visually inspect if the exhaust pipe and muffler are
1 Repair or
normal No
replace
Start the engine and operate it at idle speed; listen if Yes Next step
2 there is sound of exhaust leakage before the three-way Repair or
No
catalyst. replace
Yes Next step
3 Listen if there is leakage at the exhaust manifold Repair or
No
replace
Yes Next step
Check if the ignition time is 0°-15°BTDC; check if the
4 Carry out basic
target idle speed is 800±50rpm (MT) No
check
Yes Next step
Check the fuel injector; stop the engine and turn the
ignition switch to ON; check if the voltage output Carry out the
5 process of fuel
between foot J1-55, J1-70, J1-56 and J1-71 of ECU and No
the earth point is normal injector
diagnosis
Turn the ignition switch to OFF; dismantle the ignition
Yes Next step
coil and connect a normal spark plug; ground the end
6
and rotate the engine, and check if the spark plug is Check the
No
normal ignition coil
Replace the
Turn the ignition switch to OFF; dismantle the fuel
Yes three-way
injector but remain the injection pipe and all injector
catalyst
7 connectors; disconnect the connector of injection coil
Replace the
lead; turn the ignition switch to ON, and ensure that the
No fuel injector that
gasoline has not just flowed from the fuel injector
leaks
第 77 页共 221 页
xvi. Engine misfiring
General fault locations: 1. ignition coil; 2. spark plug; 3. severe leakage in intake system; 4.
connecting lead from ignition coil to spark plug; 5. faulty fuel injector; 6. engine cylinder pressure
Table 2-3-16 Engine misfiring
Inspection
result
Yes Next step
Start the engine and operate it at idle speed; listen if
1 Find out the leakage
there is air leakage at the air inlet No
location and repair it
Stop the engine and visually inspect if the exhaust pipe, Yes Next step
2
three-way catalyst and muffler are normal No Repair or replace
Disconnect the lead connector of each ignition coil one Yes 5
3 by one, and check if any cylinder has no instantaneous Next step
No
drop of engine rotation speed
Yes Next step
4 If each fuel injector has working sound at idle speed Check the fuel injector
No
and relevant circuit
Detach the metal wire used for ignition from the spark Yes Next step
plug; install the metal wire on a good spark plug; ground Check the ignition coil,
5
the end of the spark plug and then rotate the engine; No giant transistor and
check if the spark is normal their circuits
No Next step
Repair or replace it
6 Remove the spark plug and check if there is dirt in it
Yes with a standard-type
spark plug
Yes Next step
Check the piston,
Check the engine cylinder pressure; standard value:
piston ring, intake
7 1275kPa/300rpm; minimum value: 981kPa/300rpm;
No valve, intake valve
difference among cylinders: 98kPa/300rpm
seat and cylinder top
washer
Yes Next step
Install all detached parts; release the fuel pressure to 0;
Check the fuel
8 install the fuel pressure scale and check if the fuel
No pressure as per the
pressure is normal
specific method
Check the ignition time; ignition time: 15°±5°BTDC; Yes Next step
9
target idle speed: 800±50rpm (MT) No Carry out basic check
10 Start the engine and warm it up to the normal operating Yes Next step
第 78 页共 221 页
temperature; check by a voltmeter the voltage between
foot J1-62 (front oxygen sensor high signal) or J1-06
(front oxygen sensor low signal) of ECU and the earth
point; check the voltage when engine runs at 2000rpm;
Replace with a new
there should be no less than 5 times of voltage change No
front oxygen sensor
within 10 seconds between 0V-0.3V and 0.6V-1.0V; at
least one time for the maximum voltage over 0.6V; at
least one time for the minimum voltage under 0.3V;
voltage must not exceed 1V.
Yes Replace the ECU
Check the intake sensor signal by a diagnostic Check if the connector
11 instrument: 2.0-6.0gm/sec (at idle speed); of intake temperature
7.0-20.0gm/sec (at 2500rpm) No
sensor circuit is rusty
or loose
Chapter III Chassis System

Section I Drive Shaft
I. Structure
Lifan minivan adopts an arrangement with the engine placed at the middle in a vertical manner
and the drive shaft connecting the rear axle and rear wheel drive. The drive shaft is to transmit the
power of the transmission to the drive axle. See Fig. 3-1-1 for the structure of the drive shaft. The
drive shaft assembly consists of drive shaft and universal joint assembly, sleeve fork and flange fork.
The front part is fastened by the sleeve fork on the transmission output shaft spline and the rear part
is fixed by the flange fork on the flange of the drive axle drive gear with bolts. Each cross shaft of
universal joint is equipped with 4 needle roller bearings.
II. Check and repair of main parts
i. Check and repair of the drive shaft and universal joint assembly
6
3
4 4
5
3
4
2 3
1
Fig. 3-1-1 Structure of the drive shaft

1-bolt, 2-flange fork, 3-snap spring, 4-cross shaft and bearing assembly, 5-drive shaft and universal joint assembly,
6-sleeve arm fork
第 79 页共 221 页
1. Visual inspection: Check the drive shaft, universal joint fork, sleeve fork and flange fork for
crack, break and bend.
2. If click or vibration noise of the universal joint is heard, check the universal joint, the cross
shaft in the universal joint fork or the spline for abrasion.
3. Check the flexibility of the drive shaft. Support the drive shaft on the V-iron and measure the
radius run-out of the shaft with a dial indicator, see Fig. 3-1-2. If the measurement value exceeds the
standard value (0-7 mm), correct it with cold pressure or heating straightening method; if fails, replace
the drive shaft.
Fig. 3-1-2 Check of drive shaft flexibility
4. Dynamic balance of the drive shaft. When the rotation speed is 4,000 r/min, the dynamic
unbalance should be no more than 10-15 g.cm.
ii. Check and repair of the cross shaft with bearing
1. The cross shaft should be without crack and metal peeling. The cross shaft bearing race and
the sleeve fork seat hole or the flange fork seat hole should be not loose.
2. Check and repair the sleeve fork and flange fork

The sleeve fork and flange fork should be without crack.
3. The 2 bearing seat holes should be concentric. If the crack or bearing seat hole abrasion
exceeds the limit (carry out the check by putting the new cross shaft sleeve into the seat hole),
replace the sleeve fork or flange fork.
4. The sleeve fork on the transmission output shaft spline should move freely without block or
looseness. If the sleeve fork spline is abraded, replace it.
III. Maintenance operation
i. Removal
1. Assembly removal
(1) Drive the vehicle to the vehicle lifting frame or park it above the trench.
(2) Make the assembly marks on each joint flange and the drive shaft. See Fig. 3-1-3.
第 80 页共 221 页
Fig. 3-1-3 Drive shaft removal 1
(3) Screw off the bolts on the drive shaft and drive gear flange to remove the drive shaft. Move the
vehicle forward and backward during the removal above the trench and pay attention to the safety.
See Fig. 3-1-4.
(4) Plug up the installation hole of the drive shaft with cloth on which the fibre will not fall to
avoid the gear oil leakage.
2. Removal of the drive shaft universal joint fork
(1) Remove 2 snap rings with snap spring pliers A. See Fig. 3-1-5.
Pull out the cross shaft bearing race from the universal joint race with special tool B for a=3-4mm.
See Fig. 3-1-6.
第 81 页共 221 页
a
Note: Before pulling out the cross shaft bearing, apply the permeable lubricant between the bearing
race and fork race.
(2) Knock out the drive shaft universal fork with a hammer to completely remove the bearing
race. See Fig. 3-1-7.
Fig. 3-1-7 Removal of the drive shaft bearing race
(3) Take out the bearing race on the other side with the same methods in (2) and (3).
3. Removal of the flange fork
(1) Pull out the flange fork bearing race with the method (1) and (2) for removing the drive shaft
universal joint fork. And then clamp the bearing race with a jaw and knock the flange fork to take out
the bearing race. Take out the bearing race on the opposite side with the same method.
Note: ① Don’t lose the needle roller in the bearing race when removing the cross shaft bearing
race.
② Temporarily install the bearing on the cross shaft in order to re-install it on the original
position.
4. Cross shaft assembly
(1) Use new snap ring, cross shaft and needle roller bearing for the new assembly. The removed
snap ring and cross shaft bearing can’t be used any more.
(2) Properly install the needle roller in the cross shaft bearing race and apply lubricant grease on
it.
(3) Insert the bearing race in the universal joint seat hole and knock it with a hammer to maintain
the flatness between the bearing race and the differential level. See Fig. 3-1-9.
第 82 页共 221 页
A 1
2
3
Fig. 3-1-8 Drive shaft assembly 1 Fig. 3-1-9 Drive shaft assembly 2
A: Lubricant grease 1-copper hammer, 2-bearing race, 3-universal joint fork, 4-cross
shaft
(4) Insert the cross shaft into the bearing race to avoid rolling out of the needle roller in it.
(5) Insert the other bearing race on the opposite side into the universal joint fork and knock it with
a hammer till the bearing race is level with the fork surface. See Fig. 3-1-10.
Fig. 3-1-10 Drive shaft assembly 3
(6) Insert the bearing race into the seat hole of the flange fork on the other side with the
above-mentioned methods.
Note: Place a metal plate on the bearing race to avoid damaging the universal joint fork when
knocking in the bearing race.
(7) Put 4 snap rings into the groove.
Note: Check the shaft for flexible operation and whether each snap ring is in the groove after the new
assembly.
(8) Check the bearing fork and flange fork for flexible operation.
ii. Installation
Installation should obey the reverse order of the removal. Pay attention to 2 points: (a) Make
assembly marks on the drive shaft to avoid vibration, see Fig. 3-1-11; (b) Screw down the universal
joint flange according to the tightening torque below.
第 83 页共 221 页
a
Fig. 3-1-11 Drive shaft assembly 4
Tightening torque: a=75N.m
Note: Fill the differential with specified brand gear oil to the specified liquid level.
iii. Common faults and actions
The common faults for the drive shaft are vibration and noise. See the table below for the main
reasons and elimination methods.
Table 3-1-1 Faults of drive shaft

S/N Main reasons Actions
1 Drive shaft bend Straighten or replace
2 Unbalance of drive shaft rotation Dynamic balance correction
3 Cross shaft bearing abrasion Replace
Abrasion of sleeve fork or flange fork
4 Replace
bearing seat hole.
5 Excessive abrasion of sleeve fork spline Replace
Screw it down by a specified tightening
6 Looseness of drive shaft mounting bolt
torque
Lubricating material: C（99000-25030）
Section II Steering System
I. Structure
A mechanical steering system consisting of steering control system, steering transmission

mechanism and steering gear is applied in the steering system of Lifan minivan.
Structure of the steering control mechanism
i. The steering control system mainly consists of steering wheel and steering column
assembly and lower steering shaft. See Fig. 3-2-1. Functions are as follows:
(a) The steering system can maintain the sound flexibility and returnability of the vehicle.
(b) The steering column can reduce the front impact with the energy absorption design scheme.
(c) The steering wheel can be locked with the anti-theft lock on the steering column.
第 84 页共 221 页
3 1
Fig. 3-2-1 Steering control mechanism

1-steering wheel, 2-steering column assembly, 3-lower steering column, 4-steering gear
ii. Structure of the steering transmission mechanism and steering gear
The steering transmission mechanism mainly consists of steering tie rod and steering tie rod joint.
The steering gear mainly consists of steering pinion and steering rack. For their structures, see Fig.
3-2-2.
1
24
2
26 3
23
10 4
11 9 25
12 5
18 6
7
8
9
22 10
13 21
19 20
1 41 5
16
17
17
16
15
14
13
11
12
Fig. 3-2-2 Structure of the steering gear

1-steering pinion dustproof cover, 2-steering gearbox oil seal, 3-pinion bearing oil seal piston, 4-O-ring, 5-steering
pinion, 6-bearing, 7-needle roller bearing, 8-steering rack housing and gearbox assembly, 9-steering tie rod fixed
washer, 10-steering tie rod, 11-nut, 12-pin, 13-steering rack plunger, 14-steering tie rod joint fixed nut, 15-rack
protective clip, 16-dustproof cover, 17-metal clip, 18-steering rack, 19-20-rack shock pad retaining nut, 21-rack
plunger spring, 22-steering rack plunger, 23-steering rack side assembly part, 24, 26-steering rack side assembly part
support, 25-steering pinion side assembly part
II. Basic check
i. Appearance check
1. Check the steering system fixed bolt for looseness.
第 85 页共 221 页
2. Check the steering tie rod joint in the ball joint for looseness, if so, replace it.
3. Check the steering shaft joint for abrasion or rupture, if so, replace it.
4. Check the steering rack dustproof cover and steering tie rod dustproof cover for crack, if so,
replace them to avoid damaging the components for moisture and dust.
Check the free play of the steering wheel. The free play for the steering wheel of Lifan minivan is
10-15°, if fails to meet the requirement, check the above parts; if damaged, replace them.
ii. Faults check table
See Table 3-2-1 for the common faults and elimination methods for the steering system.
Table 3-2-1 Faults of the steering system
Fault Cause Action

Insufficient tire pressure of the steering wheel Complement the tire pressure
Incorrect front wheel location Front wheel location
Steering tie rod ball joint block Replace
Suspension arm ball joint block Replace
Heavy steering
Bend and deformation of steering transmission Repair or replace
rod Steering column block Repair or replace
Incorrect adjustment of rack and pinion Adjust
Rack bend and deformation Replace
Steering tie rod end ball joint block Replace the steering tie rod end
Ball joint block Replace the front suspension
Steering column block arm
Poor lubrication of rack and pinion Repair or replace
Check and repair it, or apply
Poor
Incorrect front wheel location lubricant on the rack and pinion
returnability
Check and adjust the front
Incorrect adjustment of rack and pinion wheel location
Check and adjust the torque of
Improper tire pressure the rack and pinion
Adjust the tire pressure
Steering gearbox bolt looseness Fasten

Wheel bearing looseness Replace the wheel bearing
Inflexible and Steering shaft, universal shaft and universal Replace
unstable joint abrasion
steering Abrasion of steering tie rod ball joint or steering Replace
tie rod inner ball joint
Front suspension arm ball joint abrasion Replace
Excessive large mesh clearance between the Repair or replace
steering gear and rack
Steering wheel Tire dynamic balance
vibration Wheel unbalance Correct or replace
第 86 页共 221 页
Drive shaft bend Front wheel location
Incorrect wheel location Replace
Abrasion of steering tie rod ball joint or steering
tie rod inner ball joint Repair or replace
Excessive large mesh clearance between the
steering gear and rack
Steering system bolt looseness Fasten
Steering column assembly looseness and Adjust or replace
abrasion
Steering tie rod ball joint abrasion or block Replace
Wheel bearing abrasion or looseness Adjust or replace
Abnormal Incorrect adjustment of the steering gear and Repair or replace
steering noise rack
Support or mounting parts abrasion Repair or replace
Arm bush abrasion Replace
Stabilizer bar looseness Screw down the bolt and replace
the bush
Wheel nut looseness Screw down the wheel nut
Wheel bearing abrasion Replace the wheel bearing
Spring damage or sag Replace the spring
Unstable
Insufficient tire air Inflate air in the tire to reach
steering when
proper air pressure
braking
Incorrect front wheel location Check and adjust the front
wheel location.
Mismatching tire or uneven tire pressure Replace the tire or inflate air to
reach proper air pressure
Looseness of front suspension arm ball knuckle Replace the suspension arm or
and steering tie rod end steering tie rod end
Replace the support or repair
the mounting parts
Swaying or
Shock damper or mounting parts fault Screw down or repair the
unstable
stabilizer rod or bush
steering
Stabilizer rod looseness Replace
Spring damage or sag Replace
Incorrect adjustment of rack and pinion Check
Incorrect front wheel location Adjust the front wheel location
Stabilizer rod connecting ball knuckle looseness Replace the stabilizer rod
connecting ball knuckle
iii. Components check
1. Check the steering rack plunger (see Fig. 3-2-3).
(1) Check the rack plunger for abrasion, deformation, etc.; if so, replace it.
(2) Check the rack plunger spring for deformation or fracture; if so, replace it.
2. Check the steering pinion (see Fig. 3-2-4)
(1) Check the tooth surface of the pinion for abrasion or breakage; if so, replace it.
第 87 页共 221 页
(2) Check the oil seal and gearbox seal for deformation or damage; if so, replace them.
(3) Check the steering pinion bearing for abrasion; if so, replace it.
1
3
4
3 2 1
Fig. 3-2-3 Steering rack plunger Fig. 3-2-4 Check of steering pinion
1-rack shock pad nut, 2-rack plunger spring, 3-rack plunger 1-gearbox oil seal, 2-O-ring, 3-steering pinion, 4-bearing
3. Check the steering rack:
(1) Check the rack for abrasion or damage.
(2) Check the back of the rack for abrasion or damage.
As shown in Fig. 3-2-5, check the rack for bend. If it exceeds the bend limit of 0.1mm, replace
the rack.
Fig. 3-2-5 Check the rack for bend
1. Removal and installation of the steering wheel
As shown in Fig. 3-2-6, remove the upper cover of the steering wheel.
(1) Remove the air bag module (Deluxe scheme).
(2) Remove the steering wheel nut.

第 88 页共 221 页
6
5
4
Fig. 3-2-6 Removal of the steering wheel

1-steering shaft assembly, 2-steering wheel, 3-steering wheel nut, 4-air bag module, 5-air bag module
retaining bolt, 6-upper cover of the steering wheel
As shown in Fig. 3-2-7, mark the steering wheel and steering shaft to correctly install the steering
wheel.
Fig. 3-2-7 Marks on the steering wheel and steering shaft
(3) Remove the steering wheel with a special tool, but never knock at the shaft end of the
steering wheel to avoid the looseness of the cut-type plastic lockpin for maintaining the steering
column’s length and its special buffering performance.
(4) Installation should obey the reverse order of the removal.
2. Removal of the steering column and lower steering shaft
(1) Remove the steering wheel.
第 89 页共 221 页
Fig. 3-2-8 Removal of the upper guard panel of the steering column Fig. 3-2-9 Removal of the
lower guard panel of the steering column
(2) Remove the guard panels on the steering column. See Fig. 3-2-8.
(3) Remove the combination switch and ignition switch harness interfaces.
(4) Remove 3 fixed bolts on the steering column guard panel. See Fig. 3-2-9.
(5) Screw off the joint bolt of the steering column and lower steering shaft.
(6) Screw off the steering column assembly bolt and the lower steering shaft dustproof cover.
See Fig. 3-5-10.
(7) Remove the steering column.
(8) Remove the lower steering shaft joint bolt to dismantle the lower steering shaft. See Fig.
3-2-11.
(9) Installation should obey the reverse order of the removal. Install the lower steering shaft
dustproof cover on the front dash panel after applying lubricant on the lower steering shaft dustproof
cover.
Note: Align the lower steering shaft with the relevant position of the steering column.
Fig. 3-2-10 Removal of the steering shaft Fig. 3-2-11 Removal of the lower steering shaft
assembly and dustproof cover
1-fixed bolt, 2-fixed bolt 2, 3-dustproof cover
第 90 页共 221 页
3. Removal of the steering gear
(1) Unscrew the joint bolt (25N.M) on the lower steering shaft, remove the lower steering shaft
dustproof cover from the front dash panel, and remove the lower steering shaft lower joint. See Fig.
3-2-12.
4
Fig. 3-2-12 Removal of the steering column
(2) Remove the steering tie rod joint nut (25N.M) and disconnect the tie rod joint at the steering
knuckle.
(3) Remove the steering gear fixed bolt to dismantle the steering gear assembly. See Fig. 3-5-13.
2
2
2
Fig. 3-2-13 Removal of the steering gear assembly
1-steering gearbox, 2-fixed bolt (25N.M)
(4) To make proper adjustment after installation, mark the steering tie rod thread end retaining nut,
as shown in Fig. 3-2-14.
(5) As shown in Fig. 3-2-15, unscrew the steering tie rod retaining nut, disconnect the steering tie
rod joint retaining nut from the steering tie rod joint and remove the dustproof cover metal clip and
clip.
2 1
1
2
4 3
Fig. 3-2-14 Removal mark of the steering tie rod Fig. 3-2-15 Removal of the dustproof
cover
第 91 页共 221 页
1-snap ring, 2-metal wire
1-retaining nut, 2-steering tie rod
3-steering tie rod end, 4-mark
(6) Dismantle the retaining nuts of the rack and the steering tie rod and then remove the steering tie
rod at the rack, as shown in Fig. 3-2-16.
1
2
3
2 1 3
Fig. 3-2-16 Steering tie rod
1- lock washer, 2-steering tie rod, 3-steering rack
iv. Removal and installation of the steering wheel anti-theft lock
1. Removal
①As shown in Fig. 3-2-17, unscrew and take down the fixed bolt of the steering wheel anti-theft
lock with a punch.
1
2
3
Fig. 3-2-17 Removal of anti-theft lock fixed bolt
1-punch, 2-anti-theft fixed bolt
Note: Carefully use the punch to avoid damaging the aluminum part of the steering wheel anti-theft
lock.
②Turn the ignition key to “ACC” or “ON” and take down the steering wheel anti-theft lock
assembly from the steering column.
(2) Installation
① Align the quadrate hole of the steering shaft with the inner hole center of the steering column.
See Fig. 3-2-18.
第 92 页共 221 页
2
1
3
Fig. 3-2-27 Installation of the steering column

1-steering column, 2-steering shaft, 3-assembly mark
② Turn the ignition key to “ACC” or “ON” and turn the steering wheel anti-theft lock assembly to the
steering column.
③ Turn the ignition key to “LOCK” and pull it out.
④ Align the lock pin with the quadrate hole of the steering shaft and rotate the shaft to completely
lock it.
⑤ Screw down 2 new bolts till each bolt head falls off. See Fig. 3-2-19
.
Fig. 3-2-19 Installation of the anti-theft lock
(6) Turn the ignition key to “ACC” or “ON” and check the steering shaft for smooth rotation.
(7) Check the anti-theft lock for normal operation.
第 93 页共 221 页
Section III Front Suspension and Front Wheel Location System
I. Structure
The MacPherson type independent suspension is applied in the front suspension of Lifan minivan.
The upper part of front support assembly is connected with the vehicle body through the mounting
seat components and nuts on the front support. The wheel runs around the master pin (shock
damper). The lower part of front support assembly is connected with the steering knuckle with 2 bolts.
The side arm end of the steering knuckle is connected with the steering tie rod ball pin. While steering,
the steering tie rod drives the steering knuckle, the steering knuckle drives the wheels, the shock
damper piston rod rotates, and thus the front wheel steering is completed. The lower arm of the
steering knuckle is connected with the swing arm pin; track bar with swing arm; track bar with the
vehicle body by 4 bolts; stabilizer bar connecting rod with stabilizer bar and track bar. See Fig. 3-3-1
for the structure of the front suspension.
7
9
6
2
5
8
3
4
Fig. 3-3-1 Front suspension

1-front support assembly, 2-steering knuckle, 3-suspension swing arm, 4-swing arm ball pin, 5-wheel bearing, 6-front
wheel hub, 7-wheel, 8-track bar, 9-stabilizer bar
i. Check and repair of the suspension parts
1. Check the stabilizer bar and bush for damage, abrasion or deformation, if so, replace them.
2. Check the track bar and bush for damage, abrasion or deformation, if so, replace them. See
Fig. 3-3-2.
3. Check the front swing arm for crack, deformation or damage, if so, replace it. See Fig. 3-3-3.
第 94 页共 221 页
Fig. 3-3-2 Structure of the track bar Fig. 3-3-3 Front swing arm
4. Check the front swing arm ball pin for flexible rotation and the ball pin for looseness, if so, replace
the front swing arm.
5. Check the ball pin dustproof cover for damage, if so, replace it.
6. Check the wheel bearing for noise, looseness, etc., if so, replace it.
ii. Check and repair of the front support assembly
1. Check the function of the front support assembly: Heavily push the front of the body for several
times with the same strength each time to make the vehicle sway for 3-4 times, and observe the
capacity of the shock damper and the swaying times after releasing. If the shock damper is normal,
the body may stop immediately or just slightly sway for 1-2 times. Check the shock damper at the
other side. Compare the damping capacity of the two shock dampers.
2. Check the shock damper for oil leakage, if so, replace it.
3. Check the front support assembly bearing for abrasion or block, if so, replace it.
4. Check the coil spring for crack or deformation, if so, replace it.
5. Check the front support rubber parts for aging and damage, if so, replace it.
6. Check the mounting seat components on the front support assembly for crack or deformation,
if so, replace it.
iii. Common faults table
See Table 3-3-1 for the common faults and elimination methods for the front suspension.
Table 3-3-1 Common faults

Fault Cause Action
1. Front support assembly Replace
Both sides of the body height
damage Repair
inconformity
2. Body deformation
1. Looseness of front Fasten
suspension fixed bolt
2. Shock damper damage Replace
Body declining or swinging
3. Ineffectiveness of shock Replace
when turning
damper spring
4. Stabilizer bar looseness or Fasten
connecting rod damage
1. Shock damper damage Replace
Weak damping capacity on
2. Ineffectiveness of shock Replace
uneven road
damper spring
第 95 页共 221 页
i. Removal of the front support assembly
1. Removal
(1) Lift the vehicle with a jack or lifting frame to remove the wheel.
(2) Remove the E-clip of the fixed brake hose to take down the brake hose from the support.
(3) Remove the 2 bolts of the steering knuckle and the front support assembly. Remove 2
fixed nuts of the mounting seat components on the front support assembly to dismantle the front
support assembly.
(4) Slightly unscrew the central nut of the front support assembly. (Never remove the nut for
avoid injury.)
(5) Compress the middle and lower part of the damping spring with a spring compressor to
keep the upper part of the spring free. Remove the central nut of the front support assembly to
separate the shock damper with the spring.
2. Installation
Installation should obey the reverse order of the removal. Pay attention to the following points:
(1) Align the lower part of the shock damper spring with the base. See Fig. 3-3-4.
Fig. 3-3-4 Installation drawing of the shock damper spring lower part and base A: Shock damper
base
(2) Align the "OUT" sign on the upper spring seat with the center of the shock damper support. See
Fig. 3-3-5.
第 96 页共 221 页
1
Fig. 3-3-5 Removal of the shock damper spring-upper mounting seat component, 2-support
ii. Removal and installation of the wheel hub bolt
(1) Lift the vehicle with a jack or lifting frame to remove the wheel.
(2) Remove the shaft nut, as shown in Fig. 3-3-6 (a).
(3) Take down the brake caliper support bolt to remove the caliper and support.
(4) Remove the brake disc.
(5) Take down the wheel hub with special tools. See Fig. 3-3-6 (b).
(7) Remove the wheel hub bolt.
(8) Installation should obey the reverse order of the removal.
iii. Removal of the steering knuckle
(1) Take down the wheel hub according to the "removal and installation step of the wheel hub bolt".
(2) Remove the steering track rod ball joint from the steering knuckle.
(3) Remove the lower swing arm ball joint fixed bolt to separate the arm with the steering knuckle.
(4) Remove the 2 shock damper support bolts to dismantle the steering knuckle.
（A）
（B ）
( C)
（a ）（b ）
Fig. 3-3-6 Removal of the front wheel hub
C: Brake disc fixed nut
第 97 页共 221 页
(5) Installation should obey the reverse order of the removal. See Fig. 3-3-7.
2
3
Fig. 3-3-7 Removal of the steering knuckle
1-shock damper support fixed bolt (95N.M), 2-steering knuckle, 3-steering track rod ball joint fixed nut (43N.M), 4-
swing arm ball joint fixed nut (55N.M)
iv. Front wheel location
1. Front wheel location value
The front wheel location value consists of toe-in, front wheel camber angle, master pin caster
angle and master pin inclination angle. Lifan minivan's front wheel and toe-in can be adjusted, while
other parameters couldn't. See Table 3-3-2 for the front wheel location value.
2. Toe-in adjustment
Note:
See Fig. 3-3-8 for the toe-in measurement. Adjust the toe-in through changing the steering tie
rod. The specific steps are as follows:
Fig. 3-3-8 Toe-in measurement
(1) As shown in Fig. 3-3-9, unscrew the retaining nuts of the right and left steering tie rod joints.
Tightening torque: 45N.M.
第 98 页共 221 页
Fig. 3-3-9 Toe-in adjustment
(2) Turn the tie rod right and left to adjust its length. Measure the right and left tie rods. Keep the same
length while meeting the toe-in requirement.
Table 3-3-2 Wheel location parameter

Location parameter Value
Toe-in (no load) (0.0±1.0) mm
Wheel camber angle (no load) 1°18′±30′
Wheel caster angle (no load) 30°24′±30′
Master pin inclination angle (no load) 9°47′±30′
(3) After properly adjusting the toe-in, screw down the tie rod retaining nut.
3. Adjustment of camber angle and master pin caster angle
Wheel camber angle and master pin caster angle are nonadjustable. If the measurement result is
inconformity with the standard, check the vehicle body or suspension. If the body is damaged, repair
it; if the suspension is damaged, replace it.
第 99 页共 221 页
Section IV Rear Suspension
I. Structure
Lifan minivan rear suspension mainly consists of shock damper, steel plate spring and rear axle. See
Fig. 3-4-1. The half-round steel plate spring assembly is installed on the rigid shaft and supported by
lifting lug rubber bush at both sides. The telescopic shock damper with very good effect can ensure
the comfort even when driving on the uneven roads.
Fig. 3-4-1 Structure of the rear axle

1-steel plate spring, 2-shock damper, 3-limiter component, 4-rear axle, 5-bearing, 6-rear axle half shaft oil seal,
7-brake hub, 8-bearing snap ring, 9-rear axle half shaft, 10-wheel bearing spacer
1. Rear shock damper
The bidirectional telescopic shock damper is applied for the rear shock damper of Lifan minivan.
Compress or pull the shock damper with hands to check its capacity. If the shock damper oil leakage
or poor effect is found, replace it.
2. Steel plate spring lifting lug rubber bush
Check the rear and front lifting lug rubber bushes for abrasion, damage or aging, if so, replace
them. See Fig. 3-4-2 for the removal, disassembly, assembly and installation of the rear suspension
steel plate spring.
第 100 页共 221 页
1
6
6
3 7
4
8
5 10
11
14 12
15
16 13
Fig. 3-4-2 Rear suspension steel plate spring

1-U-bolt, 2-limiting stopper component, 3-steel plate spring bolt, 4-steel plate spring fixed bolt, 5-steel plate spring
fixed nut, 6-bush, 7-bush, 8- rear steel plate spring fixed bolt, 9-#1 steel plate spring, 10-#2 steel plate spring, 11-#3
steel plate spring, 12-#4 steel plate spring, 13-rear shock damper, 14-rear shock damper fixed nut, 15-U-bolt seat,
16-steel plate spring fixed nut, 17-steel plate spring assembly nut
i. Removal of the steel plate spring
(1) Jack and support the vehicle body
Use a lifter or jack to lift the vehicle body and support it.
(2) Lift the axle housing till the steel plate spring is free. See Fig. 3-4-3.
第 101 页共 221 页
Fig. 3-4-3 Lifting the axle housing
(3) Remove the rear wheel
(4) See Fig. 3-4-4. Separate the steel plate spring with the parking brake cable.
(5) See Fig. 3-4-5. Remove the rear shock damper.
1
Fig. 3-4-4 Removal of the brake cable Fig. 3-4-5 Removal of the rear shock damper
1-shock damper fixed nut
A. Remove the bolt and remove the shock damper from the spring seat.
B. Check the rear shock damper for oil leakage and damage, if so, replace it.
Fig. 3-4-6 Removal of U-bolt Fig. 3-4-7 Lifting lug bolt and nut
component
A-U bolt fixed nut
(6) Screw off the fixed nut of the U-bolt. (See Fig. 3-4-6)
(7) Remove the lower spring seat.
(8) Remove the U-bolt.
第 102 页共 221 页
(9) Remove the steel plate spring.
A. Remove the lifting lug pin bolt. (See Fig. 3-4-7)
B. Remove the bolt and nut of the lifting lug. (See Fig. 3-4-8)
Fig. 3-4-8 Lifting lug bolt and nut component
C. Remove the steel plate spring
(10) Replace the bush (See Fig. 3-4-9)
Replace the bush with press and sleeve wrench.
Fig. 3-4-9 Removal of the bush Fig. 3-4-10 Removal of the spring clip
ii. Disassembly and installation of the steel plate spring
1. Disassembly of the steel plate spring. (See Fig. 3-4-10)
(1) Unclench the spring clip with a chisel.
(2) Remove the central bolt. (See Fig. 3-4-11)
Fig. 3-4-11 Removal of the central bolt
(4) Fix the steel plate spring near the central bolt on the standing vice to remove the central bolt.
第 103 页共 221 页
2. Assembly of the steel plate spring
(1) Install the central bolt
(2) Fix the steel plate spring near the central bolt on the standing vice to install the central bolt.
Tightening torque: 44N.M
(3) Fasten the spring clip
(4) Clinch the spring clip to relevant position with a hammer.
Fig. 3-4-12 Tap out rivet
(5) Drill on the top of the rivet to tap it out.
(6) Mount the new rivet in the steel plate spring and the hole of the spring clip; and then press it
down with a punching machine or a hammer and puncher.
(7) Tighen the spring clip with a hammer, as shown in Fig. 3-4-13.
iii. Installation of the steel plate spring
(1) Place the front end of the steel plate spring on the front lifting lug and install the lifting lug pin
bolt.
(2) Screw down the lifting lug pin nut. (See Fig. 3-4-7)
(3) Properly place the back end of the steel plate spring and install the lifting lug, 2 bolts and 2
nuts on it.
Fig, 3-4-13 Tightening the clip

(4) Screw down the bolt and nut by hand.
(5) Install the U-bolt (See Fig. 3-4-14).
第 104 页共 221 页
1
3 2
Fig. 3-4-14
1-U-bolt, 2-limiting stopper component, 3-steel plate spring assembly bolt, 4-steel plate spring, 5-U-bolt seat,
6-steel plate spring fixed nut, 7-steel plate spring assembly nut
(6) Install the lower seat component on the steel plate spring. (See Fig. 3-4-14)
A. Install the lower spring seat and U-bolt.
B. Screw down the 4 nuts.
Tightening torque: 90N.M
Remarks: Screw down the nut to ensure the same length of all U-bolts under the spring.
(7) Connect the shock damper with the lower spring seat (See Fig. 3-4-5 for tightening torque of
50N.m)
(8) Connect the parking brake cable with the steel plate spring (See Fig. 3-4-4)
(9) Lower the vehicle after installing the rear wheel.
(10) Stabilize the suspension system (See Fig. 3-4-15)
A. Screw down all bolts and nuts.
B. Stabilize the suspension through moving up and down for several times.
Fig. 3-4-15 Stabilize the suspension system
第 105 页共 221 页
Section V Wheel and Tire
I. Overview
Wheel is an important part of the driving system and is used to uphold the whole vehicle, ensure
the sound contact between the vehicle and the ground, transmit the drive torque, brake torque and
side torque and reduce the shock from the ground with the suspension.
The vehicle is equipped with 14×5J steel rim. Type 175/70R14LT wheel tire without inner tube is
applied for the vehicle.
i. Appearance check
(1) Check the tire for abnormal abrasion, if so, find out the fault reason.
(2) Check the tire for crack and damage, if so, replace it.
(3) Check the tire surface for iron nail, gravel or impurities, if so, clean them.
(4) Check the tire pressure for meeting the specification in Table 3-5-1; if not, adjust it.
Table 3-5-1 Specification of tire pressure

Tire Front wheel Rear wheel
Load
No load 240 240
Full load 260 300
(5) Regularly do the tire rotation as shown in Fig. 3-5-1.
Fig. 3-5-1 Tire rotation
(6) Check the dynamic balance of the wheel.
ii. See Table 3-5-2 for common faults and elimination methods of the wheel.
Table 3-5-2 Table of faults

Faults Cause Action
1. Disqualified tire pressure Adjust
Uneven 2. Incorrect front wheel location Front wheel location
abrasion of 3. Looseness of steering tie rod ball joint Replace
both sides of 4. Shock damper damage Replace
tire 5. Looseness of wheel bearing Adjust or replace
6. Poor returnability of brake Adjust or replace
1. Impurities on the tire Clean
Rolling noise
2. Excessive abrasion of the tire Use the method for eliminating “uneven
of tire
abrasion of both sides of tire”
第 106 页共 221 页
1. Out-of-round tire or rim Replace
Wheel hop 2. Bump on the tire Replace
3. Shock damper fault Replace
1. Mismatching or uneven tire Replace
2. Improper tire pressure Adjust the tire pressure
3. Spring rupture or looseness Replace the spring
Wheel
4. Radial tire warping due to horizontal Replace the tire
driving in
stress
wrong
5. Unbalance of front wheel location Check and adjust the front wheel location
direction
6. One wheel is locked (tied) Repair the brake system
7. Looseness, bend or damage of front Screw down or replace the suspension
and rear suspension components
1. Looseness or damage of the spring Replace the spring
2. Tire unbalance Adjust the balance or replace the tire
3. Unbalance of front wheel location Check and adjust the front wheel location
4. Support fault Replace the support
Abnormal or
5. Poor road surface Replace the tire
excessive
6. Vehicle over loading Replace the tire
abrasion of
7. No tire rotation Replace or change the tire position
tire
8. Abrasion or looseness of wheel Replace the wheel bearing
bearing Replace the wheel or tire
9. Wheel or tire swings Adjust the tire pressure
10. Insufficient wheel air pressure
1.Wheel unbalance Balance the wheel or replace the tire or
2. Wheel bearing damage or abrasion wheel
3. Abrasion of steering tie rod end Replace the wheel bearing
4. Abrasion of front oscillating arm ball Replace the steering tie rod end
joint Replace the front suspension
Front wheel 5. Excessive radial run-out of wheel
swings, 6. Tire bump or damage Repair or replace the wheel or tire
vibrates or 7. Overloading radial run-out of wheel Replace the tire
hops 8. Unbalance of front wheel location Replace the tire or wheel
9. Looseness or abrasion of the steering Check and adjust the front wheel location
driving rod Screw down or replace the driving rod
10. Looseness of the steering system
mounting bolt Screw down the steering system mounting
bolt
1. Defect of front support Replace
2. Wheel bearing damage Replace the wheel bearing
Tire
3. Excessive deflection of tire and wheel Replace the tire and vehicle rim
deformation
4. Damage of front suspension ball joint Replace the front suspension arm
5. Tire unbalance Adjust the tire
iii. Common faults and elimination methods of the tire
1. Fast abrasion of shoulder
(1) Fault: fast abrasion of two crown shoulders, as shown in Fig. 3-5-2.
Fig. 3-5-2 Fault of tire pressure
(2) Fault diagnosis: The contact area between the crown and the ground is widened for
第 107 页共 221 页
insufficient tire pressure. The middle part of the tire bends and slightly arches outward, so the two
crown shoulders contact with the ground, which may accelerate the abrasion of two shoulders and
crack the tire surface in high-speed running. See Fig. 3-5-3.
(3) Cause and elimination methods: Insufficient tire pressure and too long driving time. The tire
pressure should be made up.
2. Fast abrasion of the middle part of the crown
(1) Fault: Too early abrasion of the middle part of the crown. See Fig. 3-5-4.
(2) Fault diagnosis: High tire pressure may increase the contact area per unit and abrade the
middle part of the crown. The too heavy tensile stress undertaken by the cord ply thread may cause
the early wear.
(3) Cause and elimination methods: Too high tire pressure and insufficient rotation. Adjust the
tire pressure to the standard.
Fig. 3-5-3 Analysis of insufficient tire pressure Fig. 3-5-4 Too early abrasion of the middle part of
the crown.
Fig. 3-5-5 Analysis for the middle part abrasion of the crown
3. Excessive abrasion of outer or inner part of the crown
(1) Fault: Fast abrasion of outer or inner part of the crown
(2) Fault diagnosis: Excessive abrasion of the outer or inner part of the tire is related to the camber
angle of the wheel. The outside of the crown abrasion shows that the camber angle of the wheel is
too big, and the inside of the crown abrasion shows that the camber angle of the wheel is too small.
(3) Cause and elimination methods: Too big or small camber angle of the wheel. Find the cause of
the abnormality and adjust it to normality.
4. Zigzag abrasion of the crown
第 108 页共 221 页
(1) Fault: See Fig. 3-5-6 for the zigzag abrasion of the crown.
(2) Fault diagnosis: The abrasion is always related to improper adjustment of toe-in when turning the
wheel. If the abrasion is from the outside to inside, the toe-in is too big; if the abrasion is from inside to
outside, the toe-in is too small.
Fig. 3-5-6 Zigzag abrasion of the crown
(3) Cause and elimination methods: The size of toe-in may be changed due to the deformation of
the suspension rod or looseness of the joint. Try to avoid too big or small toe-in and adjust it to the
specified value.
5. Partial tire abrasion with deboss
(1) Fault: Partial tire abrasion with deboss (as shown in Fig. 3-5-7).
(2) Fault diagnosis: The abrasion is related to the dynamic unbalance of the wheel. When the
wheel is unbalanced, the wheel vibration may cause directional abrasion with deboss.
(3) Cause and elimination methods: The wheel abrasion with deboss is related to dynamic
unbalance of the wheel, so balance the wheel.
6. Fan-shaped abrasion of the tire
(1) Fault: Fan-shaped abrasion of one side of the crown. See Fig. 3-5-7.
Fig. 3-5-7 Abrasion with deboss and fan-shaped abrasion of tire
(2) Fault diagnosis: Fan-shaped abrasion of tire may be caused by no tire rotation for a long time or
improper position of the suspension.
(3) Cause and elimination methods: Regularly change the tire position, check and eliminate the
suspension fault.
7. Excessive abrasion of some tire
(1) Fault: Excessive abrasion of some tire while little abrasion of other tires.
第 109 页共 221 页
(2) Fault diagnosis: Check the suspension of the abraded tire, wheel location, wheel hub bearing gap,
wheel balance and rim deformation to find out the reason. The excessive abrasion of the crown
shows that the wheel camber angle is not standard. If the camber angle is too big, the outside of the
crown may be abraded too early; if the camber angle is too small, the inside of the crown may be
excessively abraded.
(3) Cause and elimination methods:
1) The abnormality of suspension system of the excessive abrasion wheel and deformation of
the supporting part may cause the abnormal single wheel location and overloading. Check the single
suspension spring, shock damper and the wheel location to find out and eliminate the fault.
2) Adjust and replace the wheel hub bearing due to its too large gap.
3) Excessive abrasion is caused by overloading of single tire due to wheel unbalance. Dynamic
balance inspection should be made.
4) Replace the deformed wheel rim.
8. Bump on the tire
(1) Fault: Bump or bulge on part of the tire.
(2) Fault diagnosis: Too large tire body stress and partial damage of the cord ply.
(3) Cause and elimination methods: High tire pressure causes bump on the tire due to too large
stress, or damaged tire bead during manual repair or tire removal. Replace the tire with large bump.
In addition, inflate the tire according to the specified air pressure, install and removal the tire on the
special tire changer to eliminate or reduce the bump.
i. Wheel removal
1. Unscrew the wheel nut for 180° (half-turn), see Fig. 3-5-8.
2. Lift the vehicle.
3. Remove the wheel.
Note: Never loosen the tight wheel through heating, which may shorten the useful life of the wheel.
ii. See Fig. 3-5-9 for the wheel installation.
Fig. 3-5-8 Wheel removal Fig. 3-5-9 Wheel installation
第 110 页共 221 页
Note:
1. Orderly tighten the wheel nuts to a proper torque to avoid bend of the wheel or brake disc.
See Fig. 3-5-9.
2. Before the installation, scrape off the rust on the mounting surface of the wheel or brake disc,
or brush it off with a steel brush.
3. While installation, align the wheel mounting surface with the brake to avoid looseness of the
wheel nut.
iii. Tire removal
1. Tire removal
Firstly, remove the wheel from the vehicle, and then remove the tire on the tire changer. Never
remove the tire with hands, which may damage the bead and rim. Never knock the rim and heavily
pry it with a tommy bar, to avoid deformation and damage to air impermeability. Tire and wheel
supporting installation should be done in the assembly plant, i.e. the “light point” of the tire should be
matched with the “heavy point” of the wheel to maintain steady driving.
(1) Deflate the tire.
(2) Loosen the joint between the tire and rim on the tire changer, rotate the tire and repeatedly
extrude it, and overturn the tire to loosen the other side. As shown in Fig. 3-5-10.
(3) Remove the clump weight on the rim.
(4) Place the wheel rim on the working plate 6 with its convex surface facing upward (as shown
in Fig. 3-5-10), slightly press it and control the pedal to firmly clip the bead.
(5) Apply a little lubricant on the rim edge. Press it down and fix the lifting rod to form a gap about
3 mm between the changer 7, 8 (as shown in Fig. 3-5-10) and the rim edge.
10
8
7
5
4
3
1
2
Fig. 3-5-10 Tire removal with a tire changer

1-press board, 2, 3, 4, 5-control pedal, 6-working plate, 7, 8-tire changer, 9-handle, 10-alignment pin
(5) Take the F end of the changer as a supporting point and pry the outer tire edge with a lever to
第 111 页共 221 页
join the F end of the changer. See Fig. 3-5-11.
Fig. 3-5-11 Installation of service plug
(7) Operate the pedal to start the working plate till the tire edge is completely removed.
(8) Remove the other outer tire edge with the above method.
2. Tire service
Most of the tire holes can be repaired with a service plug or vulcanizing sticking patch from the
inside of the tire. The two methods are as follows:
(1) Repair the tire hole with a service plug
1) File up the near side of the inner tire hole with a tire-repairing file.
2) Choose a larger service plug and insert it into the oillet of the lead tool.
3) Lubricate the service plug and lead tool by vulcanized liquid.
4) Insert the service plug in the hole from the inside of the tire with the lead tool.
(As shown in Fig. 3-5-12), heavily extrude the plug head to make the service plug head fit with the
inside of the tire.
Fig. 3-5-12 Installation drawing of the service plug
5) Leave the service plug at 0.8mm to the bead surface, and cut other parts.
(2) Repair the tire hole with cold tire-repairing patch
1) File up the near side of the inner tire hole with a tire-repairing file.
2) Evenly apply the vulcanized liquid for the filed surface in the tire and dry in the air to reach the
stickiness.
3) Peel off the protective cover of the tire-repairing patch, align the center of the patch with the
inner tire hole, and adhere the patch to the hole.
第 112 页共 221 页
4) Move forward and backward on the tire-repairing patch with a press-fit tool to firmly affix the
patch to the tire.
3. Tire installation
Fig. 3-5-13 Tire installation
Tire installation should be done on the tire changer. Pay attention to the marks on the tire. The
side with red mark should be outward. Align the repaired tire with the mark made in the removal. The
installation steps are as follows:
(1) Clean the bead seat on the rim.
(2) Fix the rim on the working plate (see Fig. 3-5-13), and lubricate the surface of the bead with
lubricant.
(3) Put the tire on the rim and inlay its left side and close-body side into the groove in the middle
of the rim.
(4) Adjust the changer 7 and 8 to proper position, lock the lifting rod and place the right tire edge
that is put into the rib groove on the G end and under the F end of the changer. See Fig. 3-5-13.
(5) Hold down the tire with hands and start the work bench to install one side of the tire edge.
(6) Evenly install the other side of the tire edge on the rim with the above method. Inflate the tire
and make dynamic balance inspection after the installation.
Note: Never stand on the tire while inflating, otherwise, the tire crack may injure the personnel.
Never exceed the specified tire pressure. If the bead doesn’t fall to the ground, deflate the tire. And
then re-lubricate the tire and inflate it.
Wheel balance
There are static balance and dynamic balance for the wheel and tire. See Fig. 3-5-14 for the
static balance. The weight is averagely distributed around the wheel. The wheel may hop (vertically
swing) due to non static balance. As a result, the wheel may be abraded unevenly.
See Fig. 3-5-14 for the dynamic balance. The weight is evenly distributed at both sides of the
center line to avoid swinging from right to left while running. The vehicle may horizontally swing due
to dynamic unbalance.
第 113 页共 221 页
Fig. 3-5-14 Wheel balance
Note: Clean the mud sediment from the rim.
Warning: To achieve sound balance, clean the stones in the tread pattern to avoid injuring the
operator while running.
第 114 页共 221 页
Section VI Drive Axle, Final Drive and Differential
I. Structure
The drive axles of Lifan minivan are of complete type and composed of final drive, differential, half
axle and rear axle housing.
15
18
14
13 16
12
17
19
16
17
18
15
8 14
9
7
6
5
10
11
12
4 13
3
2
1
Fig. 3-6-1 Structure of the final axle

1-flange, 2-oil seal, 3-front bearing, 4-final drive housing, 5-distance piece, 6-bearing, 7-adjusting shim, 8-final drive
cone driving gear, 9-final drive cone driven gear, 10-differential housing, 11-washer, 12-half axle bearing,
13-differential adjust nut, 14-differential bearing cap, 15-half axle gear thrust washer, 16-half axle gear, 17-planet gear,
18-planet gear thrust washer, 19-planet gear shaft
II. Check, repair and adjustment
i. Check
1. Check the roller and roller path of the bearing for oil-fired sign or metal peeling and pocking
mark, if any, please replace it.
2. Check the gear for eccentric wear or excessive wear, if any, please adjust or repair it.
3. Check the housing for crack, if any, please repair it.
ii. Check and adjustment of the differential half axle gear clearance
1. Check
The standard value of the differential half axle gear clearance is 0.05-0.15mm. The clearance
can be measured by flattening the soft fuse.
The half axle gear clearance can be reflected through half axle gear thrust clearance. Place a
washer on the half axle gear and measure it by dialgauge, as shown in Fig. 3-6-2. The thrust
clearance of the half axle gear must not exceed 0.37mm.
第 115 页共 221 页
Fig. 3-6-2 Differential half axle gear clearance
2. Adjustment
The differential half axle gear clearance can be realized through altering the half axle gear thrust
washer. There are four kinds of thickness for thrust washer, i.e. 0.9mm, 1.0mm, 1.1mm and 1.2mm.
iii. Adjustment of the final drive cone driving gear
1. Check of the bearing preload
Install the special tools (installation and repairing tools for cone driving gear) with bearing on the final
drive, connect the spring balance pulling hook to the excircle edge and loosen the shaft end nut of the
cone driving gear. When the initial motoricity of the flange is 9.8-25.5N (1.0-2.6), the preload of the
cone driving gear bearing should reach 50-130 N.M. See Fig. 3-6-3. If not applicable, it can be
adjusted through altering the thickness of the washer placed between the distance piece and the
bearing inner race. If the thickness of the washer is increased, the preload of the bearing will be
reduced, and vice verse.
Fig. 3-6-3 Check of the cone driving gear preload
Fig. 3-6-4 Imitated planet gear placed in the final drive housing
第 116 页共 221 页
Fig. 3-6-5 Adjustment of the imitated planet gear tools
b c
Fig. 3-6-6 Final drive housing a, b, c dimensional standard
Fig. 3-6-7 Standard value on the cone driving gear
2. Determining the cone driving gear adjusting shim
(1) The thickness of the shim must be redefined after each removal of the cone driving gear. For
convenience, special tools should be used. The method below is determined according to special
tools, with the imitated planet gear tool (A) placed in the differential housing. The shim is not installed,
as shown in Fig. 3-6-4.
(2) Place a dialgauge on the imitated tool, with the feeler shaft of the dialgauge placed 5-6mm
deep at the bottom of the imitated tool. Place the imitated tool on a panel and make the dialgauge
return to zero, as shown in Fig. 3-6-5.
(3) Place the imitated planet gear tool in the final drive housing, as shown in Fig. 3-6-6. Among
the three dimensions of a, b, c shown in the Fig., b stands for the thickness of the shim required to be
calculated and a+c=85.
Fig. 3-6-7 Standard value on the cone driving gear

第 117 页共 221 页
(4) When the copying machine is firmly fixed, the indicator of the dialgauge has deflected from
“0” to a certain value (i.e. b). Add b to the value of a+c (85), and then use the total minus the value
shown on the cone driving gear (see Fig. 3-6-7), as a result, the difference is just the shim thickness
required. Namely, the shim thickness required = (85 + b) - standard value.
There are 5 kinds of shim of different thickness for the vehicle, i.e. 0.05mm, 0.1mm, 0.2mm, 0.3mm
and 0.5mm. In the selection and combination of shims, the total shim thickness should be in
conformity with the required shim thickness as much as possible, and then insert the shim selected
into the clearance “d”, as shown in Fig. 3-6-8.
85MM
Fig. 3-6-8 Cone driving gear clearance
3. Check and adjustment of the cone driving and driven gear tooth surface position of
engagement.
Check the mark of engagement of the cone driving gear. See Table 3-6-1 for common marks of
engagement. In which (a) is normal contact type, which requires: the mark on the cone driven gear is
in the middle of the tooth depth, near the small end and occupying over 60% of the tooth width. The
rest is normal contact, which must be adjusted or processed as per Table 3-6-1.
4. Adjustment of the final drive cone driving and driven gear clearance
Install the dialgauge as per Fig. 3-6-9 and let it face to the root of the convex side of the gear.
Check the bearing cap bolt. The torque is 15N.M. And then grasp the cone driving gear and turn the
cone driven gear round and round. The indication of the dialgauge at the moment is the clearance
value and the standard value should be 0.10-0.20m. If not applicable, it can be adjusted through the
differential adjust nut.
Fig. 3-6-9 Adjustment of the cone driving and driven gear clearance
III. Maintenance
i. Installation and removal of the final drive and differential assembly
第 118 页共 221 页
(1) Let out the gear oil in the drive axle and remove the left/right half axle of the drive axle.
(2) Remove the drive shaft.
(3) Unscrew the 8 bolts connecting the final drive housing and the drive axle and remove the
final drive assembly.
(4) Install as per the reverse order for removal.
ii. Disassembly of the final drive and differential assembly
(1) Lock the shaft end flange of the cone driving gear and remove the shaft end nut.
(2) Make marks on each bearing cap and seat surface of the right and left differential housing for
identification and installation.
(3) Remove the lock piece of the differential housing bearing adjust nut and remove the adjust
nut. Remove the right and left bearing caps and then remove the differential assembly out of the final
drive housing.
(4) Remove the half axle bearing using special tools.
(5) Remove the retaining bolt of the cone driven gear and then remove the cone driven gear.
(6) Remove the planet gear shaft and then remove the planet gear, half axle gear and thrust
washer.
(7) Remove the half axle bearing using special tools.
IV. Common faults and elimination methods
See Table 3-6-2 for drive axle common faults and elimination methods.
Fig. 3-6-1 Check and adjustment of the cone driving and driven gear tooth surface position of
engagement
Engagement Engagement system

Processing method Processing method
system (marks) (marks)
Replace the
Normal
differential housing
High-order contact 1. Check the cone

The cone driving gear is driven gear seat or
too far, so the thickness of the differential
the cone driving gear 内端 housing.
内端
内端
adjusting shim should be 2. Replace the cone
increased. （e ） driving gear and the
（b ）
cone driven gear.
第 119 页共 221 页
Low-order contact
The cone driving gear is
too near, so the thickness 1. Replace the cone
of the cone driving gear driving gear and the
adjusting shim should be cone driven gear.
reduced. 2. Replace the
differential housing.
Table 3-6-2 Drive axle common faults and elimination methods
Faults Fault causes Elimination

methods
Insufficient or unmatched lubricant. Add or replace
The final drive gear back lash is too large or too small. Adjust
The final drive gear position of engagement is incorrect. Adjust or replace
Abnormal
The final drive gear area of engagement is too small. Adjust or replace
sound
The differential back lash is too large. Check and repair
The circulation of bearing, the higher vehicle speed, the louder noise. Replace the
Less noise for sliding. bearing
The connecting bolt and the drain screw plug are loosened. Screw down
The sealing pad of the final drive and the differential is damaged. Replace
The rear axle breather valve is blocked. Lubricate the
breather valve
Oil Excessive lubricant. Discharge
leakage The oil seal lip of the final drive or the half axle is deformed, worn or Replace
cracked.
The cone driving gear bearing preload is too large, the bearing emits Adjust the
excessive heat during operation, and the pressure in the axle housing bearing preload
rises or the oil seal is damaged.
第 120 页共 221 页
Section VII Brake System
Note:
All the fasteners on the brake connection are very important, because they will influence the
performance of main parts and the system and increase maintenance costs. When necessary, it is
required to use the parts of same part No. or equivalent parts rather than defective products or
replace parts to replace the old ones. For reassembly, all the parts must be screwed down as per the
specified torque. The welding method is prohibited, because welding may result in large-area
damage and softening.
I. Structure
The brake system is divided into service brake system and parking brake system.
i. Structure of the service brake system
The service brake system is composed of vacuum booster with brake master cylinder assembly,
brake pipeline, wheel cylinder, loading sensing pressure proportioning valve, etc., as shown
in Fig. 3-7-1.
4
3 5
2
1
Fig. 3-7-1 Structure of the service brake system without ABS

1-primary oil line, 2-master cylinder, 3-secondary oil line, 4-brake booster, 5-four-way connection,
6-loading sensing pressure proportioning valve
iii. Parking brake system
The parking brake system is composed of brake lever assembly, brake cable assembly, etc. See Fig.
3-7-2 for the structure of rear wheel brake and parking brake system.
第 121 页共 221 页
Fig. 3-7-2 Structure of the parking brake
1-center cross member, 2-front parking brake cable, 3-right parking brake cable, 4-left parking brake cable
II. Check, repair and adjustment

i. Adjustment of the brake pedal free travel
The brake pedal free travel is the travel of the brake pedal within the period when the brake
pedal is depressed to the brake master cylinder starts to work. The brake pedal free travel reflects the
total clearance of the brake drive units, if it is too large or too small, it will influence the braking
efficiency. The free travel is 6-12mm, if not as specified, the pedal axle bolt and the master cylinder
pin should be checked for loose and the installation position of the brake lamp switch should be
checked for appropriate.
ii. Check of the brake pedal free travel
The brake pedal travel is the moving distance of the brake pedal when it is depressed with the
force of 294N (30kg) by depressing the brake pedal for several times after the engine starts to work.
The pedal travel (50-75mm) of Lifan minivan is measured by the distance between the pedal and the
inner wall of the dash board, which should be more than 155mm.
ii. Check of the brake pedal free travel
Fig. 3-7-3 Brake pedal travel Fig. 3-7-4 Brake pedal free height
第 122 页共 221 页
a
Fig. 3-7-5 Adjustment of the brake pedal free height
The brake pedal free height is the distance between the brake pedal and the inner wall of the
dash board (see Fig. 3-7-4) when the brake pedal is in free status. The brake pedal free height can be
realized through releasing the brake master cylinder push-rod fork lock nut, adjusting the push-rod
fork lock nut and adjusting the push-rod fork (see Fig. 3-7-5). The standard for adjustment: the
distance a between the installation surface of the vacuum booster and the center of the push-rod fork
pin hole is 99.5-100.5vmm. When adjusting the brake pedal free height, the position of the brake
switch should also be adjusted.
iv. Check and adjustment of the parking brake
It is required to pull the parking brake lever with the force of 196N (20kg) and output the number of
teeth of the ratchet through the “click” sound produced by the ratchet, which should be 6-8. If the
number of teeth is few, it is difficult to release the parking brake; if the number of teeth is excessive, it
is difficult to tighten the parking brake. If the number of teeth is not in conformity with the standard, it
can be adjusted through the cable adjust nut at the back of the parking brake lever assembly. See Fig.
3-7-6. The adjustment of the parking brake should pay attention to:
(1) Ensure that the clearance between the two rear wheels is in specified range. The rear wheel
shoes can not be over worn.
(2) The brake pedal travel must conform to the standard.
(3) Depress the brake pedal for several times before adjustment and pull the parking brake lever
to the maximum for several times.
1
2
Fig. 3-7-6 Hand brake lever

1-adjust nut, 2-lock nut
v. Change of the brake fluid
There are the highest and lowest marks for the brake fluid level on the brake master cylinder
fluid reservoir. If the brake fluid is insufficient, please add in time; if the fluid level decreases too much
in a short time, please check for leakage.
第 123 页共 221 页
The brake fluid is provided with hygroscopicity, which is able to absorb the water content in the
air. Excessive water content will reduce the braking efficiency, so the brake fluid should be replaced
regularly.
For adding or replacing brake fluid, the brake fluid of specified brand should be used. The brake
fluid of different brand contains different chemical composition. Filling mixed brake fluid will damage
the parts of the brake system and influence the safety performance.
vi. Brake system bleeding
After the brake pipeline is removed or subjected to leakage, the brake system will be filled with
air, at the same time, the aerification of the brake fluid will also generate air in the brake pipeline. If
there is air in the brake system, the brake pedal will feel spongy, the brake pedal travel when braking
will increase, the braking efficiency will be reduced, and this may result in brake failure in severe
cases. So if there is air in the brake system, it must be bled fully.
The bleeding should be done by two persons cooperatively as per the following steps:
(1) Check the brake fluid level in the brake master cylinder fluid reservoir, the fluid level should
be in the standard range.
(2) Remove the air bleed nut at the brake caliper, insert one end of the special hose into the air
bleed plug and insert the other end into the reservoir with brake fluid.
(3) After depressing the brake pedal for several times continuously, keep it depressed and
loosen the air bleed plug with wrench till fluid gets out. When the fluid in the cylinder is almost fully
bled, screw down the air bleed plug once again.
(4) Repeat the above operation till no air bubble emerging in the hydraulic pipe. Continuously
observe the fluid level in the brake master cylinder fluid reservoir in the process of air bleed, add
immediately when the fluid level is too low.
(5) After no air bubble, screw down the air bleed plug with the brake pedal depressed.
(6) Bleed air for other wheels’ brake pipelines in the same way.
(7) Check if the brake pedal is spongy, if any, please repeat the air bleed steps.
(8) Recheck the height of the brake fluid level to make it reach the specified level.
vii. Check of the brake booster
The brake booster can be checked using instrument or simple method, for maintenance, simple
method is priority.
1. Check of the air tightness
Start the engine and let it run for 1-2 minute(s), and then close the engine, depress the brake
pedal for several times, the height of the brake pedal above ground level should increase gradually
(especially for the first and the second time). If so, it indicates good air tightness for the vacuum
booster. If the pedal height doesn’t change or changes a little, it indicates poor air tightness for the
brake booster, for which the vacuum pipeline and the inner side of the brake booster should be
checked for leakage.
2. Check of the load tightness
Start the engine and let it run for 1-2 minute(s), and then depress the brake pedal, and close the
第 124 页共 221 页
engine with the pedal force unchanged, the height of the brake pedal should not change in 30
seconds. If any change, it indicates fault of the brake booster.
3. Functional check
When the engine doesn’t work, depress the brake pedal for several times with the same force till
the pedal travel doesn’t change any more, depress the brake pedal by foot and start the engine, for
the time being, it is able to feel slight downward movement of the brake pedal, which indicates that
the brake booster works well. If the pedal travel doesn’t change, it indicates fault of the brake booster.
viii. Check of the brake pipeline
(1) The brake pipeline should be free of oil leakage, deformation, corrosion, damage, etc.
(2) The brake hose should be free of ageing phenomenon.
(3) The brake pipeline should be fixed firmly and be free of collision, friction, etc. with other parts.
III. Installation, removal, check and repair of main parts
i. Check and repair of the brake master cylinder
Structure of the brake master cylinder (see Fig. 3-7-7)
7
5 6
4
3
2
1
Fig. 3-7-8 Structure of the brake master cylinder

1-master cylinder, 2-O-ring, 3-secondary piston assembly, 4-first piston assembly, 5-cylinder cover and base plate,
6-piston locating piece, 7-snap spring
1. Removal
(1) Take out the brake pump snap ring with a snap spring plier and remove the 1st piston.
(2) Remove the positioning bolt of the 2nd piston, blow off the compressed air in the bolt and blow off
the 2nd piston.
2. Check
Check if there is sewage in the master cylinder. Check the piston and cylinder wall for breakage,
corrosion, etc. and check the packing cup for damage.
3. Installation
Apply brake liquid on the master cylinder wall and in piston surface marmite. Firstly put the 2nd piston
in the cylinder and then the 1st piston, install the snap spring and then the 2nd piston positioning bolt,
properly position the piston and screw down the bolt with a torque of 10N.m.
ii. Check and repair of the front brake assembly

第 125 页共 221 页
The front brake adopts disc brake, with structure as shown in Fig. 3-7-8.
1. Check and repair of the guide pin
Check the guide pin for corrosion, free movement, bending, etc. If not good, please repair or replace
it.
2. Check and repair of the brake plate
(1) Check the brake plate for oil stain, if any, please clean it with gauze.
(2) Check the brake plate for crack, obscission, etc. if any, please replace the brake plate.
(3) Check the thickness of the brake plate, the standard thickness should be 15mm (including the
base plate) and the limit value should be 9mm (including the base plate). If the limit value is exceeded,
it should be replaced.
1 2
3
4
5 6
17 7
8
18 9
10 11
12
16
13
15
14
Fig. 3-7-8 Structure of the front brake
1-bolt, 2- air bleed bolt, 3- caliper, 4-brake piston, 5-piston seal, 6-dustproof cover locating ring, 7-dustproof cover,
8-guide pin, 9- shield, 10-caliper locating rack, 11-brake plate lining, 12- snap spring, 13-brake plate, 14-brake disc,
15-brake base plate, 16-steering knuckle, 17-retaining bolt, 18-washer
3. Check and repair of the brake disc
(1) Check the brake disc for oil stain, if any, please clean it with gauze.
(2) Check the brake disc for crack, corrosion, severe damage, etc. if any, please replace it.
(3) Check the thickness of the brake disc, the standard value is 17mm and the limit value is 15mm. If
the limit value is exceeded, it should be replaced.
(4) Measure the end face runout of the brake disc
Measure the end face runout of the brake disc using dialgauge, if it exceeds 0.15mm, the brake
disc surface should be corrected by means of turning, polishing, etc. If it exceeds too much, please
replace the brake disc.
4. Caliper assembly
(1) Check the caliper for crack, deformation, etc., correct or replace as appropriate.
(2) Check the piston dustproof cover for damage or crack, if any, please replace it.
(3) Check the piston seal for ageing, crack, etc., if any, please replace it.
(4) Check if the piston shows oil leakage, the movement is blocked and the return is smooth, if there
are any defects, please do the repair. Check the piston and the cylinder wall for damage, corrosion,
第 126 页共 221 页
etc., if any, please replace the caliper assembly.
iii. Check and repair of the rear brake
The rear brake adopts drum brake, as shown in Fig. 3-7-10.
3
7
5 8
6 4 9 10 14
12 15
11
16
13
15
14
17
Fig. 3-7-10 Structure of the rear brake
1-bolt, 2-brake shoe pressure pin, 3-wheel cylinder, 4-self-adjusting unit assembly, 5-brake shoe upper return spring,
6-latch, 7-brake trailing shoe assembly, 8-ring washer, 9-left self-adjusting switch plate, 10-ring washer,
11-self-adjusting switch plate return spring, 12-right self-adjusting switch plate, 13-brake leading shoe assembly,
14-brake shoe pressure spring seat, 15-brake shoe pressure spring, 16-brake shoe lower return spring
1. Check and repair of the brake shoe
(1) Check the brake shoe for oil stain, if any, please clean it with gauze. Check the brake shoe
for crack, obscission, etc. if any, please replace it.
(2) Check the thickness of the brake shoe, the standard thickness is 5mm and the limit value is
2mm. If the limit value is exceeded, please replace it. If the thickness of one of the brake shoes
exceeds the limit value, all the brake shoes must be replaced at the same time.
2. Check and repair of the brake drum
(1) Check the work surface of the brake drum: if there is oil stain, please clean in time; if there is
crack or deformation, please replace the brake drum.
(2) Check the diameter of the brake drum, the standard value is 228.6mm and the limit value is
230.6mm. If the diameter exceeds the limit value, the brake drum should be replaced.
(3) Check if there is notch on the work surface of the brake drum, if any, please polish it with
gauze (turning is prohibited here).
3. Check and repair of the wheel cylinder
See Fig. 3-7-11 for the structure of the wheel cylinder.
(1) Check if the wheel cylinder shows oil leakage and if the dustproof cover is broken.
(2) Check if the wheel cylinder piston and the cylinder wall are damaged, the spring is broken
and the oil seal is damaged, if any, please replace the wheel cylinder assembly.
第 127 页共 221 页
1
2
5 3
4
5
2
1
Fig. 3-7-11 Structure of the rear wheel cylinder

1-dustproof cover, 2-piston, 3-cylinder, 4-spring, 5-oil seal
Fig. 3-7-12 Structure of the vacuum booster

1-piston, 2-diaphragm, 3-return spring, 4-push rod, 5-check valve, 6-air filter, 7-air vent, 8-cavity vacuumization duct,
9-control rod, 10-plunger vacuum valve, 11-thrust disc, 12-air valve
4. Check and repair of the spring
Check if the spring is broken, deformed or the elasticity is reduced, if any, please replace it.
iv. Vacuum booster
See Fig. 3-7-12 for the structure of the vacuum booster. The vacuum booster of Lifan minivan can not
be examined and repaired through disassembly and only the assembly can be replaced.
1. Removal
(1) Remove the brake cylinder assembly.
(2) Cut off the brake lamp switch lead. Remove the pedal bracket extension. For vehicle with ABS,
remove the oil pipe nuts with open connection and take down the brake pipe. Remove No. 1 vacuum
hose from the vacuum booster and No. 2 vacuum hose from the instrument panel and take down the
oil pipe and hose (see Fig. 3-7-13).
第 128 页共 221 页
1
2
3 4
Fig. 3-7-13 Removal of the external accessories of the booster

1-vacuum hose, 2-four-way valve, 3-brake lamp switch, 4-lower steering shaft
(3) Cut the clutch cable off the clutch pedal wall.
(4) Remove the lower steering shaft.
(5) Unscrew the installation nut of the pedal bracket at the instrument panel and remove the pedal
bracket with brake booster (see Fig. 3-8-14).
Fig. 3-7-14 Pedal of the vacuum booster

a- retaining nuts of the brake pedal bracket
(6) Remove the U-shape clip of the push rod from the brake pedal wall. Unscrew the retaining nuts of
the brake booster. Remove the brake booster from the brake pedal bracket (see Fig. 3-7-15).
Fig. 3-7-15 Removal of the brake booster

a- retaining nuts of the vacuum booster
2. Assembly
第 129 页共 221 页
Assembly should be done following the order opposite to removal.
3. Adjustment of the clearance between the vacuum booster push rod and the master cylinder
piston
Adjust the length of the vacuum booster push rod to keep the specified clearance between the push
rod and the master cylinder piston (see Fig. 3-7-16).
Fig. 3-7-16 Clearance between the booster push rod and the master cylinder piston
Through the below adjustment, it is ensured that the idle speed operation of the engine places
negative pressure on the booster to make the clearance between the piston and the push rod,
a=0.25～0.5mm.
(1) Place the special tool on the master cylinder and rotate the push rod till it touches piston (see Fig.
3-7-17).
(2) Reverse the special tool and put it on the booster. Adjust the length of the booster push rod till the
push rod end touches the pin cap, namely, clearance b=0mm (see Fig. 3-7-18).
第 130 页共 221 页
A
“ b”
1
2
Fig. 3-7-18 Adjustment of the clearance between the booster push rod and the master cylinder piston
(3) Adjust the clearance through rotating the piston rod adjusting bolt clamp (see Fig. 3-7-19).
Fig. 3-7-19 Adjustment of the clearance between the booster piston rod and the master cylinder
piston
B Special tools
v. Loading sensing proportioning valve (LSPV)
1. See Fig. 3-7-20 for the structure of LSPV.

1 8 2 3
7
4
6 5
Fig. 3-7-20 Loading sensing proportioning valve assembly

1-LSPV assembly, 2-spring, 3/6-oil pipe, 4-LSPV spring, 5-LSPV rod, 7-oil pipe, 8-nut
LSPV consists of the following parts:
(1) The sensor part is composed of control lever, spring, etc., which could sense the height change of
第 131 页共 221 页
vehicle and turn the change into loading signal when the spring is influenced by loading.
(2) The hydraulic pressure control part is composed of plunger and proportioning control valve
system, etc.
(3) The failsafe part is composed of piston chamber and failsafe piston, etc. The piston chamber
absorbs hydraulic pressure through the front wheel brake. When a fault happens to the front wheel
brake system, the failsafe piston will release valve system pressure to connect this system with the
rear wheel brake.
2. Visual inspection
(1) Check if LSPV spring carrier, rod or oil pipe is deformed, if any, please do the repair.
(2) Check if there is leakage at LSPV assembly, if any, please do the repair.
3. Check and adjustment of LSPV spring
Park vehicle on level ground, as shown in Fig. 3-7-21. Push LSPV rod upwards with hand until it can
not be pushed. Measure the spring length “L”, which should be 305 mm. If it doesn’t conform to
regulation, please adjust it through nut a.
Fig. 3-7-21 Check of LSPV spring
4. LSOV hydraulic test
Before the test, fill up the fuel tank and ensure the standby tire, tools, jack and jack handle in
place.
(1) Install the pressure indicator on the front and rear brake, slowly add the weight to the rear
axle to make it reach 660kg, as shown in Fig. 3-7-22.
制动器 A
Brake
C
A 重量
Weight
D L
第 132 页共 221 页
Fig. 3-7-22 Press measurement of the front and rear brakes
(2) Gradually step down the brake pedal to keep the pressure of the front brake in the specified
range, and check if the pressure of the rear brake is in the specified range. The specified pressure of
the front brake is 4200～5600kpa.
(3) While meeting the above requirements, apply the pressure of 10,000kpa on the front brake.
Check if the pressure of the rear brake is 4,800～6,200kpa; if not, change the tightening position of
bolt a, adjust it orderly, as shown in Fig. 3-7-23. If the pressure of the rear brake is higher than the
specified value, screw up bolt a downward; to the contrary, screw up bolt a upward till the pressure of
the rear brake meets the specified technical requirements. After that, screw down the nut with
specified torque.
（a) 3
1.LSPV拉杆
2.LSPV弹簧
1. 3.LSPV撑
LSPV pull rod条
Fig. 3-7-232.Adjustment
LSPV spring
of LSPV spring
3. LSPV strut
(4) Disconnect the brake pipe to the master cylinder (connection pipe between the master
cylinder and 4-way joint), screw down the screw plug on the master cylinder with special tool, and
step down the brake pedal. If the pressure of the front brake is 10,000kpa and the pressure of the
rear brake is 9,500～10,000kpa, the brake system is in sound condition.
(A)
1. Master1.主泵
cylinder
Fig. 3-7-24 Screw down the screw plug on the brake pump
(5) After the test, dismantle the hydraulic pressure indicator or oil pipe, exhaust the brake system
and make the brake efficiency meet the requirements.
IV. Common faults and elimination methods
Method of depressing brake pedal should be used for checking. If the height of the pedal
increases gradually and elasticity is felt, depress the brake pedal again after the vehicle drives for a
moment. If the brake pedal is sensed to be too low, there may be air in the brake system.
(2) Depress the brake pedal once. If the pedal is too low, depress it for several times
continuously and the height of the pedal becomes normal, which may be caused by that the free
travel of the pedal is too big or that the brake clearance is too big.
第 133 页共 221 页
(3) The brake pedal is depressed and the pedal height is normal but braking efficiency is poor,
which is generally a fault of wheel brake, such as oil stain on brake shoe, bad contact of brake shoe,
aging or broken lining, uneven wear of brake hub, etc.
2. Braking drag
(1) If there is braking drag for the four wheels, it is generally a fault of brake master cylinder.
(2) If there is braking drag for one or two wheels, lift the vehicle with jack and loosen bleed bolts
of the drag wheel to let brake fluid flow out through bleed hole. If drag disappears, the fault may be
caused by that the oil return of brake master cylinder or the brake line is not smooth, or that the free
travel of the brake pedal is too big. If there is still drag, the fault may be caused by that brake
clearance is too small, brake shoe return spring is too soft or parking brake system is blocked.
ii. Table of common faults

Table 3-7-1 Table of the brake system faults
Fault Possible position and reasons of fault Elimination method
1. Wheel brake fault
(1) Brake disc is distorted or its wear exceeds limit. Replace
(2) Bad contact between brake drum and brake shoe Repair or replace
(3) There is oil stain or water at brake lining. Clean
(4) Brake plate wear exceeds the regulated value. Replace
(5) Brake caliper assembly fault Repair or replace
2. Wheel cylinder fault

(1) Wheel cylinder piston is out of nimbleness. Replace
(2) There is oil leakage at wheel cylinder. Replace
3. LPSV
(1) Sensor of LSPV is improperly adjusted. Adjust
(2) Sensor spring of LSPV is damaged. Replace
(3) LSPV assembly is damaged. Replace
Insufficient
3. Master cylinder fault
braking force
(1) Rubber sealing ring in master cylinder is Replace
damaged. Replace
(2) Wear between piston and cylinder is so much
that the piston becomes loose, causing oil leakage. Replace
(3) Return spring of master cylinder piston is too Clean the spill port and
soft. the compensating port
(4) Spill port or compensating port of master cylinder
is blocked.
Repair
4. Vacuum booster fault
(1) Vacuum booster pipe connection is loose or Replace
there is air leakage of hose. Replace
(2) Inner vacuum booster is blocked. Replace
(3) There is air leakage of vacuum booster.
(4) Single check valve of vacuum booster is out of
work.
Table 3-7-1 Table of the brake system faults (continued)

Fault Possible position and reasons of fault Elimination method
1. Master cylinder and wheel cylinder fault
Braking drag (1) Spill port of master cylinder is blocked. Clean
(2) Master cylinder or wheel cylinder sealing ring is aged, Replace the master cylinder
第 134 页共 221 页
distorted or out of nimbleness.
(3) Return spring of master cylinder piston is too soft or Replace the master cylinder
broken.
(4) Inner vacuum booster is blocked. Replace the vacuum booster
2. Brake fault
(1) Automatic regulating apparatus of brake clearance is bad. Check and repair
(2) Brake spring is too soft or broken.
(3) There is no clearance between brake drum and brake Replace the spring
shoe, or between brake disc and lining. Adjust
(4) Brake drum or brake disc is out of round.
Turning or replacing
3. Other reasons
(1) There is no free travel of brake pedal.
(2) Parking brake system is blocked. Adjust
Check and repair the parking
(3) Brake line is dirty. brake system
(4) Brake line is flattened. Clean
Replace
1. Brake fault
(1) There is water or oil stain at lining of brake disc or lining of Clean
brake shoe.
(2) Clearance between brake drum and brake shoe of brake Adjust
is maladjusted.
(3) Brake disc or brake drum of brake is out of round. Turning or replacing
(4) Wheel cylinder fault Replace
(5) Brake caliper fault Replace
Braking
2. Wheel status
deviation
(1) Tire doesn’t match. Replace
(2) Wheel pressure is different. Check the inflation
(3) Wheel hub bearing is worn or loose. Replace or adjust
3. Other reasons
(1) Suspension component is loose. Check & tighten
(2) Clip pin is loose. Check & tighten
(3) Locating of front wheels is inaccurate. Do rotation for front wheels
(4) Left/right wheelbase is unequal. Adjust
Rear brake is 1. LSPV sensor spring length is adjusted improperly. Adjust
locked too early 2. LSPV assembly fault Repair or replace LSPV
(for vehicle assembly
equipped with
LSPV)
1. Brake fluid is insufficient. Replenish
2. There is air inside brake system. Bleed
Travel of brake 3. Clearance between brake drum and lining of the rear brake Adjust
pedal is too big system is too big.
4. Brake shoe is bent. Replace
5. Rear brake shoe is worn. Replace

1. Brake master cylinder is broken or loose. Adjust or replace
2. Steering knuckle is distorted. Replace
Brake pedal jumps during
3. Brake disc steering jumps greatly. Turning or replacing
braking.
4. Parallel speed of brake disc doesn’t meet Turning or replacing
technical requirements.
第 135 页共 221 页
5. Rear brake drum is maladjusted. Turning or replacing
1. Brake shoe is worn or attached with impurity. Polish or replace
2. Brake shoe is worn or distorted.
There is noise during when
3. Front wheel bearing is loose. Replace
braking is done.
4. Base plate is distorted or installation bolts are Replace
loose. Check and repair
1. Parking brake is not loosened. Release
Brake warning lamp is on 2. Brake fluid is insufficient. Replenish
after engine starts. 3. There is oil leakage at brake pipe. Repair
4. Brake warning lamp circuit fault Check and repair the circuit
Brake warning lamp is on 1. There is oil leakage at brake pipe. Repair or replace
when braking is done. 2. Brake fluid is insufficient. Replenish
1. Wheel brake fault
(1) Brake disc is distorted or its wear exceeds Replace
limit.
(2) There is bad contact between brake drum and Repair or replace
brake shoe.
(3) There is oil stain or water at brake lining. Clean
(4) Wear of brake plate exceeds the regulated Replace
value.
2. Brake caliper assembly fault Repair or replace

3. Wheel cylinder fault
(1) Wheel cylinder piston is out of nimbleness. Replace
(2) There is oil leakage at wheel cylinder.
Replace
4.LPSV
(1) Sensor of LSPV is improperly adjusted.
(2) Sensor spring of LSPV is damaged. Adjust
(3) LSPV assembly is damaged. Replace
Insufficient braking force Replace
5. Master cylinder fault
(1) Rubber sealing ring in the master cylinder is
damaged. Replace
(2) Wear between piston and cylinder is so much
that the piston becomes loose, causing oil Replace
leakage.
(3) Return spring of master cylinder piston is too
soft. Replace
(4) Spill port or compensating port of master
cylinder is blocked. Clean the spill port and the
compensating port
6. Vacuum booster fault
(1) Vacuum booster pipe connection is loose or
there is air leakage of hose. Repair
(2) Inner vacuum booster is blocked.
(3) There is air leakage of vacuum booster. Replace
(4) Single check valve of vacuum booster is out of Replace
work. Replace

1. Master cylinder and wheel cylinder fault
(1) Spill port of master cylinder is blocked. Clean
Braking drag (2) Master cylinder or wheel cylinder sealing ring is Replace the
aged, distorted or out of nimbleness. master cylinder
(3) Return spring of master cylinder piston is too soft or Replace the
第 136 页共 221 页
broken. master cylinder
(4) Inner vacuum booster is blocked. Replace the
vacuum booster
2. Brake fault
(1) Automatic regulating apparatus of brake clearance Check and repair
is bad. Replace the
(2) Brake spring is too soft or broken. spring
(3) There is no clearance between brake drum and Adjust
brake shoe, or between brake disc and lining.
(4) Brake drum or brake disc is out of round. Turning or
replacing
3. Other reasons
(1) There is no free travel of brake pedal. Adjust
(2) Parking brake system is blocked. Check and repair
the parking brake
system
(3) Brake line is dirty. Clean
(4) Brake line is flattened. Replace
第 137 页共 221 页
Chapter IV Electrical System
Section I Overview
The operating power of the electrical element is supplied by battery or generator, with standard
voltage of 12V. The electrical system adopts negative earth.
I. Notes for maintenance
The following notes should be obeyed in the relevant electrical system maintenance to protect
electrical elements and avoid fire disaster.
1. Firstly check the ignition switch and all other switches for closing when taking town the battery
from the vehicle or disconnecting the lead from the battery terminal to check and maintain the
electrical system. Otherwise, the semiconductor element may be damaged.
2. Firstly disconnect the negative terminal and then the positive terminal to disconnect the lead
from the battery. Connect the lead with the battery in a reverse order of disconnection.
3. Never pull or drag the harness when disconnecting the interface. Firstly open the lock pin of
the interface, and then grasp the joint with hands to disconnect it. When connecting the interface,
grasp the joint with hands and push the interface in till it’s firmly locked.
When installing the harness, fasten it with a clip without looseness.
4. When installing parts for the vehicle, the part should never block the harness or press the
harness.
5. To avoid damaging the harness, twine the harness contacting with the edge with PVC tape.
6. Use the fuse with specified current fusing value. Using the fuse with larger fusing value may
burn the electrical parts or cause fire disaster.
7. Be careful not to treat the spare parts of the electrical appliances with hand rudely or make
them fall off.
8. If the surrounding temperature exceeds 80℃, remove the electrical parts with poor
resistance-to-high-temperature during the maintenance.
9. Never contact the interface and electrical elements with water; otherwise, it may cause failure.
10. Insert the probe of the inspection equipment from the harness side when checking the
conduction or measuring the voltage with inspection equipment.
II. Symbol and marks
1. In the circuit diagram of this manual, each electrical element should be marked with the following
symbol and mark.
表 4-1-1 符号与标记
第 138 页共 221 页
HOT
M M speed tacho temp

flue
S α
M
f L E
M M λ
OFF
ACC
I G1
ST
2 1 3
1 4 3 2
Table 4-1-1Symbol and mark

Nam Normal diode LED VCD Thermal diode Photodiode PNP NPN transistor Automatic reset Non-automat Automatic
e transistor button switch ic reset reset
button switch rocker
switch
Mark
Nam Non-automatic Normally Normally close Resistor Adjustable Photo Capacitor Polar capacitor Adjustable Noise filter
e reset rocker open machine resistor/ resistanc capacitor
switch machine operating switch potentiomet e
operating er
switch
Mark
第 139 页共 221 页
Nam Coil without Electric D/C motor A/C motor Bulb/lamp Various Speedometer Fuel gauge Tachometer Water
e magnetic core sensor indicator thermomet
with signals er
magnetic
core
Mark
Nam Odometer Starter Generator Fusible link Fast acting Slow Electromagnet Speed sensor Angular Temperatur
e fuse acting ic clutch displacement e sensor
fuse sensor
Mark
Nam Fuel sensor Speed Throttle position Weak Coolant Relay A Relay B Double-contact Flash relay Fuel pump
e sensor sensor acceleration temperature relay
sensor sensor
Mark
Nam Washer motor Cooling Fuel injector Oxygen sensor Canister Battery Disconnected Interconnected Ground point Separable
e fan motor solenoid lead lead connector
valve
Mark
Nam Safety belt Outside Ignition switch Defroster Spark plug Cigar Electric horn Buzzer Audio Electrical
e pretensioner/A rear view lighter speaker elements
ir bag module mirror or control
motor module
assembly
Mark
Nam Digital clock Pointer Ignition coil Wiper motor

e clock
Mark
2. Lead color marks
The lead color is marked with the first (or 2) letter(s) of a word.
Table 4-1-2 Abbreviation for lead color

Lette W B R G P Bl O Br Y Gr Lg V
r
Color Whit Blac Red Gree Pink Blue Orang Brow Yello Gra Light Viole
e k n e n w y gree t
n
III. Numbering rule
1. S/N of butt connector between two harness assemblies
The S/N of connector is based on the harness. The S/N of butt connector between two harnesses is
marked by 3 or 2-digit code. For example: when there are several butt connectors between the front
第 140 页共 221 页
harness and the body harness, the S/Ns are UA1, UA2….And the S/Ns for connectors between the
body harness and the front harness are BA1, BA2….The first letter of the abbreviation marks the
harness of the connector, and the latter 2 codes (the same) show the relation of each connector for
two pair of harnesses. If there is only one connector, the latter number can be omitted; thus the S/N is
UA or BA.
The S/N of connector should start from the butt position between two harnesses. See Table 4-1-3 for
the numbering rule of common harness code and connector code.
Fig. 4-1-1 Numbering rule
2. S/N of butt connector of parts
Table 4-1-3 Numbering rule for common harness code and connector code
Main harness Butt harness Main harness Butt harness
Harne
Harness Name of butt Connect Harness Harnes Name of butt Connect
ss
name connector or code name s code connector or code
code
Power assembly
Body harness
A harness B
connector
connector
Instrument panel Instrument panel
Forecabi harness B harness C
Chassis
n U connector C connector
harness
harness Power assembly Forecabin
harness C harness E
connector connector
Chassis harness Body harness
E F
connector connector
Power assembly Instrument panel
harness A harness A
connector connector
Forecabin Power
Instrume Chassis harness
harness B assembly E B
nt I connector
connector harness
harness
Forecabin
Chassis harness
C harness C
connector
connector
Body harness D Roof R Body harness B
第 141 页共 221 页
connector harness connector
Instrument panel
Roof harness
E harness E
connector
connector
Air bag harness Door harness
F B
connector connector
Rear
Air conditioning
compartment
harness G C
door harness
connector
connector
Floor
Door harness F Body harness
H harness E
connector connector
Antenna harness
J
connector
Forecabin
harness A
connector
Roof harness Floor harness
B B
connector connector
Rear
Instrument panel
compartment
harness D C
door harness
connector Door
D connector
harness
Body Floor harness Body harness
B E G
harness connector connector
Instrument panel
Chassis harness
F harness H
connector
connector
Door harness Floor harness
G C
connector Rear connector
Rear compartme
L
compartment nt door Body harness
H H
door harness harness connector
connector
Instrument Air Instrument panel
Antenna
W harness J conditionin A harness G
harness
connector g harness connector
Instrument panel
Air bag
S harness F
harness
connector
The S/N of connector is based on the harness. The S/N of butt connector between the harness and
part is marked by 2-digit code, as shown in Fig. 4-1-2. For example: when there are several butt
connectors between the front harness and part, the S/Ns are U1, U2…The first letter of the
abbreviation marks the harness of the connector, and the Arabic number shows the S/N code of the
butt connector. See Table 4-1-3 for harness code.
3. Numbering rules for relay and safety connector
第 142 页共 221 页
Fig. 4-1-2 Numbering rules for butt connectors of the parts
a. Numbering rules for central control box
The S/N of central control box is expressed by Arabic numerals, 1, 2, 3…N. Central control box
in the cab is represented by the number 1, the central control box in the engine compartment is
expressed by the number 2, and the other central control boxes are numbered in a regular order.
b. Numbering rules for relay and safety connector
S/N of the connectors are based on the central control boxes. The S/N of the relays and safety
connectors are expressed by double-digit code. For instance, the relays or safety connectors in the
central control box in the cab are number as 1A, 1B…, in which the first Arabic number represents the
central control box the relay locates at, and the second code represents the S/N code of the
connector. Definition of each code is shown in Fig. 4-1-3.
c: Numbering rules for harness, relay and safety connector
Fig. 4-1-3 Numbering rules for relay and safety connector
4. Numbering rule for earth point
The S/N of earth point is expressed by a three-digit code, in which the letter G represents the
earth point code and the latter two numbers represent S/N of the earth point. Take G21 for example, it
represents the first earth point from the front of the vehicle to the rear. The numbering rule for earth
point is shown in Table 4-1-4.
Fig. 4-1-4 Numbering rules for harness, relay and safety connector
Table 4-1-4 Numbering rules for earth point

Power assembly In the engine In the compartment Other positions
第 143 页共 221 页
compartment or on the
chassis
G01~G09 G11~G19 G21~G29 G31~G39
III. Position chart of fuse and relay in central control box
1. Positional chart of central control box
Fig. 4-1-5 Engine compartment central control box
Fig. 4-1-6 Cab central control box
2. Position chart of fuse and relay
(2) Control box for fuse and relay in the cab central control box, as shown in Fig. 4-1-7
第 144 页共 221 页
(2) Control box for fuse and relay in the engine compartment central control box, as shown in Fig.
4-1-8
第 145 页共 221 页
第 146 页共 221 页
IV. Electrical components structure
1. Instrument cluster
2
8 0 1 0 01 2 0
1 60 3
km/h 1 4 0
40 160
F H
20
RPM
TRIP
E
0 ODO
C
6 5 4
Fig. 4-1-9 Instrument cluster
1-fuel gauge, 2-speedometer, 3-water thermometer, 4-tachometer, 5-accumulative odometer, 6-trip odometer
2. Headlamp
2
3
1 4
5
6
7
8
Fig. 4-1-10 Front combination lamp

1-left front combination lamp, 2-hexagon flange bolt, 3-low beam lamp bulb, 4-position lamp bulb, 5-high beam lamp
bulb, 6-steering lamp bulb, 7-alignment pin buckle, 8-optical axis high-low adjustment motor component of the low
beam lamp
4. Windshield wiper, as shown in Fig. 4-1-11
第 147 页共 221 页
4
3
2
19 15
20 15
6 8 10 14
11 14
5
6
6
10
12 11 13
Fig. 4-1-11 Wiper system

1-swing arm component of the wiper, 2-wiping framework of the wiper, 3-wiping steel piece of the wiper, 4-wiper blade,
5-washing water pipe connector, 6-front hose of the washer, 7-hexagon flange bolt, 8-T-connection of washing water
hose, 9-washing pot, 10-front nozzle of the washer, 11-sealing washer of the front nozzle, 12-washing pot cover,
13-connecting rod mechanism component of wiper, 14-all-metal hexagon flange retaining nut, 15-I hexa
V. Electrical equipment lighting and signal system parameter, as shown in Table

4-1-5.
Table 4-1-5 Parameter table of equipment lighting and signal system

High beam lamp White 55W 2 pcs
Front combination Low beam lamp White 55W 2 pcs
lamp Front position lamp White 5W 2 pcs
Front steering lamp Amber 21W 2 pcs
Rear steering lamp Amber 21W 2 pcs
Rear position lamp White 5W 2 pcs
Lighting and signal system
Rear combination
Reverse lamp White 21W 1pcs
lamp
Rear fog lamp White 21W 1 pcs
Brake lamp White 21W 2 pcs
High-mounted brake lamp Red (optional)
License plate lamp White 5W 2 pcs
Side steering lamp Amber 5W 2 pcs
Instrument lamp White 2W 5 pcs
Front fog lamp White 55W 2 pcs
Front interior lamp White 8W 1 pcs
Front interior lamp
Front reading lamp White 5W 2 pcs
Rear interior lamp White 8W 1 pcs
Reflector Red 2 pcs
Section II Faults Diagnose

Common faults and elimination methods of the electric system are showed in Table 4-2-1
Table 4-2-1 Common faults and elimination methods of the electric system
第 148 页共 221 页
Fault Cause Action
Check the bulb.

Bulb damaged Check the headlamp switch.
Fault in the headlamp Check the fuse and ask for replacement
The headlamps
Headlamp fuse blown when necessary (in this case, check for
do not work.
Fault in the lead or grounding short circuit).
Repair the circuit.
Check the bulb.

Bulb damaged Check the fuse and replace it when
Only one lamp Fault in the headlamp necessary.
does not work. Fault in the headlamp switch Check front headlamp switch.
Fault in the lead or grounding Check the circuit.
Check the bulb.

Bulb damaged
The front fog Check the fuse and replace it when
Fog lamp fuse blown
lamps do not necessary (and check for short circuit).
Fault in the front fog lamp switch
work. Check the front fog lamp switch.
Fault in the lead or grounding
Repair the circuit.
Only one front

Bulb damaged Check the bulb.
fog lamp does
Fault in the lead or grounding Repair the circuit.
not work.
The bulbs on the faulted side
damaged or incorrectly
Check the bulb.
configured.
Check the bulb.
Flashing with Fault in the steering signal/urgent
Check the relay.
high frequency alarm relay
Repair the circuit.
or flashing of Open circuit or excessive
Repair the resistor
one side resistance between the steering
Repair the circuit.
signal/urgent alarm switch and the
lights
Excessive resistance between the

battery and the switch Check the bulb/check the circuit.
No flashing Fault in the steering signal/alarm relay Check the relay.
Fault in the combination switch/alarm Check the switch.
relay
Flashing with low Low supply voltage

Check the charge system.
frequency
Check the bulb.

Bulb damaged
All the lights do Check the fuse and replace it when
Tail lamp/ parking lamp fuse blown
not work. necessary.
Repair the circuit.
第 149 页共 221 页
Some lights do Bulb damaged Check the bulb.
not work. Fault in the lead or grounding Repair the circuit.
Check the bulb.

Bulb damaged
The reverse Check the fuse and replace it when
Reverse lamp fuse blown
lamps do not necessary.
Fault in the reverse lamp
work. Check the switch.
Check the circuit.
The reverse
lamps can not be Fault in the reverse lamp switch Check or replace the switch.
turned off.
Check the bulb.
Bulb damaged Check the fuse and replace it when
The brake lamps Rear brake lamp fuse blown necessary (and check for short
do not work. Fault in the brake lamp circuit).
Fault in the lead or grounding Check the switch.
Repair the circuit.
The brake lamps
can not be turned Fault in the brake lamp switch. Check, adjust or replace the switch.
off.
Check the bulb
Bulb damaged
The rear fog Check the fuse and replace it when
Rear fog lamp fuse blown
lamps do not necessary.
Fault in the rear fog lamp switch
work. Check the rear fog lamp switch.
Repair the circuit.
Fuse blown Check the fuse.
Fault in the fuel
Fault in the circuit Repair the circuit.
indicator light
Fault in the fuel level sensor Check the sensor.
Fuse blown Check the fuse and replace it when
Fault in the water
Fault in the engine cooling temperature necessary.
temperature
sensor Check the engine coolant.
indicator light
Fault in the circuit Check the circuit.
The brake
Check the fuse and replace it when
warning lamp Fuse blown
necessary.
does not work Fault in the circuit
Check the circuit.
when the brake Fault in the brake fluid level switch
Check the brake fluid level switch.
fluid level is low.
When starting
(the ignition
switch is at the Fault in the ignition switch
Check the ignition switch.
position of “ON”), Fault in the circuit
Check the circuit.
the brake warning
lamp does not
work.
The parking brake Fuse blown
necessary.
warning lamp Fault in the circuit
Check the circuit.
does not work. Fault in the parking brake switch
Check the parking brake switch.
Check the seat safety belt switch.
The seat safety Fault in the seat safety belt switch
belt warning lamp Fuse blown
necessary.
does not work. Fault in the lead or grounding
Repair the circuit.
第 150 页共 221 页
necessary.
The defroster
Check the heating lead.
does not work.
Check the switch.
Repair the circuit.
The windshield
Windshield wiper fuse blown Check the fuse and replace it when
wipers do not
Fault in the windshield wiper bottom and necessary.
work or are not
motor Check the windshield wiper motor.
able to return to
Fault in the windshield wiper switch Check the windshield wiper switch.
their original
positions.
The washer hose or nozzle blocked Clean or wash the blocked washer
The washer does Fault in the washer motor hose or nozzle.
not work. Fault in the washer switch Check the washer switch.
Power window fuse blown
All the power necessary.
Fault in the ignition switch
windows do not Check the ignition switch.
Fault in the power window switch
work. Check the power window switch.
Repair the circuit.
Fault in the lead or interface Check the lead or interface.
Only one power Fault in the power window switch Check the power window switch.
window does not Fault in the window regulator Check the window regulator.
work. Fault in the window locking switch Check the window locking switch.
Fault in the grounding Repair.
Radio/cigarette lighter fuse blown
The cigarette necessary.
Fault in the ignition switch
lighter does not Check the ignition switch.
Fault in the cigarette lighter
work. Check the cigarette lighter.
Repair the circuit.
Bulb damaged Replace.
Lamplet fuse blown Check the fuse and replace it when
The interior lights Fault in the interior light switch necessary.
do not work. Fault in the door switch Check the switch.
Fault in the lead or grounding Check the switch.
Repair.
Bulb damaged Replace.
One of the interior
Fault in the interior light switch Check the switch.
lights does not
Fault in the interior switch Check the switch.
work.
Fault in the lead or grounding Repair.
第 151 页共 221 页
Section III On-vehicle Repairing
I. Headlamp
i. Headlamp switch
1. Definition of combination switch interface
13 14 17
11 15 7 6
12 8 16
5 18 9 4
Fig. 4-3-1 Foot of combination switch
2. Removal of headlamp
1) Disconnect the negative pole from the battery.
2) Screw off the mounting bolt of the headlamp.
4) Disconnect the headlamp assembly from the interface.
3) Remove the headlamp assembly from the vehicle.
5) Take down the headlamp assembly.
Fig, 4-3-2 Removal of the front headlamp
3. Installation of the headlamp

Reverse the disassembly procedure.
ii. Bulb replacement
第 152 页共 221 页
Fig. 4-3-3 Bulb replacement of front headlamp
Warning: Don’t touch the bulb when it’s hot.
1) Disconnect the negative pole from the battery.
2) Disconnect the harness from the bulb.
3) Take down the protection cover.
4) Remove the bolt and jump spring.
5) Remove the bulb.
iii. Adjust the headlamp beam with a screen.
X-X: Horizontal high (low) center beam of the front combination lamp
A-A: Vertical high (low) center line of the left front combination lamp
B-B: Vertical high (low) center line of the right front combination lamp
Fig. 4-3-4 Lamp test of the front headlamp assembly
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Fig. 4-3-5 Lamp test chart of the front lamp
Note:
1) Adjust the high (low) beam of the front combination lamp according to the following methods,
except where they conflict with the local mandatory rule of law.
2) Adjust the headlamp beam after replacing the bulb of the front combination lamp assembly.
1. Make sure the following requirements are met prior to adjustment:

a) Park the car on the flat ground in front of a white wall (screen), with a distance “a” of 10m
between the screen and the headlamp surface;
b) Adjust the pressure of the tire to the regulated value;
c) Seesaw the car body by hand to stabilize the suspension;
d) One driver is needed.
Weight of the driver: 75kg.
2. Adjustment
1) Check the highlight of each high (low) beam light axle, as is shown in Figure. Interval: H=about
130mm.
Fig. 4-3-6 Headlamp beam debugging
2) If the headlamp beam is not properly set up, adjust the adjusting screw and adjusting gear to
meet the specified requirement
II. Front fog lamp (if available)
i. Front fog lamp switch
1. Interface definition
2 1
6 5 4 3
Fig. 4-3-7 Protection sleeve of front fog lamp
ii. Front fog lamp
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前雾灯
Front foglight
Fig. 4-3-8 Front foglight
Hole position Definition

1 B+
2 Power supply trigger
3 Background light ILL+
4 Output
5 Grounding
6 Null
Table 4-3-2 Terminal foot definition of front fog lamp switch protection sleeve
1. Disassembly
1) Remove the headlamp.

2) Remove front bumper.
3) Disconnect the interface of the front fog lamp.
4) Remove the fog lamp assembly from the bumper.
2. Assembly
iii. Bulb replacement
Warning: Do not touch the bulb when it is hot.
1) Disconnect the negative lead (I) from the battery

2) Remove the front headlamp.
3) Remove the front bumper.
4) Disconnect the interface of the front fog lamp.
5) Remove the lampshade holder and the lead on the terminal.
6) Screw out the screw used for mounting the bulb and then remove the bulb from the fog lamp
assembly.
7) Replace the bulb and reassemble the all removed parts.
Note: Be sure to cover the bulb terminal.
III. Steering signal lamp and urgent warning signal lamp
The same with the front headlamp
2. Disassembly and assembly
Please refer to the detailed description of “steering pillar and steering lower shaft” for
disassembly and assembly.
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IV. Rear fog lamp
i. Rear fog lamp switch
Fig. 4-3-9 Foot of rear foglight

Table 4-3-3 Terminal foot definition of rear fog lamp switch protection sleeve

1 B+
2 Power supply trigger
3 Background light ILL+
4 Output
5 Grounding
6 Null
V. Ignition switch
i. Interface definition
ii. Disassembly and assembly
Please refer to the detailed description of the steering safety lock (ignition switch) in the chassis part
for disassembly and assembly.
Fig. 4-3-10 Foot of ignition switch

1 IG1
2 IG2
3 ACC
4 AM
5 ST
Table 4-3-4 Definition of ignition switch interface
VI. Instrument cluster
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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17
Fig. 4-3-11 Terminal foot definition of instrument cluster protection sleeve
Table 4-3-5 Instrument cluster interface definition

Hole Definition Hole Definition
position positio
n
1 Door ajar signal 17 Theft alarm signal input
2 No air bag 18 Reserved
3 Oil pressure extremely insufficient 19 Charging indicator
alarm
4 Seat belt reminder 20 Ground
5 Reserved 21 Speed signal input
6 Right steering 22 Ground
7 Power supply of instrument indicator 23 Working power supply of the
instrument cluster
8 Power supply of the door ajar 24 Fuel signal input
indicator
9 Ground 25 coolant temperature signal input
10 Reserved 26 Ground
11 Left steering 27 rotation speed signal input
12 High beam lamp 28 Backlight power negative of the
instrument
13 Low beam lamp 29 Backlight power positive of the
instrument
14 ABS Anti-lock Braking System 30 Reserved
15 Parking brake 31 Engine fault indicating signal
16 Low brake fluid level indicator 32 SVS trouble lamp
i. Disassembly
1. Disconnect the negative lead from the battery.
2. Screw out screw 3 and 4 and remove the upper and lower protective covers of the steering
column.
3. Remove the instrument cluster cover. Note: when a screwdriver is used to do this, cover the
screwdriver with cloth in order not to damage the cover.
4. Screw out screw 6 (4 pieces), disconnect the instrument cluster interface and remove the
cluster.
第 157 页共 221 页
7
8
5
6
4
3
2
Fig. 4-3-12 Disassembly of the instrument cluster
1-upper protective cover of the steering column, 2-lower protective cover of the steering column, 3-fixing bolt, 4-screw
5-instrument cluster, 6-screw, 7-buckle, 8-instrument cluster cover
ii. Assembly
VII. Fuel pump
i. Fuel pump
Fig. 4-3-13 Fuel pump

1-fuel tank, 2-fuel pump assembly, 3-fuel pump cover, 4-hoxagon flange bolt
ii. Interface definition
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2 1
4 3
Fig. 2-1-43 Fuel pump protective sleeve

2 Signal earth
3 Fuel pump relay 87
4 Earth
Table 4-3-6 Terminal foot definition of fuel pump protective sleeve
VIII. Brake fluid level signal lamp and parking brake signal lamp
1. Brake fluid level switch interface definition
Fig. 4-1-43 Protection sleeve of the brake fluid level sensor

2 Signal grounding
3 Fuel pump relay 7
4 Grounding
Table 4-3-6 Definition of fuel pump interface

2. Parking brake switch
Fig. 4-3-16 Protection sleeve of the parking brake switch
Hole Definition
position
1 Grounding
Table 4-3-7 Definition of brake liquid level switch interface
IX. Safety belt signal lamp
Fig. 4-3-17 Foot of the safety belt signal lamp switch

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1 Grounding
Table 4-3-9 Definition of the safety belt signal lamp switch interface
X. Front windshield wiper

i. Front wiper and washer
1. Wiper switch plug foot definition
1 3 14 17
11 15 7 6
12 8 16
5 18 9 4
Fig. 4-3-18 Wiper switch foot

16 Left steering signal
17 Right steering signal
9 Low beam relay control signal output
7 Lamplet relay control signal output
4 High beam relay control signal output
13 Front wiper high-speed power output
14 Front wiper low-speed power output
15 Front wiper clearance power output
11 Front washer motor power output
6 Grounding
12 ACC power input
8 Connect air bag clock spring
5 Grounding
18 Warning alarm power input
Table 4-3-11 Wiper switch plug foft definition
ii. Wiper motor
1. Front wiper motor interface definition
2. Check
1) Connect the (+) terminal of a battery with voltage of 12V to the low speed pin on the terminal,
and connect the (-) terminal to the bracket (wiper grounding). If the motor starts to rotate at a
speed of 44 to 52 rounds per minute, it means the wiper motor is in a fine condition. When
carrying out high speed check, connect the (+) terminal of the battery to the high speed pin on
the terminal, and connect the (-) terminal to the bracket (wiper grounding). If the motor starts to
rotate at a speed of 64 to 78 rounds per minute, it means the motor is in a fine condition.
2) Automatic stop test
a) Connect the (+) terminal of a battery with voltage of 12V to the low speed pin on the terminal,
and connect the (-) terminal to the bracket (wiper grounding) to start the motor.
b) Remove the low speed pin on the terminal from the battery to stop the motor.
c) Connect the low speed pin to the return pin with a jumper, and connect the positive pin to the
(+) terminal of the battery. Then observe the running of the motor and stop it at a given position.
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d) Repeat step a) to step c) for several times and check whether the motor stops at the given
position.
2 1
4 3
Fig. 4-3-23 Foot of front wiper motor

1 High speed
2 Low speed
3 Return
4 Positive pole
Table 4-3-12 Definition of front wiper motor interface
iii. Washer pump
1. Disassembly
1) Disconnect the negative lead from the battery.

2) Remove mounting screws of the cleaning solution tank.
3) Disconnect the pump lead interface and remove the hose.
4) Remove the cleaning solution tank.
5) Remove the pump from the washer box.
2. Check
Connect the (+) and (-) terminals of the battery to the (+) and (-) terminals of the pump
respectively and check the delivery volume of the pump.
Delivery volume of the pumps of both the front and rear window should be within the following
limit: delivery volume of the washer pump of the front window should be over 1.0L/min, and that
of the rear window should be above 0.72L/min.
3. Assembly
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Section IV System Circuit Diagram
1. Schematic diagram of power-supply distribution in the cab central control box (Fig. 4-4-1)
Fig. 4-4-1 Schematic diagram of power-supply distribution in the cab central control box
2. Schematic diagram of power-supply distribution in the front cabin central control box (Fig. 4-4-2)
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Fig. 4-2-2 Schematic diagram of power-supply distribution in the front cabin central control box
3. Power supply and charge system
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Fig. 4-4-3 Schematic diagram of power supply and charge system
4. Starting, ignition and fuel supplying system of the engine
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Fig. 4-4-4 Starting, ignition and fuel supplying system of the generator
5. Engine and A/C radiator system
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Fig. 4-4-5 Schematic diagram of engine and A/C radiator system
6. Engine control system
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Fig. 4-4-6 Schematic diagram of engine control system
7. Instrument cluster
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Fig. 4-4-7 Schematic diagram of instrument cluster
8. Front and rear combination lamps
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Fig. 4-4-8 Schematic diagram of front/rear combination lamps
9. Parking brake indicator, brake lamp, brake fluid level indicator and reverse lamp
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Fig. 4-4-9 Parking brake indicator, brake lamp, brake fluid level indicator and reverse lamp
10. Front rear fog lamp and interior light
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Fig. 4-4-10 Schematic diagram of front rear fog lamp and interior light
11. Wiper & washer system
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Fig. 4-4-11 Schematic diagram of wiper & washer system
12. Cigarette lighter, horn and audio & visual system
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Fig. 4-4-12 Schematic diagram of cigarette lighter, horn and audio & visual system
13. A/C control system and rear window defroster
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Fig. 4-4-13 Schematic diagram of A/C control system and rear window defroster
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Chapter V A/C System
Section I A/C System Overview
The A/C system of Lifan micro cars integrates the functions of refrigerating, heating and
ventilation. In summer, the A/C could be used to lower the temperature in the compartment, and in
winter, it could be used for heating and defrosting/defogging. The A/C system is characterized by its
compact structure, easy operation and multifunction.
I. Refrigeration principle of A/C
The refrigeration system consists of compressor, evaporator, condenser with fluid drier, expansion
valve, blower and control mechanism, etc., see Fig. 5-1-1.
5
3
4
TU
6
7
1
Fig. 5-1-1 Constitutional diagram of A/C refrigerating system

1-condenser, 2-liquid reservoir, 3-pressure switch, 4-blower, 5-evapertor, 6-expansion valve, 7-compressor
The refrigeration principle of the refrigerating system in a Lifan vehicle is shown in Fig. 5-1-2.
Firstly, the compressor driven by the engine extracts the gaseous refrigerant from the evaporator and
presses it into the condenser. Secondly, when the high-pressure gaseous refrigerant flows past the
condenser (liquefaction), heat exchange (releasing heat) occurs and then the heat is taken by the air
outside. Thirdly, under the throttling effect of the expansion valve, the high-pressure liquid refrigerant
is depressurized; and the low-pressure liquid refrigerant is gasified in the evaporator, thus heat
exchange occurs (absorbing heat); then the cooled air near the evaporator will be blown into the
compartment. Fourthly, the gaseous refrigerant is extracted from the evaporator and pressed into the
condenser by the compressor. By this way, the refrigerant will flow in a circular and closed manner,
and the heat in the compartment could be expelled out so that the temperature in the compartment
would drop to a suitable degree, as shown in Fig. 5-1-2.
第 175 页共 221 页
Fig. 5-1-2 Refrigerating schematic diagram
II. Heating system principle
Water heating is adopted in the heating system. The heat source is the engine coolant. The
system consists of a heat exchanger, coolant pipeline, a blower, air duct, control mechanism, etc.,
among which the blower and air duct are shared by the refrigerating system.
When engine works, heated by the high temperature of the engine cylinder, the coolant is
pumped into the heat exchanger through water pipe by the water pump of the cooling system. Air
from blower can take the heat given off by the coolant into the vehicle or the windscreen to raise the
temperature in the vehicle or defrost. After the cooling process in the heat exchanger, coolant is
pumped back by water pump. Repeating the circulation can make warm air heating. As shown in Fig.
5-1-3.
Function of the A/C control system is to ensure that the A/C system will operate effectively at any
time and to ensure safe operation of the A/C system and the engine.
1. Refrigerating temperature control
Fig. 5-1-3 Principle of heating system of A/C control system
The evaporator mainly consists of temperature sensor, A/C controller, etc. When the
temperature of evaporator changes, the resistance of sensor changes accordingly, making A/C
controller receive the relevant voltage signal of the temperature, which controls the work of
electromagnetic clutch relay: when connecting electromagnetic clutch relay, compressor
electromagnetic clutch connects, compressor starts to work, and the temperature will decrease; when
disconnecting the electromagnetic clutch relay, compressor electromagnetic clutch disconnects,
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compressor stops working, and the temperature will increase. By controlling compressor, air
conditioning control system maintains the refrigeration temperature in the set range.
2. To reduce the engine load under certain circumstances, electronic fuel injection engine also
controls the compressor: when engine starts, drives off, suddenly accelerates and overspeeds, the
air conditioner compressor stops working.
3. Security protection control
Security protection control mainly guarantees the normal operation of the system. Monitoring the
system pressure and temperature by the pressure switch can realize the security protection control.
Functions of security protection control as follows:
1) Low pressure protection: for pressure below 0.196±0.02 MPa, pressure switch switches off,
the power of compressor clutch is cut off, and compressor stops working;
2) Over pressure protection: for pressure over 3.14±0.2 MPa, pressure switch switches off, the
power of compressor clutch is cut off, and compressor stops working;
3) Low temperature protection: for temperature below 2.5℃ sensed by evaporator temperature
sensor, the power of compressor clutch is cut off, and compressor stops working;
4) High temperature protection: for temperature over 125℃ sensed by coolant temperature
sensor, apply overheat protection for compressor. Then the power of compressor clutch is cut off,
and compressor stops working.
4. Engine cooling system (electric fan) control. Engine cooling system control consists of coolant
temperature sensor, engine ECM, 1#, 2#, 3# electric fan control relay, cooling fan, cooling fan
regulation resistor, condensation fan and relevant circuits. Depending on relevant temperature
sensors and switching signals, engine ECM controls the on off state of relevant fan control relay
circuits, as follows:
1) For coolant temperature of 93℃~96℃, engine ECM electrifies 1# relay and 3# relay. Then the
2 electric fans are connected in parallel and work at low speed simultaneously.
2) For coolant temperature of 98℃~100℃, engine ECM electrifies 2# relay. Then the cooling fan
works at high speed.
3) For coolant temperature reaching 110℃, instrument cluster lightens the warning lamp.
4) While the air conditioner switch is closing, the electric fan works at low speed no matter
coolant temperature is high or low.
5) For the pressure of air conditioning refrigeration system over or equal to 1.52±0.2MPa, the
electric fan works at high speed.
6) For abnormal coolant temperature signals (broken coolant temperature sensor), engine ECM
will judge the engine runs with heavy load, and the electric fan works at high speed.
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Section II System Layout
I. System layout
3 4
Fig. 5-2-1 A/C system arrangement diagram
1-condenser, 2-evaporator assembly, 3-air-inlet box assembly, 4-air duct assembly, 5-roof-mounted evaporator
intake elbow, 6-exhaust pipe of the roof-mounted evaporator, 7-right weeping pipe of the roof-mounted evaporator,
8-roof-mounted evaporator assembly, 9-left weeping pipe of the roof-mounted evaporator, 10-compressor assembly
II. Control system layout
1 2 3 3 2 1
Fig. 5-2-2 A/C instrument panel control component diagram

1-side defogging vent, 2-windsheield glass defogging/defrosting vent, 3-central vent, 4-side air outlet, 5-lower air
outlet
III. Control panel
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1 4 3
Fig. 5-2-3 A/C control panel
1-temperture control knob, 2-air volume adjustment knob, 3-selector knob for blow mode, 4-internal and external
air circulating control rod
IV. Breakdown drawing of HAVC components

11 12
9 14
10
13
7
6
5
1
4
2
3 4 2
23
17
25
16
15 18
20 17
19 21
22
15
Fig. 5-2-4 Breakdown drawing of HAVC components

1-blower motor, 2-speed-adjusting resistor of A/C blower motor, 3-left housing of warm air blower, 4-mode air duct
component, 5-right housing of warm air blower, 6-temperature air throttle component, 7-heater assembly, 8-heater
protection cover, 9-spongy cushion, 10-temperature air throttle connecting rod, 11-temperature air throttle rotating rod,
12-plastic gasket, 13-mode air duct rotating rod, 13-cross countersunk head self-tapping screw, 15-air intake sponge,
16-upper housing of front-mounted evaporator, 17-air outlet sponge, 18-expansion valve, 19-evaperator strainer,
20-evaperator core, 21-lower housing of front-mounted evaporator, 22-weeping pipe of front-mounted evaporator,
23-air-inlet box assembly, 24-fresh air transiting air duct assembly, 25-temperature sensor of the front-mounted
evaporator
V. Breakdown drawing of roof-mounted evaporator
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3
2 8
1 7
9
6
5
4
Fig. 5-2-5 Breakdown drawing of air duct assembly

1-defroster air duct assembly on the left side, 2-central defroster air duct assembly, 3-defroster air duct assembly
on the right side, 4-left face blowing air duct assembly, 5-left transition face blowing air duct, 6-central face blowing air
dust assembly, 7-right transition face blowing air duct, 8-right face blowing air duct assembly, 9-cross slot pan head
self-tapping screw
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Section III Performance Parameter of A/C System Components
Performance parameter of A/C system components of the vehicle
Table 5-3-1 Performance parameter of A/C system components of the vehicle

Compressor Model WXH-066
Type Parallel flow
Condenser
Specification L×W×D mm 520×370×16mm
assembly
Heat transfer capacity 12 Kw
Type Cascading style
Specification
Evaporator （50×172×235）
D×H×W mm
core
Refrigerating
3.2±10%kw
capacity
Type Cascading style
HVAC
Heat Specification
assembly （26×165×150）
exchanger D×H×W mm
core 240m³/h air flow rate, heating
Heating capacity
capacity≥3.0±0.3Kw
Air flow regulation 4th gear
Refrigerating face blowing ≥450m³/h
Maximum air flow
Heating foot blowing ≥300 m³/h
Type R134a
Refrigerant
Injection quantity 580g
Type PAG56
Lubricant
Injection quantity 110ml
Compressor
4PK830
belt
Air Maximum refrigerating capacity Compressor 3000 revolutions, ≥5.2KW
conditioning
Temperature regulating range
system
Section IV Diagnosis of A/C System Trouble

I. Diagnosis of A/C system trouble
i. Visual inspection
1. The A/C system inoperative or non-stationary will show some symptoms, which can be
found out conveniently through visual inspection (watch with eyes, touch with hands and hear
with ears) and solved quickly.
1) Carefully inspect the pipe line for damage as well as the surface of the condenser and
evaporator for crack or oil stain. If there is oil stain on the condenser, evaporator or pipe, it is
necessary to check for leakage with soap bubble method. The locations to be carefully checked are
as follows:
① The joint of each pipe and valve;
② Hose and hose joint;
③ Compressor oil seal, front & rear cover plate, and gasket;
④ The surface of condenser and evaporator with scratch and deformation

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2) Check the refrigerant through the inspection window of the pipe. Start the engine at first
before inspection, and then open the A/C system and run the engine for 5 minutes at a fast idle speed
(1500~2000r/min). After that, check the refrigerant for circulation through the inspection window.
① If the flow of the liquid is normal, with an air bubble occasionally, the refrigerant is normal.
② If clear, without air bubble, the refrigerant is full or no refrigerant in the pipe. If it is cold at the
air outlet, the refrigerant is normal. If it is not cold at the air outlet, the entire refrigerant may have
leaked out.
③ If with many air bubbles, the refrigerant is insufficient.
3) Check the electrical line, and carefully check the related joint for normal connection.
Fig. 5-4-1 Refrigerant inspection window
2. Check the trouble by your hands
1) Check the high pressure end of the A/C refrigerating system
Turn on the A/C switch, and run the refrigerating compressor for 10~20 minutes, after that, touch
the pipes and parts at the high pressure end of the A/C refrigerating system by hand. The
temperature along compressor outlet → condenser → dryer → expansion valve inlet should be hot to
warm.
If it is very hot at certain location along the line, the system is under poor cooling. If the parts
along the line are cool, the A/C refrigerating system may have such troubles as blockage, without
refrigerant, inoperative compressor or poor operation of compressor.
2) Check the low pressure end of the A/C refrigerating system
the pipes and parts at the low pressure end of the A/C refrigerating system by hand. The temperature
from evaporator to compressor inlet should be cool to cold. If not cool or frost found at certain location,
the refrigerating system is abnormal.
3) Check the temperature difference at the outlet end of the compressor
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both the inlet and outlet ends of the compressor by hand. The high pressure and low pressure end of
the compressor should have obvious temperature difference.
If the temperature difference is not obvious or no temperature difference is felt, the refrigerant
may have been completely used or be quite insufficient.
4) Check A/C system line
Check the lead connector for normal connection by hand. The connector of the A/C system line
should not be loose and hot. If loose or hot, the contact within the connector is poor, so that the A/C
system can not work or work normally.
3. Check the trouble by your ears
Carefully listen if there is abnormal noise from the compressor and if the compressor is under
operation to check if the failure or poor operation of the A/C system is caused by the compressor or
the compressor control circuit.
4. Common troubles and treatment
1) Control circuit fuse blown---replace new fuse with the same specification.
2) Control line or ground cable broken---check each terminal or ground cable for normal
connection, if not, connect again.
3) Blower relay damage---Check blower relay coil and the contact point for damage. Repair or
replace if damaged.
4) Electromagnetic clutch coil burnt---check if there is circuit in the clutch coil. If not, repair or
replace.
5) Electronic temperature controller damage---Check the thermal resistor temperature sensor for
damage and the thermal resistor for normal performance. Repair or replace if any trouble occurs.
6) Pressure switch fault---Fill 300KPa(G) refrigerant into the refrigerating system. If the
refrigerating system recovers for work, the low pressure switch is normal. If the system fails to
recover, the low pressure switch is abnormal. Then, short the pressure switch. If the system begins to
work, the pressure switch is abnormal. The shorting method can also be used for high pressure
switch. Any pressure switch with fault should be repaired or replaced.
7) Blower not rotates---Check if the circuit of the blower is normal, the blade of the blower is
blocked and the motor of the blower is burnt.
(2) Poor refrigeration of A/C
1) The refrigerant is too little---high & low pressure too low. Check for leakage and repair, and
refill refrigerant till the pressure becomes normal.
2) The refrigerant is too much---high & low pressure too high and the pressure indicator shakes
strongly. Recycle the refrigerant, create vacuum again and fill the refrigerant of fixed amount.
3) With water in the system---after the A/C has worked for a period, low pressure & vacuum,
frosty expansion valve, ice block, and not being cold at the air outlet occur, and if reopen the A/C after
stopping for a moment, the A/C can work normally again. However, the above mentioned troubles will
appear again soon. Under such a situation, the wet air may come into the system or there is too much
water in the refrigerant and refrigerant oil. At this moment, the dryer should be replaced and the time
for creating vacuum should be longer and then refill refrigerant and lubricant.
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4) With dirt in the system---vacuum at the low pressure side, pressure at the high pressure side
too low, frost or dew formed on the front and rear pipe of the fluid dryer or expansion valve, outlet air
not cold, and the troubles still exist after stopping the A/C for a while. Actually, the system is blocked
by dirt. Then, replace the fluid dryer and the dirty and blocked parts.
5) Compressor damage, with leakage from the internal---the low pressure is too high and the
high pressure is too low, and sometimes with abnormal knock noise from the compressor. Then,
replace the compressor.
6) The drive belt of the compressor is too loose---the rotation speed of the compressor is too low
and the outlet air is not cold and the noise from the slip of the belt can be heard. Adjust the tensioning
force of the drive belt or replace the drive belt.
7) Slipping of the compressor clutch---the compressor can not operate normally. Remove the
clutch for repair or replacement.
8) Little cooling wind of condenser---high & low pressure too high. Check the rotation speed of
the blower and the wind speed switch for normal operation.
9) The condenser fin is blocked by dust---high pressure too high, with poor cooling effect. Then,
clean up the dust on the condenser.
10) Little wind from evaporator---wide frost on the surface of the evaporator and the wind at the
outlet not cold. Check blower switch and relay or replace the blower.
11) The evaporator fin is blocked by dust---less wind. Blow with nitrogen or compressed air.
12) The air filter net of the evaporator is blocked by the dust or foreign materials---less wind.
Wash or replace the air filter net.
13) Excessive opening of the expansion valve---both high & low pressure too high, and the
excessive refrigerant flowing through the evaporator can not be completely evaporated. Replace an
expansion value with appropriate opening.
14) Leakage of expansion valve power head---expansion valve blocked and both the high & low
pressure too low. Replace expansion valve.
15) Too much lubricant in the system---both high & low pressure too high and turbid stripe can
be seen from the sight glass. Then, let out the excessive lubricant.
16) The A/C fresh air door not firmly closed---a large quantity of high temperature air outside the
vehicle coming in. Then, close the fresh air door firmly.
17) HVAC cooling/heating air door not firmly closed---air is heated. Then, close the
cooling/heating air door firmly.
18) A/C air duct is blocked---little wind and more noise. Remove the blocking materials in the
duct.
5. Interrupted temperature fall of A/C
Main reasons include: the system is blocked by ice, temperature sensor & relay failure, slipping
of compressor clutch and poor contact of coil.
1) Controller and relay failure, the slipping of compressor clutch, and poor contact of coil.
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2) Loose contact of compressor clutch coil, poor grounding and loose connection---the clutch will
be separated too early during operation. Then, tighten the connector.
3) Temperature sensor abnormal---serious frost on the surface of the evaporator, without cold air.
Then, replace temperature sensor.
6. A/C noise too high
1) Noise from blower, compressor, drive belt and the collision of parts;
2) Expansion valve operation noise.
7. Insufficient heating of A/C
1) Blower motor damage---check blower motor and repair or replace;
2) Wind leakage of heater---replace gasket;
3) Abnormal opening of cooling/heating air door---check the working mode of the cooling/heating
air door;
4) Accumulation of dust on heater fin or deformation, and unsmooth ventilation---clean or

replace the heater;
5) The hot water pipe of the heater is blocked by the accumulated dirt---replace heater;
6) Insufficient cooling water for engine---check the cooling system for leakage, and repair and
add cooling water;
7) Engine thermostat inoperative---replace thermostat;
8) There is air in the core tube of the heater, and discharge the air in the pipe.
Table 5-4-1 Diagnostic trouble table of A/C system
Symptom Reason analysis Treatment measure
Create vacuum again and refill
1. Air mixed into the system.
refrigerant.
Remove the excessive
2. Too much refrigerant.
refrigerant.
Remove the excessive lubricant
3. Too much lubricant.
Both high & low or renew the lubricant.
pressure too high Wash the dust on the surface of
4. Poor cooling of condenser. the condenser or replace
condenser.
5. The cooling fan co-used by the
condenser and water tank can not Repair or replace fan.
work normally.
1. Insufficient refrigerant. Add refrigerant.
Both high & low Check for leakage and replace
2. Leakage of refrigerant.
pressure too low the leaking part.
3. Damage of O-ring. Replace O-ring.
Table 5-4-1 Diagnostic trouble table of A/C system (continued)
第 185 页共 221 页
Symptom Reason analysis Treatment measure
1. Excessive opening of the
Replace expansion valve.
expansion valve or damage.
High pressure
Remove the excessive
normal, and low 2. Too much refrigerant.
refrigerant.
pressure high
3. Abnormal compressor. Replace compressor.
1. Insufficient refrigerant. Add refrigerant.

Replace liquid dryer or check if
High pressure 2. The expansion valve is blocked
the position of the sensor head is
normal, and low by ice.
correct.
pressure low
3. With dust on the surface of the
Wash the surface of the
evaporator or the internal is
evaporator or renew.
blocked.
High pressure low, 1. Compressor less effective. Repair or replace compressor.
and low pressure
high 2. Expansion valve blocked. Replace expansion valve.
1. Low pressure ascends quickly
after stop---the system is blocked Replace liquid dryer.
High pressure low,
by ice.
and low pressure
2. Low pressure ascends slowly
negative
after stop---the system is blocked Wash the system.
by ice.
High pressure of
Slipping of clutch or belt. Repair or replace clutch or belt.
certain value
1. Poor operation of evaporator Replace or check if the position of
temperature sensor. the sensor head is correct.
2. Poor operation of evaporator
temperature sensor harness and Inspection & repair.
plug-in.
Icy evaporator
Discharge a part of the
3. Too much refrigerant.
refrigerant.
4. The air passing through the Check if the rotation speed of the
evaporator insufficient. blower is normal.
5. Expansion valve inoperative. Replace.
1. The filter net of the air inlet is Clean or replace the filter net of
blocked. the air inlet.
2. The air duct is blocked. Clean the air duct.
Normal
3. With dust on the surface of the Wash the surface of the
voltage
Insuffi evaporator. evaporator.
cient 4. Delayed operation of blower
Repair or replace blower motor.
wind motor.
1. Unstable power supply voltage of
Insufficient the complete vehicle.
Inspection & repair.
voltage 2. Faulty grounding of the power
supply.
ii. Diagnostic trouble table of A/C system
Note: 1. If the refrigerant is enough and the ambient temperature is higher than the normal
temperature, it is normal to see air bubble through inspection window.
2. Check with the special equipment.
第 186 页共 221 页
iii. Filling of refrigerant
As shown in Fig. 5-4-2
1. The method to fill refrigerant for A/C system
(1) Begin to create vacuum (15 minutes or above 750mmHg).
(2) Stop and wait for 10 minutes.
(3) Check the system for air tightness. If abnormal, check and repair the connector and create
vacuum again.
(4) Add refrigerant for A/C and the amount is 750g.
(5) Check the leaking and adding amount of the refrigerant for the system.
(6) Performance test.
2. Recycle of refrigerant
Use recycling device and equipment to recycle the refrigerant escaping from the A/C system.
The refrigerant in the air will affect the environment.
Note: (1) The requirements of equipment instruction book must be followed while handling the
recycling equipment.
(2) The air in the A/C system should always been exhausted by vacuum pump. The A/C
system must be equipped with intake/exhaust manifold pressure indicator and the duration to create
vacuum must be about 15 minutes.
Caution: Do not create vacuum until the refrigerant has been recycled.
Connect the high and low pressure air-filling hose of the exhaust manifold pressure indicator as
per the following order respectively.
High pressure air-filling hose: high pressure maintenance valve
Low pressure air-filling hose: low pressure maintenance valve
第 187 页共 221 页
2 3
4 5 6
7
8
9
11 12
10 13
14
15
16
17
19
18 23 21 22
20
27
24 26
25
28
29
Fig. 5-4-2 Structure and principle of refrigerant filling equipment
1-microprocessor controller, 2-low pressure side, 3-high pressure side, 4-low pressure valve, 5-high pressure
valve, 6-filling valve, 7-vacuum pump protection switch, 8-recycling pressure switch, 9-automatic expansion valve,
10-vacuum solenoid, 11-recycling valve, 12-recirculation solenoid, 13-water content indicator, 14-vacuum pump,
15-air exhaust valve, 16-oil separator/heat exchanger, 17-access hole, 18-filtering dryer, 19-refrigerant oil exhaust
valve, 20-high pressure switch, 21-refrigerant air (vapor) valve, 22-refrigerant fluid valve, 23-refrigerant recycling bottle,
24-fan, 25-recycling compressor, 26-comrpessor oil separator, 27-working tank (refill of refrigerant for 23kg),
28-pressure balance and oil return valve, 29-balance assembly
Fig. 5-4-3 Curve graph of refrigerant filling
Connect the hose in the middle of the manifold pressure indicator onto the vacuum pump.
第 188 页共 221 页
Run the vacuum pump and open the valve of the manifold pressure indicator at the inlet side. If
no blockage in the system, display will be found on the high pressure indicator. Under such a
situation, open the valve of the inlet (exhaust) manifold instrument at the other side.
If no leakage occurs, the vacuum below 760mmHg will be showed on the low pressure indicator
about 10 minutes later.
Note:
If no vacuum below 760mmHg of the system is displayed, please close the two valves and then
stop the vacuum pump and carefully observe the movement of the needle of the low pressure
instrument. If the pressure increases, there exists leakage. Under such a situation, the A/C system
must be repaired before creating vacuum.
If the pressure is stable, no leakage occurs. Then, please keep on creating vacuum.
The total duration for creating vacuum must be 15 minutes.
Keep on creating vacuum until the vacuum displayed on the low pressure indicator is below
760mmHg. Then, close the two valves.
Stop the vacuum pump and remove the central air-filling hose from the inlet of the pump. At this
moment, the system has been ready for the filling of refrigerant.
3. Check the system for leakage
After finishing creating vacuum, close the high pressure valve (HI) and the low pressure valve
(LO) of the inlet (exhaust) manifold instrument and wait for 10 minutes. After that, check if the reading
of the instrument changes.
Note:
If the reading of the instrument is closer to “0”, there exists leakage at certain places. Check the joint
of the pipe and rectify if necessary. After that, create vacuum for the system again and make sure that
no leakage occurs in the system.
第 189 页共 221 页
Section V A/C System Precautions
I. Use R-134a refrigerant
(1) Only use R-134a refrigerant qualified in content, water content, foreign material and
uncondensable air and other indexes.
(2) Fill the refrigerant strictly following the instruction of the vehicle factory, and overfilling or
insufficient filling will cut the refrigerating effect of the A/C system.
(3) Thoroughly check the seal ring of each pipe joint and each part for leakage before filling
refrigerant.
(4) Before the operation of the compressor, the refrigerant can be simultaneously filled both at
the low pressure and high pressure side; after the operation of the compressor, the refrigerant can
only be slowly filled only at the low pressure side.
(5) Carefully check for leakage with electronic leak detector after filling R-134a refrigerant.
II. Correctly add lubricant
(1) Only use the lubricant with the type and make specified by the compressor manufacturer. Do
not mix with the lubricant with different type and make, or else the compressor will be damaged.
(2) The quantity of the lubricant to be filled should be in strict accordance with the instruction.
Pay attention to that the lubricant will be resistant to heat exchange and overfilling will seriously cut
the effect of the A/C system. Generally, it is not necessary to add lubricant since the lubricant has
already been filled by the compressor manufacturer. While replacing parts, properly add the lubricant
with the same model: condenser---20ml; fluid dryer---30ml; evaporator---30ml; pipe---10ml/m.
(3) Lubricant absorbs water quite easily, so the time to be exposed to air should be shortened as
practicable as possible.
(4) Before filling, check the quality of the lubricant in the system. If seriously blackened or carbon
granule observed, please thoroughly wash the whole A/C system and replace lubricant wholly. Note:
it is prohibited to use water, corrosive solvent or flammable and explosive solvent to wash the A/C
system. It is recommended to use R-141b and methane cleaner.
(5) The lubricant should be filled through the compressor exhaust hole before creating vacuum.
iii. Notes for installation
1. Check and adjustment of the vehicle
Before installation of A/C, please check and adjust the following components.
Engine ignition timing
Engine cooling system
Battery electrolyte and charge system
Passenger compartment seal

第 190 页共 221 页
Fuel system
Overall condition of the vehicle
2. Spare parts preparation of the A/C
Please disassemble the parts package as per the assembly order.
At this time, keep the components from lossing or damaging. When installing the A/C, it’s quite
necessary to cover the fender and seat with a shade.
3. Notes for installation. The negative lead must be disconnected from the battery.
Use the bolt provided by the tool-box to install the A/C components on the engine and screw
them down with the specified torque.
In the installation, correctly specify the routines of the A/C pipes and harnesses for not to disturb
the nearby components.
Apply 2-3 drops of refrigerating oil on the horn open pipe connecting nut seat. The hose and the pipe
must be connected.
Two wrenches must be used to fasten or loosen the pipe assembly parts to evenly support them
in such a tight or loose condition.
Screw down the connecting nut with specified torque.
Before connecting each component, don’t remove the pipe end plug of the accessories.
Note: to make the refrigerant leak slowly, it’s quite necessary to carefully dismantle the plug from
the compressor. The compressor contains a little refrigerant to avoid corrosion of the seal when it’s
shipped out.
The personnel must wear safety glass in processing refrigerant. Pay attention not to contact the
refrigerant with skin.
Put the refrigerant pot in the warm water and keep it at 40℃.
第 191 页共 221 页
Chapter VI Body Accessories
Section I Front Door
25 24
15 14
17
16
4 7 9
10 11
1 3
1312
2 20
22 19
5
8 23
27 28 21
6 18
26
5
23 30 32
29 31
Fig. 6-1-1 Front door I
1-door window regulator handle, 2-snap spring, 3-door window regulator handle washer, 4-left front door manual
window regulator mechanism, 5-hexagon flange bolt-with cross recessed slot, 6-front door power window regulator
mechanism, 7-cross slot pan head screw, 8-front door internal weatherstrip, 9-front door limiter assembly, 10-door
locker lift button, 11- door locker seat, 12-front door external weatherstrip, 13-front door lock catch, 14-cross slot
countersunk head screw and taper lock washer unit, 15-front door lock body, 16-left front door locker pull rod, 17-front
door lock body pull rod, 18-pull rod of front door opening from inside, 19-external handle of front door, 20-front door
external handle push rod link cover, 21-front door external handle torsional spring, 22-front door external handle latch,
23-front door external handle seat, 24- hexagon flange nut, 25-front door window sealing strip, 26-front door frame
sealing strip component, 27-front door internal handle 28-washer, 29-front door internal handle pull rod plastic cover,
30-front door internal handle axis pin, 31-front door internal handle torsional spring, 32-front door internal handle seat,
33-front door internal handle support
第 192 页共 221 页
16
18
5
5 2
15
6
17 4
3
7
19
14
13
8
11
4
12
14
9
10
Fig. 6-1-2 Front door II

1-front door waterproof film, 2-left front door internal trim plate, 3-front door internal handle, 4-plastic buckle, 5-plastic
nut, 6-front door waterproof film, 7-left front door internal trim plate, 8-left front door armrest seat, 9-left front door map
bag, 10-cross slot pan head self-tapping screw, 11-front door armrest plate seat front support, 12-front door armrest
plate seat rear support, 13-cross slot pan head self-tapping screw and big washer component, 14- hexagon flange bolt,
15-Φ21 plug cap, 16-waist-shape patch, 17-front door lower buffer pad, 18-door buffer pad, 19-cross slot pan head
self-tapping screw
I. Front door window and window regulator
1. Removal
1) Completely lower the front door glass.
2) Remove front door window regulator rocking handle.
3) Draw out the rocking handle with cloth, as shown in Fig. 6-1-3.
Fig. 6-1-3 Removal of rocking handle Fig. 6-1-4 Removal of internal handle
第 193 页共 221 页
4) Unfasten the screw, and pull off the internal handle assembly from the internal trim plate of the
door by slipping correctly.
5) Detach internal handle or armrest plate assembly.
6) Detach front door internal trim plate.
7) Detach door film.
8) Detach door rearview mirror ornament and clamp.
9) Detach internal and external weatherstrip.
10) Detach front door sealing strip.
11) Lower the glass to appropriate position (expose the two installation holes of the glass).
12) Screw off the fixing screw of front door glass bottom slot.
13) Detach front door glass.
14) Unscrew the fixing screws of the window regulator (6 screws) and take out the window
regulator through hole A.
Fig. 6-1-5 Removal of front armrest plate and map bag Fig. 6-1-6 Removal of front door internal
handle
1-front door armrest seat, 2-front door map bag 1-front door internal handle
A
A
2
Fig. 6-1-7 Removal of front door glass Fig. 6-1-8 Removal of front door window
第 194 页共 221 页
regulator
1-front door window regulator, 2-front door 1-window regulator assembly 2-fixing screw
glass mud slot, 3-front door glass
2. Check
1) Check the slipping and rotating parts of the window regulator for lubrication.
2) Check the gear for wear or damage.
3) Check the hinge for damage, as shown in Fig. 6-1-9.
" a"
1.底槽
Bottom groove 剖面
Profile
Fig. 6-1-9 Check for lubrication of front Fig. 6-1-10 Installation of front door window
regulator
door window regulator
3. Installation
To install front door glass and window regulator, reverse the removal procedure, and pay
attention to the following points.
(1) To install the glass to the bottom slot, apply soap water to the bottom slot and slightly knock
the glass into the slot with plastic hammer, as shown in Fig. 6-1-10.
(2) While installing the glass, check if the top of the glass is evenly contacted to the front door
glass mud slot and check if the up-down sliding of the glass is smooth. If the glass has fallen into the
mud slot, adjust it well with the screw as shown in the figure.
(3) Firmly seal the door waterproof film with butyl adhesive.
(4) Pay special attention to the installation of the rocking handle. The rocking handle should be at
an angle of 45 degrees after the glass has been fully lifted, as shown in Fig. 6-1-11.
3 2
45?
3
1
Fig. 6-1-11 Installation of front door accessories
1-window regulator rocking handle, 2-internal handle, 3-screw
II. Removal of front door lock
1. Removal
Rotate the rocking handle to full lift the front door glass.
第 195 页共 221 页
Remove window regulator rocking handle (if any), door rearview mirror ornament, door internal
trim plate, power window switch (if any), door internal trim plate, and front door rear sliding way (see
“removal of front door glass and window regulator”).
After removing each connector of the control rod, remove door external handle and door lock
assembly.
Fig. 6-1-12 Front door lock assembly

1-external handle, 2-lock body, 3-internal handle, 4-door lock body assembly, 5-lock catch, 6-internal lock lift
button, 7-ignition key
Fig. 6-1-13 Removal of front door lock assembly

1-lock body, 2-holder, 3-external handle, 4-door lock
2. Installation
To install, reverse the removal procedure and pay attention to the following requirements.
1) Install door lock catch.
2) Move the door lock catch up and down and aim the lock catch at the central slot of the door
lock.
Note: The lock catch should be placed horizontally and moved vertically. It is not allowed to
adjust the door lock.
Close the door and adjust the lock catch. The surface of the door should be as high as the
surface of vehicle body, with 0mm difference in height.
To correctly get the longitudinal position of the lock catch, increase or decrease the shim inserted
between the vehicle body and lock. The size “b” should be adjusted to the specified value.
第 196 页共 221 页
2
3
Fig. 6-1-14 Adjustment of front door lock catch
1-vehicle body, 2-door, 3-lock pin, 4-front side
III. Front door assembly
1. Removal
1) Remove the wiring harness connector of the door and remove the bellows from the vehicle
body, as shown in Fig. 6-1-15.
2) Knock upward slightly with a hammer to take out the front door limiter pin, as shown in Fig.
6-1-16.
1 2
2
1
Fig. 6-1-15 Removal of front door bellows Fig. 6-1-16 Removal of front door limiter
1-bellows, 2-limiter 1-door limiter, 2-pin
3) Place a wooden plate between the jack and door skin to support the door, as shown in Fig.
6-1-17.
4) Unfasten the hinge installation bolt and remove the door assembly.
Fig. 6-1-17 Removal of front door Fig. 6-1-18 Installation of front door hinge
a-wooden plate
2. Installation of front door hinge, as shown in Fig. 6-1-18
第 197 页共 221 页
To install the front door, reverse the removal procedure.
Note:
1. Apply sealant to the installation face of the hinge, as shown in the figure, and grease should
be applied to the rotation part.
2. If the sealing strip becomes hard, serious water leakage may occur and replace the sealing
strip.
3. Refer to “installation of front door lock” to adjust the position of the door lock pin and make a
proper position for the door.
4. Close the door and adjust the front door buffer pad to realize the contact between the vehicle
door and body.
第 198 页共 221 页
Section II Windshield
Note: Please use special adhesive recommended by Lifan for the installation of the windshield.
I. Removal of front window glass
1. Tools required for the removal of windshield
Piercer, steel wire, primer brush, small knife, rubber sucker, sealant gun, and putty scraper.
2. Removal
1) Wash the internal and external sides and the surrounding for the windshield.
2) Remove front wall ventilation panel.
3) Remove ornament and holding block.
4) Cover the vehicle body surface around the glass with adhesive tape to avoid damage.
5) Remove dash board and roof lining.
6) Remove rearview mirror, sun visor and the ornament of the front pillar.
7) Remove the sealing strip of the windshield.
Fig. 6-2-1 Front windshield assembly

1-windshield sealing strip, 2-windshield
8) Cut off all the adhesives around the windshield with small knife. If scrape off the adhesive with
steel wire, follow Step 9) and 10) as shown in Fig. 6-2-2.
9) Drill the adhesive with piercer and let the steel wire pass through, as shown in Fig. 6-2-3.
Fig. 6-2-2 Removal of the adhesive around the glass Fig. 6-2-3 Drill hole with piercer
10) Cut off the adhesive around the glass with the steel wire, as shown in Fig. 6-2-4.
第 199 页共 221 页
Note: The steel wire should keep close to the glass as practicable as possible to prevent
damage to the vehicle body.
1 2
4 1
Fig. 6-2-4 Removal of windshield

1-steel wire, 2-windshield, 3-adhesive tape, 4-adhesive
Scrape off the adhesive remained at the vehicle body side smoothly with small knife and the
inserting depth of the small knife is 1-2mm.
Note: Wash the small knife with alcohol before use or move the oil dirt on the knife through the
similar way, as shown in Fig. 6-2-5.
While taking off the glass again, the spacing strip and adhesive on the glass should be
completely removed, as shown in Fig. 6-2-6.
2
1
Fig. 6-2-5 Removal of the adhesive Fig. 6-2-6 Removal of the adhesive remained on the
glass
remained on vehicle body
1-small knife, 2-adhesive, 3-vehicle body 1-adhesive, 2-primer
II. Installation
(1) Clean the adhesive remained on the vehicle body with cleaning solution.
(2) Throughly clean the old adhesive surface, paint surface or the exposed metal. Carefully apply
primer at the paint surface or the exposed metal surface. Do not apply the primer to the adhesive
surface remained on the vehicle body, as shown in Fig. 6-2-7.
1
2
3
Fig. 6-2-7 Method to apply primer

1-primer, 2-brush, 3-apply primer, 4-not apply primer, 5-old adhesive
第 200 页共 221 页
Note:
1) The primer should be correctly applied following the instruction manual supplied by the primer
manufacturer and dried within the specified time.
2) The primer should not touch old adhesive surface where the vehicle body and glass will bind.
3) Insert the glass into the new insertion strip and spacing strip and pre-heat the insertion strip
for over half an hour under the temperature of 35℃ for next process.
4) Clean the adhesive on the surface of the glass with clean cloth: if clean with cleaning solution,
dry in the air for over 10 minutes.
5) Install the trim strip of the windshield onto the pillar and install the holding block, as shown in
Fig. 6-2-8.
1
2 1
4
4
3
Fig. 6-2-8 Installation of windshield accessories
1-windshield sealing strip, 2-windshield, 3-windshield gasket, 4-windshield side sealing strip
6) Apply sufficient primer along the glass binding edge with a new brush, as shown in Fig. 6-2-9.
a 1
c 2
Fig. 6-2-9 Apply primer
1-insertion strip, 2-spacing strip
Note:
1) Follow the instruction of the manufacturer and dry in the air within the specified time.
2) The primer should not be applied as the finish.
3) Do not touch the primer layer.
Width “a” about 20mm.
“b” about 15mm.
“c” about 18mm.
7) Refer to the following figure to apply adhesive.
第 201 页共 221 页
e
1
f
2
Fig. 6-2-10 Apply adhesive

1-adhesive, 2-glass
Note:
1) Start to apply the adhesive from the bottom side of the glass.
2) Take care not to damage the primer.
3) The height of the adhesive at the bottom side should be higher than the other three sides, the
upper, right and left sides. The width of “e” is about 8mm and the height of “f” is about 6mm.
4) After finishing applying adhesive, immediately press the glass into the vehicle body.
5) Catch the glass with the rubber sucker after applying adhesive.
6) Finish Step (7)-(9) within 10 minutes to ensure the effect of the adhesive.
7) Follow the instruction manual supplied by the adhesive manufacturer with respect to the
treatment method and airing time.
8) Remove the paper remained on the insertion strip and the spacing strip.
9) Use rubber sucker to press the glass into the vehicle body and fix the glass by slightly
knocking the insertion strip around the glass, as shown in Fig. 6-2-11.
Note: Take care not to damage the surface of the glass or the vehicle body.
10) Fix the insertion strip at the top.
11) Spray water with a hose outside the window to check for leakage. If there is any water
leakage, dry the glass and apply adhesive to the leaking point. If the problem can not be solved,
remove the glass and re-install the glass as per the methods mentioned above, as shown in Fig.
6-2-12.
第 202 页共 221 页
Fig. 6-2-11 Installation of glass Fig. 6-2-12 Check the glass for sealing condition
1- Rubber sucker
Note: Pay attention to the following points for installation:
To suddenly close the vehicle door before the complete drying of the adhesive will loosen or
drop the glass. Therefore, open and do not close the vehicle door before the complete drying of the
adhesive and handle carefully.
If the insertion strip can not be firmly fixed, tighten with adhesive tape till completely bound by
the adhesive.
Each adhesive has its own drying time. Follow the instruction manual of the manufacturer to get
the drying time and follow the notes beforehand.
Do not drive the vehicle until the adhesive has become firm.
12) Install rearview mirror, roof insertion strip, front pillar ornament, sun visor, ornament and
wiper.
IV. Upper steering shaft assembly (electric power steering EPS) (optional)
1. EPS overview
1.1 Product profile
The EPS electric power steering system consists of the steering column assembly, torque sensor,
servo motor, control module assembly and other relevant components. The working principle of this
system is as follows: when the vehicle speed is less than 80KM/ hour, the system will work. The EPS
control module takes advantage of the driving torque and rotation direction of the steering wheel, as
well as the vehicle speed and other related data to give signal commands to the servo motor, which
will then output the driving torque of the corresponding size and direction to generate steering force.
When the vehicle does not turn, the EPS control module will not give signal commands to the servo
motor, the servo motor will have no load output, and the current will tend to zero. Therefore, when the
vehicle goes straight without steering, it will not consume any engine power. Thus, it is more
energy-saving than traditional hydraulic power system.
The EPS electric power steering system provides power-assisted steering inversely proportional to
the vehicle speed: The higher the speed, the smaller the power. This approach of “on-demand power
supply” can have the driver maintain a balanced steering torque, greatly improve the driving safety
and comfort, and also improve the vehicle static and dynamic performances.
1.2 Function failure
When the EPS electric power steering system of your vehicle is found failed, please don't be anxious,
and it will not affect your normal driving, because it temporarily has no steering power, and is
recovered to the initial state of mechanical steering. If failed, please strictly follow the procedures for
troubleshooting.
第 203 页共 221 页
1.3 Operating environment:
1.3.1 Environment temperature: -30 ℃ ~ +70 ℃;
1.3.2 Storage temperature: -40 ℃ ~ +85 ℃;
1.3.3 Relative humidity: Annually average ≤ 75%, annually consecutive 30 days: relative humidity
95%
2. System control flow chart
Figure 3-2-29 EPS electric power steering system control diagram
3. Definitions of connector terminals
第 204 页共 221 页
Table 3-2-2 Pin definitions
Recomme
Terminal Reference Recomme
Name nded wire Remarks
No. current nded color
diameter
1 K-line - - 0.5mm2
Current manual code
diagnosis mode shall be
Fault diagnosis Yellow used (in need of DTC
2 20mA 0.5mm2
interface and red adjustment, it will be
grounded, with a fault
code table attached)
Fault, status
3 20mA 0.5 mm2
lamp Purple
Engine speed Yellow
4 20mA 0.5 mm2
signal and blue
Vehicle speed Yellow
5 20mA 0.5 mm2
signal and white
Black and
6 Ignition switch 20mA 0.75 mm2
blue
Uninterrupted
Red and
7 power supply 35A 4 mm2
white
12V
Power
8 35A Black 4 mm2
grounding GND
9 NC — — —
10 NC — — —
Electric motor
11 35A Red 4 mm2
(positive)
Electric motor
12 35A Black 4 mm2
(negative)
Sensor +12V
13 50mA Red 0.5 mm2
power supply
Sensor +5V
14 50mA Red 0.5 mm2
power supply
Sensor
15 20mA Black 0.5 mm2
grounding
Slave torque
16 20mA Green 0.5 mm2
sensor signal
Master torque
17 20mA Yellow 0.5 mm2
sensor signal
4. EPS system work flow

4.1 When the automobile engine is normally started, the ignition signal, 12V power supply and engine
speed signal will transmit information to the EPS system. If the EPS system fault diagnosis indicator
goes out after 2 seconds, it indicates that the EPS system is working properly.
第 205 页共 221 页
4.2 When the automobile engine is normally started, the ignition signal, 12V power supply and engine
speed signal will transmit information to the EPS system. If the EPS system fault diagnosis indicator
constantly lights up, it indicates that the EPS system is working improperly, warning the driver of the
EPS system failure for timely troubleshooting. Otherwise, it will come back to the mechanical steering
system without steering power, but it will not affect the normal running of the vehicle.
5. Flow for EPS fault diagnosis, fault reading, fault code instructions and troubleshooting
5.1 Method for reading of the EPS fault DTC
5.1.1 Method for reading of the EPS fault DTC: Priority shall be given to the automobile diagnosis
equipment for diagnosis. If there is no automobile diagnosis equipment, you can manually read the
EPS fault DTC according to the following steps:
5.1.1.1 Start the automobile engine, find out the EPS fault diagnosis line in the vehicle master
diagnostic kit, and ground it.
5.1.1.2 Read the fault code according to the flashing frequency of the combination switch instrument
EPS indicator (referring to the table for EPS fault DTCs).
5.1.1.3 Record the displayed fault DTCs one by one.
5.1.1.4 Note: When two or more fault codes appear, the smallest code will always be displayed at first.
The fault DTCs will be repeatedly displayed, so you can check such codes again and again.
5.2 Table for EPS instrument fault DTCs
DTC Waveform for “EPS” Remarks

Fault details Determination conditions
display indicator flashing
This code will
appear when
12
there is no
fault.
Main signal The main signal is not
11
abnormality between 0.1 and 4.9V
Great The main and auxiliary
13 main-auxiliary signals have the difference
signal differences above 0.5V. Torque
sensor
Power supply The voltage is not between
14
abnormality 9.0 and 6.0V.
Auxiliary signal The auxiliary signal is not
15
abnormality between 0.1 and 4.9V.
When the engine speed is
Vehicle- engine more than 2500RPM, the
21
speed mismatching vehicle speed is equal to
0km/h for 1min
Engine speed
and vehicle
22 No engine speed The engine speed is lower speed
than 330rpm.
Vehicle speed When the vehicle speed

24 exceeds 50km/h, it will
abnormality
suddenly come to 0, and
第 206 页共 221 页
the engine speed will
exceed 550rpm for
continuous 5 seconds.
The voltage between the
Motor terminal motor two terminals is
41
voltage abnormality higher than the supply
voltage, or equal to 0V.
Measured current value is
The motor has
42 higher than set maximum
excessive current.
current
The controller has driving
The motor has a too
43 command output, but the
low current.
motor has no current.
Motor
The controller has driving
Motor drive
44 command output, but the
abnormality
motor has no voltage.
The motor actual current is
Great difference higher than 7A, but the
between the motor controller indicator current =
45 actual current and =0 or the controller indicator
the controller current is higher than 7A,
indicator current but the motor actual current
is 0.
Voltage is not lower than
5.5V (before actuation),
52 Relay fault
voltage is not higher than
5.0V (after actuation)
The controller signal
Signal processing
53 processing circuit does not Controller
circuit fault
match with the logic circuit.
Battery voltage
54 Voltage >18.0V or < 8.0V
abnormality
Memory Memory read-and-write
55
read-and-write fault error
Note: Never use the ohm-scale to measure the EPS control module when the EPS control module
connectors are disconnected.
5.3 EPS troubleshooting process
5.3.1 First check to make sure that the 5pin sensor connector, 4pin power steering motor connector
and 8pin control module connector are firmly connected, without looseness.
5.3.2 When plugging connectors, do have the vehicle stop working.
5.3.3 If the EPS electric power steering is normal and the EPS fault diagnosis indicator is always on,
follow →Step 5 of 5.4.2 Use a digital multimeter to detect the 8Pin plug items of the EPS control
module for one-by-one checks, exclusion and treatment.
5.3.4 If the EPS electric power steering has no power output and the EPS fault diagnosis indicator is
dark, follow →Step 5 of 5.4.2 Use a digital multimeter to detect the 8Pin plug items of the EPS control
module for one-by-one checks, exclusion and treatment.
5.3.5 When the EPS fault diagnosis, read and record codes contain DTC22, DTC23, DTC52, DTC53,
第 207 页共 221 页
DTC54 and DTC55, follow →Step 1-6 of 5.4.2 Use a digital multimeter to detect the 8Pin plug items of
the EPS control module for one-by-one checks, exclusion and treatment.
5.3.6 When the EPS fault diagnosis, read and record codes contain DTC11, DTC13, DTC14 and
DTC15, follow →Step 7-9 of 5.4.3 Use a digital multimeter to detect the 5Pin plug items of the EPS
servo motor for one-by-one checks, exclusion and treatment.
5.3.7 When the EPS fault diagnosis, read and record codes contain DTC41, DTC43, DTC44 and
DTC45, follow →Step 7-9 of 5.4.4 Use a digital multimeter to detect the 4Pin plug items of the EPS
servo motor for one-by-one checks, exclusion and treatment. If the fault is not removed, replace the
EPS control module.
5.3.8 When the EPS fault diagnosis, read and record codes contain DTC11, DTC13, DTC14, DTC15,
DTC22, DTC23, DTC41, DTC43, DTC44, DTC45, DTC52, DTC53, DTC54 and DTC55: first follow →
Step 1-10 of 5.4 Test Items for checks, exclusion and treatment.
5.4. Troubleshooting when the EPS has no power steering or is not working properly
5.4.1 Remove the steering column lower cover and the EPS control module (but the connector must
be firmly connected).
5.4.2 Use a digital multimeter to detect the 8Pin plug items of the EPS control module.
第 208 页共 221 页
When the engine is idling after
Yes
started No
Step
Measured
Voltage value To next step Fault mode Indication Troubleshooting Treatment demands
terminal S/N
Indicating According to the
The automobile
normal automobile Until there is an
cannot provide
11V uninterrupted The EPS arrangement, check uninterrupted 12V
uninterrupted power
1 7 and 8 - power supply system whether Line 7 and Line power supply for the
supply for the EPS,
15V of the EPS doesn't work 8 are broken and EPS control module, it
so that the EPS
system whether the fuse is is normal.
could not work.
intact.
The automobile According to the
Indicating
cannot provide automobile
11V normal ignition The EPS Until the ignition switch
ignition switch arrangement, check
2 8 and 6 - switch power system does power supply is
power supply for the whether Line 6 is broken
15V supply of the not work normal
EPS, so that the and whether the fuse is
EPS system
EPS could not work. intact.
In case of
large
There is no vehicle According to the
Indicating steering
speed signal automobile
normal vehicle power and
supplied to the EPS, arrangement, check Until the vehicle speed
3 7 and 5 12±2V speed signal light steering
to result in large whether Line 5 is broken signal is normal
supplied to the wheel with
steering power and and whether the vehicle
EPS system the vehicle
light steering wheel speed signal is normal
speed state
in existence
According to the
Indicating There is no engine
5 ± 2V (or automobile
normal engine speed signal
measuring the The EPS arrangement, check
4 7 and 4 speed signal supplied to the EPS, Until the engine speed
speed system does whether Line 4 is broken
supplied to the so that the EPS is signal is normal
frequency Hz) not work and whether the engine
EPS system not normal.
speed signal is normal
12 ± 2V Indicating The fault 1. According to the If all faults have been
5 7and 3 。 Abnormal fault
(The fault normal fault indicator does automobile eliminated as required
第 209 页共 221 页
indicator does indicator not light up or indicator power is arrangement, check and the EPS system is
not light up) power constantly light supplied to the whether Line 3 is still not working
supplied to the up or the fault automobile EPS connected, and if properly, then replace
0 ± 1V
EPS system code cannot system, so The fault disconnected, connect the EPS control
(The fault
be read indicator does not it; module.
indicator
7and 3 light up or constantly 2. Check whether the
constantly
light up or the fault fault indicator is burnt
lights up)
code cannot be read out.
If so, replace it.
It indicates that the When Line 2 is

Indicating According to the
EPS fault diagnosis connected to the
normal fault automobile
The fault function is not control module and the
diagnosis arrangement, check
6 7 and 2 5±2V code cannot normal, so that the EPS system is still not
function of the whether Line 2 is
be read fault code cannot be working normally,
EPS control connected, and if
read (but other then, replace the EPS
module connected, it is normal.
functions will not be control module.
affected).
5.4.3 Use a digital multimeter to detect the 5Pin plug items of the EPS sensor
When the engine is idling after

started, the steering wheel can Yes No
Step naturally return
Measured
terminal Voltage value To next step Fault mode Indication Troubleshooting Treatment measures
S/N
1. Check whether the If all faults have been
15 and 13 ESP sensor has its eliminated as required
EPS Indicating It indicates terminals of Lines 13, and the EPS system is
The EPS
non-contact normal power abnormal EPS 14, 15, 16 and 17 loose. still not working
1 12±2V system does
sensor supply to the sensor power If not loose, it is normal; properly, then replace
not work
plug-in EPS sensor supplied by the EPS if loose, please firmly the EPS steering
connector control module connect and press it. column assembly.
terminal 2. Shake the connector (The EPS control
第 210 页共 221 页
up and down, as well as module does not need
15 and 14 left and right, and if the to be replaced)
EPS voltage value is kept
contact 5± stable with no change, it
sensor 0.5V is normal; if the voltage
plug-in occasionally appears
connector and disappears, please
terminal press the connector
2 15 and 16 2.5±0.07V terminal clips so that the
connector terminal
The EPS
Indicating It indicates that the could well contact the
system does
normal EPS sensor torque pins.
not work or
initialization of value is not normally
left-right
3 2.5±0.1V the EPS initialized or the 3. Use automobile
15 and 17 steering
sensor torque sensor torque value diagnosis equipment for
power is of
value is deviated calibration according to
asymmetry
the EPS calibration
procedure.
5.4.4 Use a digital multimeter to detect the 4Pin plug items of the EPS servo motor
After the engine is started Yes No
Step Measuring Treatment measures
Voltage value To next step Fault mode Indication Troubleshooting
terminal S/N
If the voltage
occasionally appears
1. Shake the connector
5V-12V (when and disappears,
up and down, as well as
the steering The EPS please press the
Indicating It indicates that the left and right, and if the
wheel is turned control connector terminal
normal power EPS servo motor voltage value is kept
clockwise and module clips so that the
1 11and 12 supply of the does not work and stable with no change, it
anticlockwise) provides no connector terminal
EPS servo there is no steering is normal.
motor driving could well contact the
motor power.
power pins.
2. Test whether Terminal Not connected:
11 and Terminal 12 are Replace the EPS
6V±1V(steering connected. If servo motor.
第 211 页共 221 页
wheel does not connected, it is normal.
move when 3. Test whether Terminal
stationary) 11 and Terminal 12 are
connected with the Connected: Replace
motor aluminum shell. If the EPS servo motor
not connected, it is
normal.
第 212 页共 221 页
Ver:LF-20141225
LIFAN1022 Service Manual
6. EPS electric power steering assembly
6.1. If no fault reason is found out when careful examination has been made according to Item 5 of
this Manual, please do not arbitrarily replace the upper electric power steering assembly (EPS) or
the EPS control module. You can make comparison for troubleshooting to replace the possibly
faulty upper electric power steering assembly (EPS) or EPS control module to a normal vehicle. If
no fault is found, you need to check the vehicle wiring harness, fuse and other relevant
components. If the fault still remains as before, then replace the corresponding faulty components.
6.2. The upper electric power steering assembly (EPS) cannot be decomposed, if any of its
components is found defective, the assembly should be replaced as a whole (Only the EPS power
steering motor and the EPS control module can be replaced separately, as shown in Figure
3-2-29). EPS control module
EPS power steering motor
EPS control module EPS power steering motor
Figure 3-2-29 Upper electric power steering shaft assembly (EPS)
6.3. When replacing the steering column assembly, take care not to cause any impact.
Ver:LF-20141225
6.4. This system is not suitable for use in instructional cars.
Note:
1. When not diagnosing the EPS system fault, you should unplug the EPS input and output plug-in
connectors so that the EPS does not work (especially during driving!).
2. As required, you should contact your local service outlets selling the electric power steering
devices of our company to replace the upper electric power steering shaft assembly (EPS), the
EPS control module assembly and the EPS power steering motor if necessary, but never attempt
to remove the torque sensor or EPS power steering motor for repair on your own.
XVI. Electronic immobilizer system (optional)

(I).The immobilizer ECU pins are defined as shown in Figure 4-3-28 and Table 4-3-17.
Figure 4-3-28 Arrangement of immobilizer ECU plug pins
Pin Definition
Functions and conditions
Power input pin, connected to the battery voltage, input voltage (9V-16V),
A1 B+ load input (0-500mA), able to prevent reverse connection and short-time
over-voltage
A2 NC Unconnected
A3 NC Unconnected
A4 GND Power supply grounding
A5 IG_ON Ignition signal input, connected to the ignition switch signal, input voltage
(9V-16V)
LED control output – The LED (ON) and LED (OFF) output features low and
high impedance respectively, with the load capacity (<50mA); it suggests
A6 LED that the peripheral components adopt appropriate current-limiting resistors
according to the LED current, and it should be noted that the system has an
internal current-limiting resistor 330Ω.
A7 R_LINE Communication request line, applicable to match the Delphi ECU (Other
（NC） ECUs are empty);
Data communication line, applicable to internationally accepted ISO 9141
A8 K_LINE K_LINE communication standard, used for key matching, status
configuration and fault diagnosis, etc.
B1 ANT_A LF antenna input / output
Ver:LF-20141225
B2 ANT_B LF antenna input / output
B3 NC Unconnected
Table 4-3-17 Definitions of immobilizer ECU pin functions
(II). See Figure 4-3-29 for the block diagram of the system working principle.
Diagnostic
instrument
GND
(offline matching
Battery B+ K-line K-line
equipment)
IGN
Combination
instrument LED
Engine ECU
Immobilizer
Coil ANT1
chip
ANT2 R-line
Immobilizer ECU
Figure 4-3-29 Working principle of the immobilizer system
(III). Immobilizer system offline matching authentication

The vehicle immobilizer system offline matching authentication can be made as follows:
Step 1: Key matching authentication
When you connect the vehicle to offline matching equipment, insert the automobile key fitted with
an immobilizer chip into the ignition switch and turn it to the “ON” position, the immobilizer ECU will
use radio frequency signals to send an authentication request and a random number to the
immobilizer chip through the read-and-write identification coil of the immobilizer system, and
establish communications in between; when the immobilizer chip has received the authentication
request, then it will start its encryption process, have the received random number achieve an
encryption result through an encryption algorithm, and then send the encryption result to the
immobilizer ECU system, which will judge whether such results are correct. If not correct, the
whole system authentication will have failed, the authentication will terminate and the car will be
locked; if correct, the process of key authentication has passed, and it will enter the second step of
the authentication.
Ver:LF-20141225
After the engine ECU receives the “ON” signal of the auto ignition switch, it will send a handshake
request to the immobilizer ECU through the K_LINE, and the immobilizer ECU will establish
communications and start the engine ECU authentication after receipt of the handshake signal;
The engine ECU will send a random number to the immobilizer ECU, after receipt of the random
number, the immobilizer ECU will start the encryption process, have the received random number
achieve an encryption result through an encryption algorithm, and then send the encryption result
to the engine ECU, which will judge whether such result is correct. If not correct, it shows that the
authentication has failed and the vehicle will be locked; if the encryption result is correct, it shows
that the engine ECU authentication process is successful.
After completion of the above two steps, a unique and independent communication code has been
established between the immobilizer chip in the vehicle key and the immobilizer ECU, as well as
between the immobilizer ECU and the engine ECU. When the vehicle needs to be started, the
immobilizer chip in the vehicle key, the immobilizer ECU and the engine ECU will confirm each
other, and if correct, then the vehicle can be started.
(IV). Immobilizer system indicator status display
In the vehicle combination instrument, there are corresponding indicators (hereinafter referred to
as LED) to display different states of the electronic immobilizer system for warning. When the
ignition switch is turned to the “OFF” state, the system will enter its standby, and the LED will
display at the state of ON (0.2s) and OFF (2.2s). When the ignition switch is turned to the “ON”
state, the system will start its authentication process, and if successful, the LED will continue to be
OFF, but if it fails (key error or no key), the LED will display at the state of ON (0.2s) and OFF
(0.7s).
Section VI Seat
Ver:LF-20141225
Fig. 6-5-1 Front seat assembly

1-driver seat assembly, 2-front passenger seat assembly, 3-headrest assembly, 4-seat fixed belt, 5-front seat front
lock catch component, 6-hexagon bolt, spring gasket and flat gasket unit, 7-hexagon flange bolt with cross
recessed slot, 8-hexagon flange nut
1. Removal
Remove the seat guide rail assembly bolt and open the front lock catch of the front seat. Then,
remove the seat assembly together with the seat guide rail (front seat).
Remove the seat and repair if required.
2. Installation
To install the seat, reverse the removal procedure.
Tighten to the specified torque as per the following value.
3. Tightening torque: the tightening torque for the rear part fixing point of the front seat is
60±5N·m and that for the fixing point of the middle and rear seat is 25±3N·m.
Section VII Safety Belt

Ver:LF-20141225
Warning: If it is necessary to replace the safety belt, the buckle and the emergent locking retractor
(or safety belt acceleration sense emergent locking retractor) should be replaced together with the
safety belt. Thus, the secure lock between the buckle and the latch can be ensured. If replace
these parts separately, the locking shall be unsafe. Therefore, only the buckle and emergent
locking retractor (or safety belt acceleration sense emergent locking retractor) in set will be
provided for replacement by Lifan Company.
Fig. 6-6-1 Safety belt assembly

1-Safety belt retractor assembly (left), 2-left front safety belt decoration part, 3- cross slot pan head self-tapping
screw with flat gasket assembly, 4-safety belt retractor assembly (right), 5-right front safety belt decoration part,
6-lock catch assembly (left), 7-lock catch assembly (right), 8-safety belt hanger ring cover palte
I. Repair of safety belt
Pay attention to the following notes before repair or replacement of safety belt:
1) The safety belt should be connected normally with the belt retractor and latch.
2) Keep the safety belt away from the sharp or improper materials that may damage the
safety belt.
3) Avoid bending or damaging the buckle and latch.
4) Do not bleach or dye the safety belt (only wash with soap and warm water).
5) While installing the fixing bolt and nut of the safety belt, tighten the bolt and nut by hand to
avoid over-tightening.
Ver:LF-20141225
6) Do not repair the retractor or retractor cap, and only replace with new one.
7) Always keep the belt dry and clean.
8) Replace if any part is under trouble.
9) Replace the safety belt with any break or damage.
10) Do not place any material at the opening of the trim panel through which the safety belt
passes.
II. Removal and installation
Refer to the previous figures to remove and install the safety belt of the front and rear seat.
Note:
Tighten the fixing bolt of the safety belt as per the specified torque. Both the fixing bolt and
nut of the safety belt has fine thread. Do not use the bolt with different type and thread under any
situation.
Tightening torque: 45±5N·m
III. Check
The safety belt and accessories are the key system for the vehicle. Thus, it is necessary to
check carefully and replace with the original parts.
1. Seat safety belt
No damage should be found on the safety belt or the sewing part.
2. Retractor
Tightly lock the belt if drawn out quickly.
Not only passing the abovementioned check, the retractor of the safety belt should tightly lock
the belt with an incline of 15° from the start to the end or from the left to the right.
3. Bolt
The bolt should be tightened to the specified torque.

Ver:LF-20141225
4. Latch
The latch should be of firm locking.
5. Warning system
Check the driver seat safety belt connection switch-3
See “vehicle body electrical system” for the detail of the warning system of the safety belt.
Ver:LF-20141225
Section Ⅷ Vehicle Body Dimension
Vehicle body dimension I
Fig. 6-7-1 Vehicle body dimension I
Vehicle body dimension II
Fig. 6-7-2 Vehicle body dimension II
Vehicle body dimension III
Fig. 6-7-3 Vehicle body dimension III

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LIFAN 1022 Service Manual

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

1. Vehicle identification number (VIN)

The VIN is posted at three locations on the vehicle:

(2) Name plate

Fig. 1-1-3 Name plate

2. Location of the engine identification code

Fig. 1-1-4 Location of LF479Q5 engine identification code

II. Notes for vehicle lifting

Fig. 1-1-4 Pit Fig. 1-1-5 Pit bridge

Fig. 1-1-6 Hydraulic lift

Fig. 1-2-1 The overall dimension of Lifan minivan

Table 1-2-1 The overall dimension of Lifan minivan

Overall 4580 4015

Section III Use and Maintenance

2) Replace the engine oil filter and the oil.

2) The vehicle always runs in dusty environment.

3) The vehicle runs in hot areas (such as in summer of the south).

The contents of the regular maintenance are shown in Table 1-3-1.

⑤ Only use 93 or above unleaded gasoline.

② As per the vehicle model.

3Month 9Month 15Month 21Month 27Month 33Month 57 63Month 69Month

3Month 9Month 15Month 21Month 27Month 33Month 57 63Month 69Month

Rotate the tires

3Month 9Month 15Month 21Month 27Month 33Month 57 63Month 69Month

3Month 9Month 15Month 21Month 27Month 33Month 57 63Month 69Month

Carrying out the

II. Routine maintenance of Lifan minivan

1. Maintenance of the air cleaner

2. Maintenance of the air cleaner

Fig. 1-3-1 Cleaning the air cleaner of Lifan minivan

Fig. 1-3-2 Tire rotation

Fig. 1-3-3 Wear mark of tires

5. Maintenance of wiper and washer

(1) Washing the vehicle body. The methods are as follows:

If detergent is used, it should be washed away by clear water.

Table 1-4-1 Common parameters for check and adjustment

II. Parameters for oils and fuels

III. Parameters for bulbs

Table 1-4-3 Parameters for lighting and signal bulbs

Front group lamp Low beam light White 55W 2

Front position light White 5W 2

1. Notes for removal and installation

3) No smoking to prevent a fire.

II. Notes for use and maintenance of electrical system

1. Notes for maintenance of electrical system

2. Notes for use and maintenance of battery

(2) Notes for disassembly and assembly:

(3) Notes for recharging:

1) For recharging, disconnect the connectors of positive and negative cables.

(4) Notes for use in winter

4) Reverse the order to remove the clamp.

3. Notes for use and maintenance of generator

4. Notes for use and maintenance of starter

III. Notes for use and maintenance of engine and vehicle

1. Notes for vehicle driving

3) Start at the first gear. Coasting is not allowed.

2. Notes for use of tires

3. Notes for vehicle washing

1. Notes for use

1) Only use unleaded gasoline of 93 or above.

3) Do not move the vehicle by a starter.

2. Notes for maintenance