MPX English Final Version VOLUME 2

Edition: September 2010 VOLUME 1
Printing: October 2010 INTRODUCTION 01

Pulication NO: FXSM-201009 PREPARATION 02
Printed in China SERVICE SPECIFICATIONS 03
DIAGNOSTICS 04
VOLUME 2
ENGINE CONTROL SYSTEM 11A
FUEL 12A
EMISSION CONTROL 13A
INTAKE AIR 14A
ENGINE MECHANICAL 15A
EXHAUST 16A
COOLING 17A
LUBRICATION 18A
IGNITION 19A
STARTING AND CHARGING 20A
ENGINE CONTROL SYSTEM 11B
FUEL 12B
EMISSION CONTROL 13B
INTAKE AIR 14B
ENGINE MECHANICAL 15B
EXHAUST 16B
COOLING 17B
LUBRICATION 18B
STARTING AND CHARGING 20B
FRONT SUSPENSION 31
REAR SUSPENSION 32
TIRE AND WHEEL 33
AXLE AND PROPELLER SHAFT 34
BRAKE 35
PARKING BRAKE 36
TRANSMISSION 41
VOLUME 3
CLUTCH 42
STEERING COLUMN 51
POWER STEERING 52
HEATER AND AIR CONDITIONING 61
SUPPLEMENTAL RESTRAINT SYSTEM 62
SEAT BELT 63
LIGHTING 64
WIPER AND WASHER 65
AUDIO SYSTEM 66
WIRING 71
COMMUNICATION SYSTEM 81
WINDSHIELD 82
© 2010 Beiqi Foton Motor Co., Ltd INSTRUMENT PANEL 83
SEAT 84
All right reserved. No part of this service DOOR LOCKS 85
manual may be reproduced or stored in a
SLIDING ROOF 86
retrieval system, or transmitted in any form, or
by any means, electronic, mechanical, photo- ENGINE HOOD AND DOORS 87
copying, recording or otherwise, without the EXTERIOR AND INTERIOR TRIM 88
proir written permission of Foton. VEHICLE CONTROL SYSTEM 91
INDEX
ENGINE CONTROL SYSTEM
11A
ENGINE CONTROL SYSTEM.......................................................... 11A-1
PRECAUTION............................................................................ 11A-1
SYSTEM OVERVIEW ................................................................ 11A-2
INTRODUCTION TO SYSTEM FUNCTION .............................. 11A-6 11A
BASIC PRINCIPLE .................................................................... 11A-8
MAIN COMPONENTS ............................................................. 11A-13
ENGINE CONTROL MODULE (ECM) ........................................... 11A-15
PRINCIPLE .............................................................................. 11A-15 11A
REPLACEMENT ...................................................................... 11A-16
ENGINE COOLANT TEMPERATURE SENSOR........................... 11A-20
PRINCIPLE .............................................................................. 11A-20
OVERHAUL ............................................................................. 11A-21
THROTTLE BODY ......................................................................... 11A-23
THROTTLE BODY ................................................................... 11A-23
THE FIXED SPEED ADJUSTING SCREW (SAS)
ADJUSTMENT ......................................................................... 11A-24
BASIC IDLE SPEED ADJUSTMENT ....................................... 11A-25
OVERHAUL ............................................................................. 11A-26
IDLE AIR CONTROL MOTOR ....................................................... 11A-28
PRINCIPLE .............................................................................. 11A-28
ON-VEHICLE INSPECTION .................................................... 11A-29
OVERHAUL ............................................................................. 11A-30
THROTTLE POSITION SENSOR (TPS) ........................................ 11A-32
PRINCIPLE .............................................................................. 11A-32
OVERHAUL ............................................................................. 11A-34
INTAKE MANIFOLD PRESSURE/TEMPERATURE SENSOR .....11A-35
PRINCIPLE .............................................................................. 11A-35
OVERHAUL ............................................................................. 11A-37
KNOCK SENSOR...........................................................................11A-40
PRINCIPLE .............................................................................. 11A-40
OVERHAUL ............................................................................. 11A-42
CKP SENSOR ................................................................................ 11A-44
PRINCIPLE .............................................................................. 11A-44
OVERHAUL ............................................................................. 11A-45
UPSTREAM OXYGEN SENSOR ................................................... 11A-47
PRINCIPLE .............................................................................. 11A-47
DOWNSTREAM OXYGEN SENSOR............................................. 11A-51
PRINCIPLE .............................................................................. 11A-51
OVERHAUL ............................................................................. 11A-53
CANISTER SOLENOID VALVE..................................................... 11A-55
PRINCIPLE .............................................................................. 11A-55
OVERHAUL ............................................................................. 11A-57
ODOMETER SENSOR ...................................................................11A-61
PRINCIPLE .............................................................................. 11A-61
OVERHAUL ............................................................................. 11A-63
IGNITION CONTROL MODULE.....................................................11A-65
PRINCIPLE .............................................................................. 11A-65
ENGINE CONTROL SYSTEM - ENGINE CONTROL SYSTEM 11A-1

PRECAUTION
1. POWER OFF. 11A
(a) The battery negative cable must be disconnected first before removing or installing any electric
appliance and when tools or facilities will touch the exposed terminals. It should be connected eventu-
ally. This will prevent injured person and vehicle damage.
(b) The ignition switch must be off without any special descriptions.
WARNING
The ignition and illuminatioin switches must be shut off before removing or installing the battery
negative cable (the semiconductor maybe damaged without doing that).
11A
2. THE PRECAUTION OF OPERATION.
(a) Please do disassembly and assembly and testing in accordance with the provisions introduced in this
manual during maintenance.
(b) Clear off the sundries on the mounting surface with a sealant scraper or a wire brush and confirm the
sealing face is level and smooth and no greasy dirt on it before the installation. Don’t forget to remove
the sealant on the mounting hole, the threaded hole and the thread.
(c) Tighten the fixing bolts with prescribed torque during installing the sensors, actuators or other parts.
ensure the engine always in clean and complete state. Clean or wipe up the parts to ensure the clean
parts and the assembly quality before removing and assembling. The complicated adjustment and
maintenance should be taken indoors to avoid the engine polluted by the environment.
(d) Tighten the fixing bolts with prescribed torque during installing the sensors, actuators or other parts.
(e) Do not pull up the spark plug wire when the engine is runing.
(f) The high impedance type digital multimeter should be used to the test except the especial description
of the procedure in place of the traditional analogue types multimeter.
(g) Removal and replacement of the oxygen sensor, the sensor can not contact with water or other liquids.
(h) Installation carrying the sensor, in order to ensure its not damaged, you must gently, no shock, drop, its
performance may cause great damage.
(i) Battery voltage is low or starter failure, not a long time starting the engine, so as not to damage the
catalytic converter.
(j) Can not use the needle puncture method of inspection system signal wiring harness.
(k) No gasoline fuel pump can not operate under a long time, can not run without petrol in the air.
(l) As most electric sprayed parts are un-repairable, after confirm the part is damaged, replace it generally.
(m) The system should use anti-type spark plugs and high-voltage, non-resistant phenotype will not only
release high-voltage spark plug and interference wave, but also on the ecm within the ignition coil driver
module adverse effects.
(n) ECM can’t be disassembled for testing and maintenance, but basic testing can be done.
11A-2 ENGINE CONTROL SYSTEM - ENGINE CONTROL SYSTEM
SYSTEM OVERVIEW
1. INTRODUCTION.
The two electrically controlled Multi-point Injection (MPI) engine control systems – 4G63 and 4G64 – take
DELPHI MT20U2 Engine Control Module (ECM) as the control center and measure various working
parameters of the engine through various sensors mounted on different components of the engine. Then the
fuel injection quantity is controlled precisely via the control injector according to the preset control program in
the ECM, which enables the engine to obtain the mixture with optimal concentration under various working
conditions. In addition, with the control program in the ECM, the electrically controlled fuel injection system can
also enable the functions of start-up enrichment, warm-up enrichment, acceleration enrichment, full-load
enrichment, deceleration dilution, forcible idle cutoff, automatic idle speed control etc, which meets the
requirements for mixture under special working conditions of the engine and enables the engine to obtain good
fuel economy and emission while enhancing the functional performance of the vehicle. In addition, ECM has
some fault diagnosis modes which can simplify the fault location.
2. ENGINE CONTROL SYSTEM FUNCTION.
• Knock control
• Mileage memory
• Over voltage protection
• Fuel pump control
• Canister solenoid valve control
• Idle air control motor control

ECM control function
• Totally main power relay control
• A/C, coolant water box fan control
• Direct ignition
• Closed-loop control multi point squence fuel injection (MAP sensor pressure
judgement)
• Intake pressure speed-density method air measurement
• Trouble self diagnosis function

3. ECM CONTROL STRUCTURE.
11A
11A
4. ENGINE CONTROL SYSTEM DIRGRAM.
1 Intake 10 MAP/IAT Sensor
2 Air Filter 11 From Fuel Pump
3 Idle Air Control Motor 12 Injector
4 Throttle Position Sensor (TPS) 13 ECT Sensor
5 Canister Solenoid Valve 14 CKP Sensor
6 Canister 15 Upstream Oxygen Sensor
7 Fuel Pressure Regulation 16 Downstream Oxygen Sensor
8 To Fuel Box 17 Three-Way Catalyst (TWC)
Positive Crankshift Ventilation (PCV)

9
Valve
5. ENGINE CONTROLSYSTEM MAIN COMPONENTS DISTRIBUTION GRAPH.
11A
11A
1 Injector 8 Vehicle Speed Sensor
2 Throttle Body Manifold Absolute Pressure/Intake Air Tem-

9
perature (MAP/IAT) Sensor
3 Spark Plug
10 Ignition Control Module
4 Idle Air Control Motor
11 Fuel Pressure Regulator
5 Engine Coolant Temperature (ECT) Sensor
12 PCV Valve
6 Knock Sensor
13 Inlet Fuel (From Fuel Pump)
7 Crankshaft Position (CKP) Sensor
14 Outlet Fuel (Return Back To Fuel Tank)
INTRODUCTION TO SYSTEM FUNCTION

1. IDLE SPEED CONTROL.
(a) Idle speed control function refers to system control of engine speed with the throttle valve closed. The
system makes the actual speed consistent with the target idle speed by controlling idle parameters.
(b) The system applies the idle stepper motor and realizes high precision idle speed control.
2. AIR METERING OF SPEED-DENSITY METHOD (INTAKE MANIFOLD PRESSURE/ TEMPERATURE
SENSOR).
With intake temperature sensor and intake manifold pressure sensor, ECM calculates and defines the
air quantity entering the cylinder. Furthermore, ECM allows air/fuel ratio to meet the requirements of
various working conditions by controlling the fuel supply.
3. CYLINDER DETECTION SEQUENCE CONTROL.
In order to realize engine sequence control, the system applies intake pressure cylinder detection
technology. The intake pressure sensor is installed near the air inlet of the intake manifold for four
cylinders. At the moment when the inlet valve opens, there is an instantaneous pressure drop of which
the value is around 1 kPa at the sensor. ECM detects the instantaneous pressure drop. After receiving
the signal, ECM identifies compression Top Dead Centre (TDC) signal through the software analysis
and processing.
4. CLOSED LOOP CONTROL.
The system applies closed loop control for the engine fuel supply and idle speed. The advantage of
closed loop control is that the system effectively eliminates the difference between the system and
relevant mechanical parts due to the manufacture and usage wear, which enhances the integrated
coherence of the whole vehicle and reduces the emission.
5. GROUPING CONTROL.
The system divides the engine cylinders into two groups of 1-4 and 2-3 which control the ignition
respectively. The grouping control optimizes and simplifies the system structure.
Ignition timing and fuel injection control (crankshaft position sensor) systems determine crankshaft
position and measure engine speed according to 58X gear signal, which controls the engine ignition
and fuel injection timing precisely.
The opening and closing of the power transistor control the continuity of the primary current in the
ignition coils. The ignition timing control is aimed to obtain the optimal ignition time so as to meet the
requirements of various working conditions of the engine. ECM determines the ignition time according
to the engine speed, intake vacuum degree, engine cooling water temperature and atmospheric
pressure.
6. SELF-DIAGNOSIS.
(a) The system fault self-diagnosis is an essential function for the engine control system. When one or
several parts in the system operate abnormally, the system will inform the vehicle owner to perform
necessary check and repair timely with fault indicator lamp ON. When the fault occurs, the system can
also control the engine operation with temporary emergency method, so as to ensure the owner can
drive the vehicle to repair.
(b) When certain sensor and actuator is detected abnormal, the engine fault inspection lamp turns on to
remind the driver.
(c) When certain sensor and actuator is detected abnormal, the fault code corresponding to the fault will be
exported.
(d) RAM data related to the sensor and actuator in ECM can be read by fault diagnostic apparatus. In
addition, in certain situation, the actuator can be forcibly driven.
7. OVERVOLTAGE PROTECTION.
When the voltage of the charging system is too high caused by the fault, the system will go to the
protection status to restrict the engine speed to avoid the ECM damage.
8. A/C COMPRESSOR CONTROL.

When the A/C is turned on, the system will receive a signal called A/C request and make preparations
before loading the A/C according to the engine working condition, and then switch on the A/C
compressor. The system will switch on or switch off the A/C according to the protection demand of the 11A
air-conditioner. To ensure the power output and protect the engine, the system will cut off the A/C under
specific working condition.
9. THREE-WAY CATALYTIC CONVERTER.
The function of three-way catalytic converter is to convert harmful exhaust gas after the engine
combustion to harmless gas to exhaust to the atmosphere. The internal structure of three-way catalytic
converter applies the cellular pipeline design. The cellular pipeline wall has precious metal coating on it,
including palladium, rhodium, platinum etc, which acts as catalytic reaction media. The three-way
catalytic converter will cause 3% - 5% of the power consumption to the engine. 11A
10. OVERHEAT SYSTEM PROTECTION FUNCTION FOR THE THREE-WAY CATALYTIC CONVERTER.
The system predicts the rising trend of the engine exhaust temperature according to actual working
condition of the engine and reduces the engine combustion temperature by timely controlling the air/
fuel ratio, so as to protect the three-way catalytic converter.
11. CONTROL OF THE COOLING FAN.
(a) The vehicle is equipped with an electrical dual-speed engine cooling fan and an air-conditioner
condenser fan.
(b) Electrical fan control function: ECM determines whether to switch on various fans according to the
engine coolant temperature and whether the temperature meets the condition for switching on the air-
conditioner, so as to reduce the engine internal power consumption.
BASIC PRINCIPLE
1. PRINCIPLE OF START CONTROL.
(a) When turning the ignition switch on, the fuel pump will stop after running for 1.5 seconds.
(b) When the engine starts to rotate, the fuel pump will start to operate after ECM having detected 2 valid
58X signals.
(c) The fuel pump stops operating 0.8 seconds after the engine speed disappears (the analogue signal is
easy to be disturbed).
(d) Pre-injection: The pre-injection only injects once during the normal start process (if the fuel is absorbed
by the carbon deposition, the mixture dilutes, which makes it difficult to start).
(e) Preliminary stage for starting: The intake manifold internal pressure is displayed as ambient
atmospheric pressure. After the throttle valve closed, ECM specifies a fixed parameter according to the
start temperature.
(f) During the start process, the fuel injection quantity varies according to the change of the engine coolant
temperature. The ignition angle also adjusts continually and changes with the engine coolant
temperature, the intake air temperature and the engine speed.
(g) End of the start process: When the engine speed exceeds 600 RPM, the start working condition ends.
2. PRINCIPLE OF FUEL INJECTION CONTROL.
(a) ECM controls the injector driving time and the injection timing, which enables the engine to obtain the
mixture with optimal air/fuel ratio under various working conditions.
(b) Each cylinder is equipped with an injector at the air inlet. The fuel pump in the fuel tank pumps out the
fuel and delivers the fuel to the fuel high pressure rail. The fuel pressure regulator keeps the injection
pressure stable. The injector injects the fuel directly to the air passage of each cylinder. During each
working cycle (when the crankshaft rotates twice) of the cylinder, each cylinder injects the fuel once (the
injection sequence is 1 - 3 - 4 - 2). This injection type is called as sequential injection.
(c) When the engine operates under cold vehicle or high-load condition, ECM performs open loop control
to supply dense mixture, so as to keep the good performance. When the engine operates under the
normal working condition (medium or small load), ECM performs closed loop control via the signal fed
back by oxygen sensor to obtain optimal air/fuel ratio, which enables the three-way catalytic converter
to get the optimal purifying effect.
(d) Inject pulse width control.
Signal Input ECM Control Output

A/F modify
Closed loop feedback modify
Intake manifold absolute pressure
Air charging temperature
Air charging efficiency
Self-learning modify
Calculate fuel charge Inject pulse width
Power supply modify
Exhaust cycle
Accelerate deepen
Decelerate fuel reduction
Decelerate fuel cut
Injector parameter
CONTROL SIGNAL DESCRIPTION
Modified Item Content
• Start air/fuel ratio. 11A

• Air/fuel ratio while engine is running.
• Air/fuel ratio at low engine coolant temperature.
Air/fuel ratio includes • Air/fuel ratio at normal engine coolant temperature.
• Theoretical air/fuel ratio.
• Enriched air/fuel ratio.
• Overheat protection air/fuel ratio.
Closed loop feedback correction • Control the actual air/fuel ratio around the theoretical air/fuel ratio via the
feedback signal from the oxygen sensor. 11A
Intake manifold pressure • Read directly via the MAP mounted on the intake manifold.
Self-learning • Modify the engine internal slow change due to long time operation.
Power voltage • When the battery voltage changes, the voltage modification can ensure
the correct fuel injection quantity.
• When ECM detects the intake manifold pressure and the opening value
Acceleration enrichment of the throttle valve increases greatly, the fuel injection quantity is
increased to avoid the engine mixture dilutes momentarily, so as to
improve the power performance.
Deceleration dilution • When the system detects the vehicle is under deceleration status, it
controls the fuel cutoff to reduce the emission and fuel consumption.
• When the system detects the vehicle is under deceleration status, it

controls the fuel cutoff to reduce the emission and fuel consumption.
Deceleration cutoff
• When the engine speed is above the setting value, fuel cutoff starts.
• When a fault occurs in the ignition system, the fuel cuts off.
Fuel injection parameter • It provides the relation between the engine and the fuel injection
quantity.
(e) Modification for the engine mixture:

• Partial load control of the engine is closed loop fuel control at the normal working temperature. Then
the system modifies fuel injection quantity via ECM according to the feedback voltage signal from the
oxygen sensor, so as to adjust the mixture concentration to around the theoretical air/fuel ratio, which
ensures the conversion efficiency of the harmful emission gas by the three-way catalytic converter
reaches the optimal status while ensuring good fuel economy.
• When the engine operates with full-load within the normal working temperature range, it applies the
open loop fuel control. At this time, in order to ensure the engine obtains the optimal power output, the
system will control the fuel injection quantity with a thick air/fuel ratio. Furthermore, with the premise
that no engine knock occurs, the engine will increase the ignition advance angle moderately. The
system will also control the exhaust gas temperature using the exhaust gas temperature mathematical
model established during calibration, so as to protect the engine and the three-way catalytic converter.
The system determines the full-load condition of the engine according to the signal supplied by the
throttle valve position sensor. When the throttle valve opening is above 80% ~ 90%, the system
considers the engine goes to the full-load status. When the driver presses the accelerator pedal to
accelerate the vehicle, the system will increase the fuel injection quantity moderately to ensure the
power demand when the engine accelerates. The increased fuel injection quantity goes a direct
proportion with the changing rate of the throttle valve opening. When accelerating, ECM will retard the
ignition advance angle moderately, then recover step by step. The aim is to avoid impact to the drive
train because the torque increases too rapidly when the engine accelerates sharply.
• When the acceleration working condition is near the engine full-load, the system will automatically
switch off the A/C system temporarily, so as to ensure the engine power output when accelerating.
Whatever the situation, when the engine speed exceeds the highest speed specified in the system, the
system will cut off the fuel supply to restrict the speed increasing unlimitedly, so as to protect the engine
and avoid the vehicle skidding. When the speed returns to below the highest speed limit specified in the
system, the system will restore the fuel supply immediately.
3. PRINCIPLE OF IGNITION CONTROL.
(a) Start: The engine applies a fixed ignition advance angle when starting, which allows the gas in the
cylinder to ignite and provide the positive torque. When the engine speed increases to certain speed,
ECM computes the ignition advance angle according to the input signal.
(b) Ignition advance angle control.
Signal Modify ECM Output Control

ECT modify
IAT modify
Elevation modify
Idle modify
Main ignition angle Calculate ignition advance angle Ignition advance angle
Decelerate fuel reduction modify
Accelerate modify
Accelerate deepen modify
A/C modify
(c) Main ignition advance angle: When the engine temperature reaches the normal value, the main ignition
angle when the throttle valve opens is usually the minimum ignition angle at the optimal torque point.
When the throttle valve closes, the ignition angle should be reduced to obtain the idle speed stability.
(d) Correction of the ignition advance angle:
• Acceleration correction: When the vehicle accelerates, ECM detects the knock signal and corrects the
ignition until the knock disappears. Furthermore, it is also used to reduce the engine speed fluctuation
caused by the drive train torsion.
• Power enrichment correction: To obtain better power and torque near the exterior feature point, the air/
fuel ratio is enriched to the thinnest air/fuel ratio with the best torque.
• Deceleration cutoff correction: When the deceleration cutoff exits, correct the ignition advance angle to
get a stable transition.
• A/C correction: Switch off the A/C when the engine is idle. Correct the ignition advance angle, which
allows the speed to get a stable transition.
4. PRINCIPLE OF IDLE CONTROL.
(a) Idle control:
• Control the air flow in the bypass of the throttle valve according to the idle condition and the engine idle
load to maintain the idle speed at the optimal speed. According to the engine coolant temperature and
the air-conditioner load, ECM drives the idle stepper motor to make the engine operate under the
preset target idle speed. In addition, when the engine operates at idle speed, turn on or turn off the A/C
switch. The idle stepper motor will regulate the air flow in the bypass according to the engine load to
avoid unstable idle.
(b) Calculate the target idle speed.
Input ECM Output Control

Basic target idle speed 11A
Voltage compensation
Vehicle speed compensation
Fan compensation Calculate target idle speed Target idle speed
Headlamp compensation
A/C compensation
11A
Deceleration adjustment
• Voltage compensation: When the voltage is below 12 V, the system will automatically increase the
target idle speed to increase the electrical energy production of the generator.
• A/C compensation: Switch on the A/C when parking the vehicle at idle speed. To compensate the
power loss of the compressor, the target idle speed increases by 150 RPM.
• Headlamp compensation: After switching on the low beam, the target idle speed increases by 50 RPM
to compensate the electricity loss.
• Fan compensation: When the coolant temperature increases and the fan operates, the idle speed
increases by 50 RPM to compensate the electricity loss for the fan operation.
(c) Idle speed control parameters:
• Control of idle air flow.
• Control of fuel injection quantity.
• Control of ignition timing.
(d) Idle speed design control timing:
• Calibration of idle stability.
• Calibration of acceleration working condition.
• Calibration of deceleration working condition.
• Deceleration cutoff.
• Calibration for the fuel supply under engine transient transition working condition.
• Calibration of constant speed driving.
• Calibration of increasing and reducing the mechanical and electricity load.
(e) Decisive factors for the target idle speed:
• When the engine water temperature is low, the system provides a high target idle speed to accelerate
the warm-up.
• When the additional load (e.g. various electrical appliances such as the headlamp, A/C, cooling fan
etc.) opens, the system will raise the idle speed to compensate the increased load and keep the idle
speed stable.
5. PRINCIPLE OF KNOCK CONTROL.
(a) Introduction to knock sensor:
• Knock sensor is a vibration acceleration sensor mounted on the engine cylinder block. Knock sensor is
usually mounted between the cylinder 2 and 3, which benefits for the engine knock balance. ECM uses
the vibration frequency signal output by the sensor to determine whether the knock occurs on the
engine via ECM internal wave filtering. When the knock signal is detected, ECM corrects the ignition
angle until the knock disappears.
(b) Knock control conditions:

• The vehicle is equipped with knock sensor.
• The engine speed is over 800 RPM.
• MAP is over 40 kPa.
(c) Knock control mode:
• Stable state control: When the engine operates normally, ECM collects and analyzes the sound during
the engine combustion process with the knock sensor, then detects the knock via filtering. Once the
knock strength exceeds the limit, the system will rapidly retard the ignition advance angle of the cylinder
with knock to eliminate the knock.
• Transient control: When the vehicle is accelerating sharply or the engine speed varies sharply, knock
will occur easily. After predicting the possibility of knock, the system will automatically retard the ignition
advance angle to avoid the knock exceeding the limit.
• Rapidly retard the ignition angle: After detecting the knock, the system rapidly retards the ignition
advance angle according to the different engine speed, and will recover to be normal within 2 or 3
seconds.
• Adaptive ignition angle adjustment: Due to the manufacture error and long-time usage wear (the
relations affecting the phase angle including the belt, toothed belt pulley, camshaft etc.), there are some
differences or changes on the engine. When the system and engine is initially used or the ECM is
powered on again, knock may occur when the engine is working, which the system will record. Through
a period of running-in, the system will automatically generate an adaptive ignition adjustment corrected
value (self-learning value). When the engine runs under the same working conditions, the system will
automatically perform adaptive adjustment to the ignition advance angle to avoid the strong knock. The
system adaptive learning will be continually updated during the engine operation process.
6. PRINCIPLE OF CARBON CANISTER SOLENOID VALVE CONTROL.
(a) Used for controlling the air flow for cleaning the carbon canister. The carbon canister is controlled by
ECM sending the duration and frequency for the electrical impulse (duty cycle) through integrated
computation according to a series of signals including engine load, engine coolant temperature, and
engine speed etc. When too much gasoline vapor is accumulated in the activated carbon canister, it will
cause the gasoline leakage, which pollutes the environment. Therefore, the effect of carbon canister
solenoid valve is to open at the proper time to allow the excess gasoline vapor to enter the intake pipe
after mixing with the air sufficiently in the carbon canister to involve in the combustion.
(b) The carbon canister will not work in the following conditions:
• During a period after the cold start of the engine.
• When the cooling water temperature is low.
• During the engine idle operation period.
• During the engine big load period.
• When the important sensors of the system have fault.
MAIN COMPONENTS
11A
11A
Component Summary Quantity Function
ECM 16 bit CPU 1 • ECM optimization control system

depending on the sensor signal.
Upstream oxygen sensor With heated 1 • Check oxygen concentration in

exhaust.
• ECM judge whether the TWC is

Downstream oxygen good compareing the upstream
With heated 1
sensor with downctream oxygen sensor
signal.
MAP/IAT sensor Piezoelectric type 1 • Check the air inlet quantity and
BTDC.
CKP sensor Magnetron induction coil type 1 • Check CKP and engine RPM.
Knock sensor Frequency response type 1 • Check whether the engine knock.
Injector 4 hole type 4 • Inject fuel depending on the sensor

form ECM.
Idle air control motor Electromagnetic coil type 1 • Control air inlet.
Carbon solenoid valve Electromagnetic type 1 • Control the exhaust depending on

the digital pulse wave from ECM.
3- lines type carbon film

TPS 1 • Check the open of throttle.
resistor sliding indicator
ECT sensor NTC thermal resistance type 1 • Check ECT.
IAT sensor NTC thermal resistance type 1 • Check IAT.
Odometer sensor Hall effect type 1 • Check vehicle speed.
Ignition coil Electromagnetic coil type 1 • Ignite mixed gas.
Fuel pump Electromagnetic type pump 1 • Supply the enough pressure fuel
for system.
ENGINE CONTROL SYSTEM - ENGINE CONTROL MODULE (ECM) 11A-15
ENGINE CONTROL MODULE (ECM)

PRINCIPLE
1. PRINCIPLE OF ECM. 11A
(a) ECM is the electric engine control center with the micro processor as the core that having sensor signal
input interface and the executor drive circuit.
(b) The ECM receives and treats the engine status signal that inputted from all sensors, sends control
signal to the executor to drive the engine running in accordance with the preset procedures so as to
make the engine run under best status, ensure good power capability, fuel economy and exhaust
capability.
2. INFORMATION OF ECM.
11A
(a) Normal operating voltage: 9 -16 V.
(b) Overvoltage protection: +24 V/-12 V < 60 s.
(c) Continuity power: terminal 17, 18.
(d) Controlled by ignition key: terminal 1.
(e) Ground wire: terminal 73.
(f) Standard 5 V power supply: terminal 4, 20.
(g) Standard 5 V ground supply: terminal 5, 21.
(h) ECM has self protection function, it may result the
ignition failure during repair and it will resume normal
after replacement of ECM, therefore we may deem as
the ecm trouble. In fact, the ECM doesn’t get damaged,
but just enters into self protection mode. ECM will
resume normal after certain time period.
11A-16 ENGINE CONTROL SYSTEM - ENGINE CONTROL MODULE (ECM)
REPLACEMENT
1. TURN IGNITION SWITCH OFF.
2. DISCONNECT BATTERY NEGATIVE CABLE.

NOTE
When disconnecting or connecting the battery cables,
please first turn off the ignition switch and lighting switch
and completely loosen the cable nut. Do not pry up the
cable when peforming these operations.
3. REMOVE STEERING COLUMN LOWER COVER.

(a) Pull open the engine hood lock handle.
(b) Remove 2 screws.
(c) Pull out the engine hood control handle.

(d) Remove the engine hood control cable.
(e) Remove 3 retaining screws of the steering column lower

cover.
11A
(f) Remove the steering column lower cover.

11A
4. REMOVE ECM SHIELD.

(a) Remove the ECM shield bolt.
(b) Take out shield.
5. REMOVE ECM.
(a) Disconnect ECM connector.
NOTE
After disconnecting the connector, confirm that the junction
of the connector avoid the dirty, water and other foreign
matter.
11A-18 ENGINE CONTROL SYSTEM - ENGINE CONTROL MODULE (ECM)
(b) Remove 3 bolts.
(c) Remove ECM.

NOTE
• After disconnecting ECM, pay attention to waterproof.
Not allow to contact water. Even more, not allow to
put into water.
• Pay attention to protect the terminals.
• Disconnect the battery negative cable for 1 minute
before removing ECM.
• Not allow to impact.
6. INSTALL ECM.
NOTE
• Pay attention to electrostatic protection when
installation.
(a) Tighten 3 bolts.
Torque: 19.6 N•m
(b) Connect ECM connector.
(c) Install ECM shield.

(d) Tighten the ECM shield bolt.
Torque: 19.6 N•m
7. INSTALL STEERING COLUMN LOWER COVER.

(a) Connect the diagnosis wire harness connector.
(b) Position the steering column lower cover properly.
11A
(c) Install steering column lower cover and tighten 3 retain-

ing screws. 11A
(d) Install the engine hood control cable.
(e) Position the engine hood control handle properly.

(f) Tighten 2 screws.
11A-20 ENGINE CONTROL SYSTEM - ENGINE COOLANT TEMPERATURE SENSOR
ENGINE COOLANT TEMPERATURE SENSOR

PRINCIPLE
1. PRINCIPLE OF ENGINE COOLANT TEMPERATURE
(ECT).
(a) The Engine Coolant Temperature (ECT) sensor uses a
thermistor to control the signal voltage to the Engine
Control Module (ECM).
(b) This ECT sensor is the 2-line type. Normally the 1-line
type is to provide coolant temperature signal to the
instrument.
ENGINE CONTROL SYSTEM - ENGINE COOLANT TEMPERATURE SENSOR 11A-21
OVERHAUL
2. OPEN ENGINE HOOD. 11A
11A

NOTE
4. DRAIN THE COOLANT. (Refer to “Chapter 17A cooling - precaution”)
5. REMOVE ENGINE COVER AND INTAKE AIR DUCT.

(a) Remove 4 engine cover retaining bolts.
(b) Remove 2 engine intake air hose retaining bolts.
6. REMOVE ECT SENSOR.

(a) Disconnect ECT sensor connector.
(b) Remove ECT sensor.
NOTE
• Clear the installation surface after removing.
• Clear the screw hollow after removing.
• Clear the thread of sensor after removing.
.
11A-22 ENGINE CONTROL SYSTEM - ENGINE COOLANT TEMPERATURE SENSOR
7. CHECK ECT SENSOR.

(a) Dip the sensing part of ECT sensor into hot water. Using
the multimeter, measure resistance of the sensor.
(b) If the check result is not OK, replace it.
Check Condition Specified Condition
0℃ 5.1 ～ 6.5 KΩ
20 ℃ 2.1 ～ 2.7 KΩ
40 ℃ 0.9 ～ 1.3 KΩ
80 ℃ 0.26 ～ 0.36 KΩ
CAUTION
Don’t let the water into terminals. After checking, dry the
sensor.
8. INSTALL ECT SENSOR.
CAUTION
Apply sealant on thread. The specified sealant: 3M NUT
LOCKING PART, type: NO.4171 or the equivalent.
(a) Install ECT sensor and tighten.
Torque: 29.4 N•m
(b) Connect ECT sensor connector.
9. FILL COOLANT. (Refer to “Chapter 17A cooling - precaution”)

10. INSTALL ENGINE COVER AND INTAKE AIR DUCT.
(a) Tighten 4 engine cover retaining bolts.
(b) Tighten 2 intake air duct retaining bolts.
11. TIGHTEN INTAKE DUCT RETAINING BOLTS.

Torque: 21 ~ 25 N•m
12. CHECK COOLANT LEAKAGE.

13. CONNECT BATTERY NEGATIVE CABLE.
ENGINE CONTROL SYSTEM - THROTTLE BODY 11A-23
THROTTLE BODY
THROTTLE BODY
1. THROTTLE BODY CLEANING. 11A
(a) Start the engine and warm it up until the coolant is heated to 80 °c or higher. then stop the engine.
(b) Remove the air intake hose from the throttle body.
(c) Plug the bypass passage inlet (arrow) of the throttle body.
CAUTION
Do not allow cleaning solvent to enter the bypass passage.
(d) Spray cleaning solvent into the valve through the throttle
body intake port and leave it for approximately five 11A
minutes.
(e) Start the engine, accelerate it several times and then idle
it for about one minute. If the idle speed becomes
unstable (or if the engine stalls) due to the bypass
passage being plugged, slightly open the throttle valve to
keep the engine running.
(f) If the throttle valve deposits are not removed, repeat
steps 4 and 5.
(g) Unplug the bypass passage inlet.
(h) Attach the air intake hose.
(i) Use the scan tool to erase any diagnostic trouble code.
(j) Adjust the basic idle speed.
NOTE
If the engine hunts while idling after adjustment of the basic idle speed, disconnect the battery
negative cable for 10 seconds or more, and then reconnect it and run the engine at idle for about 10
minutes after the engine is warmed up.
11A-24 ENGINE CONTROL SYSTEM - THROTTLE BODY
THE FIXED SPEED ADJUSTING SCREW (SAS) ADJUSTMENT

1. SINCE FIXED SAS IS ADJUSTED AT FACTORY, PLEASE DO NOT ADJUST “FIXED SAS” IN
NORMAL CASES UNLESS IT IS NECESSARY.
2. IF “FIXED SAS” IS ROTATED RANDOMLY, PLEASE RE-ADJUST ACCORDING TO THE
FOLLOWING STEPS:
(a) Loosen the tension of the acceleration cable.

(b) Loosen the "fixed SAS” lock nut.
(c) Turn the idle switch counterclockwise until the throttle
valve closes.
(d) Screw the “fixed SAS” clockwise until the point (i.e. the
position when throttle is started to be opened) of throttle
rail is reached.
(e) Keep the “fixed SAS” from moving when tighten the lock
nut.
(f) Adjust the acceleration cable tension.
(g) Adjust the basic idle speed.
BASIC IDLE SPEED ADJUSTMENT

1. The standard idle speed has been adjusted with the Speed Adjusting Screw (SAS), by the manu-
facturer, and there should be no need for readjustment.
2. If the adjustment has been changed by mistake, the idle speed maybe come too high or the idle
11A
speed may drop too low when loads A/C, defogger, etc. are placed on the engine. If this occurs,
adjust by the following procedure.
NOTE
If make the adjustment, it should be made after first confirming that the spark plugs, the injectors, the
idle air control motor, compression, etc., are all normal.
(a) The vehicle should be prepared as the past delivery state

before the inspection and adjustment. 11A
(b) Turn the ignition switch OFF.
(c) Connect the KT600 scan tool to the Data Link Connector
(DLC).
(d) Start the engine and run at idle speed.
(e) Check the idle speed.
Standard value: 750 ± 50 RPM
NOTE
• The engine speed may be 20 to 100 RPM lower than
indicated above for a new vehicle, but no adjustment
is necessary.
• If the engine stalls or the engine speed is low even
though the vehicle has been driven approximately
500 km (300 mile) or more, it is probable that
deposits are adhered to the throttle valve, so clean it.
(f) If it is not within the standard value range, turn the Speed
Adjusting Screw (SAS) to make the necessary
adjustment.
NOTE
If SAS gets to bottom completely, the idle speed is still more
than standard value, then check if “fixed SAS” was rotated.
If yes, re-adjust “fixed SAS”.
• Turn the ignition switch OFF.
• Disconnect the scan tool.
• Start the engine again and let it idle for about 10 minutes.
• Check that the idling condition is normal.
11A-26 ENGINE CONTROL SYSTEM - THROTTLE BODY
OVERHAUL
1. TURN THE IGNITION SWITCH OFF.
2. OPEN ENGINE HOOD.

NOTE
4. DRAIN COOLANT. (Refer to“Chapter 17A cooling - precaution”)

6. LOOSEN THROAT ELBOW CLIPS AND TAKE AWAY

THROAT ELBOW.
7. REMOVE ACCELERATOR CABLE.

(a) Loosen accelerator cable adjust nut on the throttle body.
(b) Take off accelerator cable clip.
(c) Move the accelerator cable aside. 11A
8. REMOVE THROTTLE BODY. (Refer to “Chapter 14A

intake air - intake manifold, replacement”) 11A

11A-28 ENGINE CONTROL SYSTEM - IDLE AIR CONTROL MOTOR
IDLE AIR CONTROL MOTOR

PRINCIPLE
1. PRINCIPLE OF IDLE AIR CONTROL MOTOR.
(a) The idle air control motor is essentially one micro motor.
since the motor will revolve in various directions when
the motor coil is supplied with current in various
directions.
(b) The motor revolution shaft will drive the moving of the
leading screw so as to control the open extent of the
valve indirectly.
(c) ECM will send the digitalized square wave signal to
control the positive rotation and the reverse rotation of
the motor so as to control the stroke of the idle air control
motor.
ENGINE CONTROL SYSTEM - IDLE AIR CONTROL MOTOR 11A-29
ON-VEHICLE INSPECTION
1. OPERATING SOUND INSPECTION.
(a) Check that coolant temperature of engine is below 20 ℃ .
11A
NOTE
If coolant temperature of engine is above 20 ℃ , remove the harness connector of engine coolant temperature
sensor, and use the less than 20 ℃ sensor for connection.
(b) Check that when ignition switch is placed in the ON position (do not start engine), the operating sound
of the stepper motor can be heard over the stepper motor.
(c) If an operating sound can be heard, check the stepper motor drive circuit. If the circuit is good, a
defective stepper motor or ECM is suspected.
2. CHECK ENGINE RPM.

11A
(a) Start the engine and warm it to normal operating
temperature.
(c) Connect the KT600 scan tool to the Data Link Connector
(DLC) - use the most current software available.
(d) Turn the ignition switch ON.
(e) Select the item “AUTO DIAGNOSIS\FOTON\ LIGHT
BUS\MPX\ENGINE\4G63 GASOLINE ENGINE OR 4G64
GASOLINE ENGINE\ MT20U2\ACTIVE TEST”.
(f) Perform the idle air control motor test.
(g) When the scan tool control the rotation of expansion of
the idle air control motor, the engine RPM changes from
high to low in synchronism (touching the idle air control
motor, can feel vibration).
(h) If it is not OK, check IAC motor control harness or con-
nector. If harness or connector is OK, check IAC motor or
ECM.
3. CHECK IDLE AIR CONTROL MOTOR STEPS.
(a) Start the engine and warm it to normal operating temperature.
(c) Connect the KT600 scan tool to the Data Link Connector (DLC) - use the most current software
available.
(d) Turn the ignition switch ON.
(e) Select the item “AUTO DIAGNOSIS\FOTON\LIGHT BUS\MPX\ENGINE\4G63 GASOLINE ENGINE OR
4G64 GASOLINE ENGINE\MT20U2\READ DATA STREAM.”
Displayed Item Detection Condition Specified Condition
• ECT: 80 ～ 95 ℃
• Lamp and all other
A/C switch: OFF → ON Add 10 ～ 70 steps
accessorie: OFF
• Transmission: N
Idle air control motor
• Engine: idle
• A/C turns ON A/C switch: OFF 2 ～ 25 steps
• A/C compressor:
works
(f) If it is not OK, check idle air control motor, harness, connector or ECM.
11A-30 ENGINE CONTROL SYSTEM - IDLE AIR CONTROL MOTOR
OVERHAUL
2. REMOVE IDLE AIR CONTROL MOTOR.

(a) Disconnect idle air control motor connector.
(b) Remove 2 idle air control motor retaining bolts.
3. REMOVE IDLE AIR CONTRROL MOTOR.

NOTE
• Clear surface after removing.
• Clear the path of the idle.
4. CHECK IDLE AIR CONTRROL MOTOR COIL

RESISTANCE.
(a) Connect special tool (for test).
(b) Check resistance between terminal 1 and 2 of idle air
control motor connector.
Standard resistance: 28 ~ 33 Ω (20 ℃ )
(c) Check resistance between terminal 3 and 4 of idle air
control motor connector.
(d) If it is not OK, replace it.
5. INSTALL IDLE AIR CONTRROL MOTOR.

(a) Install idle air control motor.
(b) Tighten 2 idle air control motor retaining bolts.
ENGINE CONTROL SYSTEM - IDLE AIR CONTROL MOTOR 11A-31
6. INSTALL IDLE AIR CONTRROL MOTOR.

NOTE
• Should not apply any axially type of force to press or
pull out the axle. 11A
• The axle must be in the place of the retreating before
the idle air control motor being installed into the
throttle body.
• After removing battery or ECM, pay attention to the
idle air control motor self-learning.
7. The idle air control motor self-learning: Turn the
ignition switch OFF, not start at once. After 5
seconds, start it again. 11A
(a) Tighten 2 idle air control motor retaining bolts.
Torque: 3.4 N•m
(b) Connect idle air control motor connector.
11A-32 ENGINE CONTROL SYSTEM - THROTTLE POSITION SENSOR (TPS)
THROTTLE POSITION SENSOR (TPS)

PRINCIPLE
1. PRINCIPLE OF THROTTLE POSITION SENSOR (TPS).
(a) Throttle Position Sensor (TPS) is used to provide throttle
angle, angle speed and engine idle position information
to the ECM, based on which the ECM can obtain the
engine load information, operating mode (such as start,
idle, reverse towing, partial load, full-load) and
acceleration & deceleration information. This sensor is
3-line type. The ECM will check the throttle open extent
by monitoring the voltage variation.
(b) The throttle position sensor is comprised of carbon film
resistance and slide indicator.
(c) The sensor slide indicator connects with the throttle and
rotates following the shaft. When the throttle open extent
changes following the accelerator pedal. The position of
the slide indicator will also change on the carbon film
resistance, at such moment the resistance output will
also change, which reflects the open extent of the throttle
indirectly.
ENGINE CONTROL SYSTEM - THROTTLE POSITION SENSOR (TPS) 11A-33
1. Start the engine and warm it to normal operating
temperature. 11A
2. Turn the ignition switch OFF.
3. Connect the scan tool to the Data Link Connector
(DLC) - use the most current software available.
4. Turn the ignition switch on.
5. Select the item “AUTO DIAGNOSIS \FOTON\LIGHT
GASOLINE ENGINE\MT20U2\READ DATA STREAM”.
11A

Idle position 0.3 ～ 1 V (0%)
• Ignition switch: ON Directly proportional with

TPS Open throttle slowly
• Engine stop the open degree
Widely open 4.5 ～ 5.5 V (100%)
6. If it is not OK, check TPS, harness or ECM.

11A-34 ENGINE CONTROL SYSTEM - THROTTLE POSITION SENSOR (TPS)
OVERHAUL
2. REMOVE TPS.
(a) Disconnect TPS connector.
(b) Remove 2 TPS retaining bolts.
3. REMOVE TPS.
NOTE
Clear the surface after removing.
4. CHECK TPS RESISTANCE.

(a) Check resistance between terminal 1 and 2 of TPS.
(b) Check resistance between terminal 1 and 3 of TPS.
Tester Connection Specified Condition
• Terminal 1 and 2 • Resistance: 3.5 ～ 6.5 Ω (20 ℃ )
• Open throttle from idle position to

• Terminal 1 and 3 open wide.
• Terminal 2 and 3 • The output value is proportional
change to the open degree.
(c) If the resistance is out of the range and the value

changes unsteadily, replace it.
5. POSITION TPS.
(a) Tighten 2 TPS retaining bolts.
Torque: 3.4 N•m
(b) Connect TPS connector.
ENGINE CONTROL SYSTEM - INTAKE MANIFOLD PRESSURE/TEMPERATURE SENSOR 11A-35
INTAKE MANIFOLD PRESSURE/TEMPERATURE SENSOR

PRINCIPLE
1. PRINCIPLE OF INTAKE MANIFOLD PRESSURE/TEMPERATURE SENSOR. 11A
(a) MT20U2 adopted speed-density air measurement
method to check the air intake volume into the engine so
as to control the fuel injection pulse width for the precise
control of engine power output. Meanwhile, this system
adopted intake pressure cylinder determination
technology and the intake air sensor is installed near the
inlet opening of cylinder 4 intake manifold. At the
moment when the throttle is opened, there will be one 11A
instantaneous pressure drop at the sensor, of which the
value is about 1 kPa.
(b) When the ECM detected and received this instantaneous
pressure drop, the ECM will determine the compression
upper dead center signal after software diagnosis
treatment (its functions is similar with the camshaft
position sensor of traditional electric injection system,
also referred as phase sensor).
11A-36 ENGINE CONTROL SYSTEM - INTAKE MANIFOLD PRESSURE/TEMPERATURE SENSOR
temperature.
3. Connect the KT600 scan tool to the Data Link
Connector (DLC) - use the most current software
available.
4. Turn the ignition switch ON.
G3ASOLINE ENGINE\MT20U2\READ DATA STREAM”.
IAT: - 20 ℃ - 20 ℃
IAT: 0 ℃ 0℃
• Ignition switch: ON
IAT sensor IAT: 20 ℃ 20 ℃
• Engine: running
IAT: 40 ℃ 40 ℃
IAT: 80 ℃ 80 ℃
6. TURN DIGITAL MULTIMETER TO VOLTAGE RANGE.

CHECK VOLTAGE OF MAP SENSOR BETWEEN
TERMINAL 3 OR 4 AND GROUND.
(a) When engine runs at idle, terminal 3 is 5 V, terminal 4 is
1.3 V.
(b) When engine runs unload, open throttle slowly, the signal
of terminal 4 is changed little.
(c) Open throttle quickly, the signal of terminal 4 is to about
4 V, then drop to 1.5 V.
(d) Turn multimeter to voltage range. Black pin to ground,
red pin to terminal 2 of the IAT sensor. Check IAT signal.
IAT: 0 ℃ 3.2 ～ 3.8 V

IAT: 20 ℃ 2.3 ～ 2.9 V
IAT sensor Ignition switch: ON
IAT: 40 ℃ 1.5 ～ 2.1 V
IAT: 80 ℃ 0.4 ～ 1.0 V
(e) If it is not OK, check MAP/IAT sensor, harness or ECM.

OVERHAUL
11A

NOTE


THROAT ELBOW.
11A-38 ENGINE CONTROL SYSTEM - INTAKE MANIFOLD PRESSURE/TEMPERATURE SENSOR
6. DISCONNECT MAP/IAT SENSOR CONNECTOR.

(a) Disconnect MAP/IAT sensor connector.
7. REMOVE MAP/IAT SENSOR.

(a) Remove MAP/IAT sensor retaining bolt.
(b) Remove MAP/IAT sensor.
NOTE
Clear surface after removing.
8. CHECK IAT SENSOR RESISTANCE.

(a) Turn digital multimeter to Ohm range. Check resistance
between terminal 2 and 3 of sensor. Using a hairdryer to
blow air to sensor (note: don’t close too near). Inspect
the change of the value, the value should decline.
(b) If it is not OK, replace it.
IAT: 0 ℃ 5.3 ～ 6.7 kΩ
IAT: 20 ℃ 2.3 ～ 3.0 kΩ

IAT sensor Ignition switch: ON
IAT: 40 ℃ 1.0 ～ 1.5 kΩ
IAT: 80 ℃ 0.30 ～ 0.42 kΩ

9. CONNECT MAP/IAT SENSOR.

(a) Connect MAP/IAT sensor and connector.
(b) Tighten MAP/IAT sensor retaining bolt.
Torque: 3 N•m 11A
NOTE
Install it by applying pressure. Any impact tool is not
allowed.
11A



11A-40 ENGINE CONTROL SYSTEM - KNOCK SENSOR
KNOCK SENSOR
PRINCIPLE
1. PRINCIPLE OF KNOCK SENSOR.
(a) Knock sensor is one vibrating acceleration sensor that
installed on the engine cylinder body, normally between
cylinder 2 and cylinder 3 to facilitate the engine knock
balance.
(b) By means of the vibrating frequency signal output from
the knock sensor, the ECM will judge for engine knock
after the ECM internal wave filter.
(c) In case of the detection of the knock signal, the ECM will
reduce gradually till the elimination of the knock and then
resume gradually till the knock threshold.
(d) Above steps will be repeated again and again.
ENGINE CONTROL SYSTEM - KNOCK SENSOR 11A-41
temperature. 11A
3. Connect the scan tool to the Data Link Connector (DLC)
- use the most current software available.
4. Turn multimeter to voltage range, check signal voltage
of terminal 1 and 2.
5. Using a small mallet, stike slightly near the KS sensor.
There should be voltage signal output.
6. Check KS signal with the hand-hold tester. 11A
7. Stike slightly near the KS sensor. There should be
wave signal output.
8. If it is not OK, replace it.
11A-42 ENGINE CONTROL SYSTEM - KNOCK SENSOR
OVERHAUL
3. REMOVE INTAKE AIR MANIFOLD. (Refer to “Chapter 14A intake air - intake manifold, replace-
ment”)
4. REMOVE KS.
(a) Disconnect KS connector.
(b) Remove knock sensor retaining bolt.
NOTE
• Clear the surface after removing.
• Don’t contact all kinds of liqulds. For example: oil,
coolant, brake fluid.
.
5. CHECK KS.
(a) Measure the resistance according to the value in the
table below.
Sensor Terminal Terminal Resistance (20 ℃ )

1 2
1 Ground ＞ 1 MΩ
2 Ground

ENGINE CONTROL SYSTEM - KNOCK SENSOR 11A-43
6. INSTALL KNOCK SENSOR.

(a) Tighten knock sensor retaining bolt.
Torque: 20 ± 5 N•m
NOTE 11A
• Confirm the KS correct direction.
• install it by applying pressure. Any impact tool is not
allowed.
• The metal surface should be pressed against the cyl-
inder body. Any type of washer is not allowed.
• Don’t let the signal cable resonance. To avoid it
brokn.
11A
(b) Connect knock sensor connector.
7. INSTALL THE INTAKE MANIFOLD. (Refer to “Chapter 14A intake air - intake manifold, replace-
ment”)
11A-44 ENGINE CONTROL SYSTEM - CKP SENSOR
CKP SENSOR
PRINCIPLE
1. PRINCIPLE OF CRANKSHAFT POSITION (CKP) SEN-
SOR.
(a) The 58x reference signal is produced by the Crankshaft
Position (CKP) sensor. The Engine Control Module
(ECM) uses the 58x reference signal to calculate engine
RPM and CKP. The ECM constantly monitors the
number of pulses on the 58x reference circuit and
compares them to the number of map signal being
received.
ENGINE CONTROL SYSTEM - CKP SENSOR 11A-45
OVERHAUL
11A

NOTE
4. RAISE VEHICLE.
5. REMOVE CKP SENSOR.

(a) Disconnect CKP sensor connector.
(b) Remove harness from bracket.
(c) Remove the CKP sensor retaining bolt.
NOTE
6. CHECK CKP SENSOR.

(a) Turn digital multimeter to Ohm range, connect two
terminals to terminal 2 and 3 terminal of sensor. Check
resistance.
Standard resistance: 560 Ω ± 10% (20 ℃ )
(b) If the check result is not normal, replace it.
11A-46 ENGINE CONTROL SYSTEM - CKP SENSOR
7. INSTALL CKP SENSOR.

CAUTION
Apply a layerof preventative oil on the O-ring of the CKP
sensor.
(a) Tighten CKP sensor retaining bolt.

NOTE
allowed.
(b) Connect the CKP sensor connector.
8. LOWER VEHICLE.
ENGINE CONTROL SYSTEM - UPSTREAM OXYGEN SENSOR 11A-47
UPSTREAM OXYGEN SENSOR

PRINCIPLE
11A
1. PRINCIPLE OF UPSTREAM OXYGEN SENSOR.
(a) This sensor is used to provide the excess oxygen
information after the injected fuel in the cylinder has
passed the full combustion in the sucked air. By means
of this information, the ECM can perform the closed loop
control upon the fuel quantity so that the 3 main toxic
substances in the exhaust, namely Hydrocarbon (HC),
Carbon Oxides (CO) and nitrogen oxides, can be
converted and purified in maximum extent in the three- 11A
way catalytic converter.
11A-48 ENGINE CONTROL SYSTEM - UPSTREAM OXYGEN SENSOR
temperature.
available.
GASOLIN+E ENGINE\MT20U2\READ DATA STREAM”.
• Engine: warm condition Decelerate suddenly

from 4000 RPM ≤ 0.2 V
• A/F: become lean when
deceleration, become rich
when acceleration Accelerate suddenly 0.6 ～ 1 V
Upstream oxygen
0.1 ～ 0.9 V (change
Engine: idle
• Engine: warm condition 5 ～ 8 times in 10 seconds）
Engine: 2500 RPM 0.6 ～ 1 V
6. IF IT IS NOT OK, THEN CHECK SENSOR, HARNESS AND ECM.

ENGINE CONTROL SYSTEM - UPSTREAM OXYGEN SENSOR 11A-49
OVERHAUL
11A

NOTE
4. REMOVE ENGINE COVER AND INTAKE AIR HOSE.


THROAT ELBOW.
11A-50 ENGINE CONTROL SYSTEM - UPSTREAM OXYGEN SENSOR
6. REMOVE UPSTREAM OXYGEN SENSOR.

CAUTION
Remove the exhaust pipe after it is cooling completely.
(a) Disconnect upstream oxygen sensor connector.
(c) Remove upstream oxygen sensor.
7. CHECK UPSTREAM OXYGEN SENSOR.

between terminal 3 and 4 of sensor.
Standard resistance: 2.5 ~ 4.5 Ω (20 ℃ )
8. INSTALL UPSTREAM OXYGEN SENSOR.

CAUTION
Apply a layer of preventative oil on the thread.
(a) Install upstream oxygen sensor and tighten.
(b) Connect upstream oxygen sensor connector.

10. TIGHTEN INTAKE DUCT RETAINING BOLTS AND

CONNECT BATTERY NEGATIVE CABLE.
ENGINE CONTROL SYSTEM - DOWNSTREAM OXYGEN SENSOR 11A-51
DOWNSTREAM OXYGEN SENSOR

PRINCIPLE
11A
1. PRINCIPLE OF DOWNSTREAM OXYGEN SENSOR.
(a) The purpose of the rear oxygen sensor is to check the
oxygen concentration in the exhaust that passed three-
way catalytic converter and the sensor will convert such
signal to dot signal and transmit to the ECM. After the
comparison of the signals of the front/rear oxygen
sensors, the ECM will judge if the three-way catalytic
converter functions well. The structure of rear oxygen
sensor is same with the one of the front oxygen sensor. 11A
11A-52 ENGINE CONTROL SYSTEM - DOWNSTREAM OXYGEN SENSOR
temperature.
available.
• Engine: warm
Downstream oxygen sensor • Check A/F with oxygen Engine: running About 0.1 V
sensor
6. IF IT IS NOT OK, THEN CHECK SENSOR, HARNESS AND ECM.

ENGINE CONTROL SYSTEM - DOWNSTREAM OXYGEN SENSOR 11A-53
OVERHAUL
11A

NOTE
4. RAISE VEHICLE.
5. REMOVE ENGINE LOWER GUARD PLATE.
6. REMOVE DOWNSTREAM OXYGEN.

(a) Disconnect downstream oxygen sensor connector.
(b) Remove the harness from bracket.
(c) Remove downstream oxygen sensor.
11A-54 ENGINE CONTROL SYSTEM - DOWNSTREAM OXYGEN SENSOR
7. CHECK DOWNSTREAM OXYGEN SENSOR.

(a) Turn digital multimeter to Ohm range, Check resistance
Standard resistance: 2.5 ~ 4.5 Ω (20 ℃ )
8. INSTALL DOWNSTREAM OXYGEN SENSOR.

CAUTION
Apply a layerof preventative oil on the thread.
(a) Install downstream oxygen sensor and tighten.
(b) Connect downstream oxygen sensor connector.
9. INSTALL ENGINE LOWER GUARD PLATE.
10. LOWER VEHICLE.

ENGINE CONTROL SYSTEM - CANISTER SOLENOID VALVE 11A-55
CANISTER SOLENOID VALVE

PRINCIPLE
11A
1. PRINCIPLE OF CANISTER SOLENOID VALVE.
(a) The carbon canister solenoid valve is one solenoid valve
mechanism internally and the ECM will send digitalized
square wave control pulse to control the open extent of
the solenoid valve. The open extent of the carbon
canister is different depending on the various engine
operating modes. In case of the great load of engine or
engine idle, the carbon canister solenoid valve doesn’t
put into operation in order to ensure the engine power 11A
output.
11A-56 ENGINE CONTROL SYSTEM - CANISTER SOLENOID VALVE
temperature.
available.
BUS\MPX\ENGINE\4G63 GASOLINE ENGINE OR
4G64 GASOLINE ENGINE\MT20U2\ACTIVE TEST”.
6. CHECK THE ACTION OF CARBON CANISTER SOLENOID VALVE.

(a) Use the “ACTION TEST” function of the diagnostic apparatus.
• Touch the fuel Evaporative Emission Control (EVAP) system carbon canister solenoid valve with hand.
• Perform the action test of carbon canister solenoid valve with the “action test” function of the diagnostic
apparatus.
• The carbon canister solenoid valve should vibrate slightly. If the carbon canister solenoid valve has no
slight vibration, check solenoid valve, harness and ECM.
(b) Vacuum test method.
• Pull out the vacuum hose from the activated carbon canister and check the vacuum hose for vacuum
suction. When the engine operates at the idle speed, if the carbon canister solenoid valve operates
normally, the solenoid valve should close and there should be no vacuum suction in the vacuum hose.
If there is vacuum suction in the vacuum hose now, remove the socket connector from the solenoid
valve. If there is voltage in the terminal 1 and 2 of the harness socket connector in the carbon canister
solenoid valve, it indicates there is a fault in ECM. If there is no voltage, it indicates the carbon canister
solenoid valve is stuck in the opening position.
• Press the accelerator pedal to allow the engine speed reach above 2000 RPM and check the vacuum
hose for the vacuum suction. If the vacuum suction exists, it indicates the carbon canister solenoid
valve operates normally. If no vacuum suction exists in the vacuum hose and the voltage on the
terminal of harness socket connector in the carbon canister solenoid valve, it indicates there is a fault in
the carbon canister solenoid valve. If the voltage is abnormal, it indicates there is a fault in ECM or
harness.
OVERHAUL
11A

NOTE

5. LOOSEN THROAT ELBOW CLAMPS.

6. REMOVE CANISTER SOLENOID VALVE RETAINING

BOLTS.
7. DISCONNECT CANISTER SOLENOID VALVE CONNECTOR.
8. DISCONNECT CANISTER SOLENOID VALVE INTAKE

HOSE CLIPS AND TAKE AWAY HOSE.
NOTE
When disconnect these hoses which used for a long time.
Twist hose first and confirm loosed, then operate
disconnection.
9. DISCONNECT CANISTER SOLENOID VALVE CONNECTOR

(CONNECT TO THROTTLE BODY LOWER INTAKE
MANIFOLD).
10. REMOVE CANISTER SOLENOID VALVE.

11. CHECK CANISTER SOLENOID VALVE.

(a) Apply battery voltage on canister solenoid valve. Sounds
should be hearded. At this time, blowing air into the inlet
port: 11A
• If air pass, then the canister solenoid valve is OK. If it is not
OK, replace it.
• If no battery applying, the solenoid should be closed. No
air passing.
(b) Check carbon control solenoid valve resistance.

• Turn digital multimeter to Ohm range. Check resistance 11A
between terminal 1 and 2 terminal of canister solenoid
valve.
• If it is not OK, replace it.
12. TIGHTEN CANISTER SOLENOID VALVE RERETAINING

BOLTS.
13. CONNECT CANISTER SOLENOID VALVE CONNECTOR

(CONNECT TO THROTTLE BODY LOWER INTAKE
MANIFOLD).
14. CONNECT CANISTER SOLENOID VALVE INTAKE

HOSE AND TIGHTEN CLIPS.
15. CONNECT CANISTER SOLENOID VALVE CONNECTOR.


ENGINE CONTROL SYSTEM - ODOMETER SENSOR 11A-61
ODOMETER SENSOR
PRINCIPLE
11A
1. PRINCIPLE OF ODOMETER SENSOR.
(a) The ECM use the sensor to receive the digital pulse
signal. Through the signal, the ECM can confirm the
vehicle speed.
11A
11A-62 ENGINE CONTROL SYSTEM - ODOMETER SENSOR
temperature.
2. Turn ignition switch OFF.
available.
6. Driving the vehicle, read the scan tool dat stream:
vehicle speed.
7. Vehicle speed: Same value as the actual vehicle
speed.
8. If the displayed value is not equal to the actual value,
then check sensor, harness and ECM.
9. RAISE VEHICLE.
10. TURN THE IGNITION SWITCH ON AND ENGINE STOP. CHECK AS FOLLOWING:
(a) Set digital multimeter to voltage range. Check voltage between terminal 1 and 2 of the sensor. It should
be 12 V. If it is not OK, replace it.
(b) Start engine, pull into gear. Using the hand-held tetser, check the wave output of terminal of sensor. If it
is not OK, check harness and sensor.
ENGINE CONTROL SYSTEM - ODOMETER SENSOR 11A-63
OVERHAUL
11A

NOTE
cable when peforming these operation.
4. RAISE VEHICLE.

11A-64 ENGINE CONTROL SYSTEM - ODOMETER SENSOR
6. REMOVE ODOMETER SENSOR.

(a) Disconnect odometer sensor connector.
(b) Remove odometer sensor retaining bolt.
NOTE
Clear surface after installation.
7. INSTALL ODOMETER SENSOR.
(a) Tighten odometer sensor retaining bolt.
Torque: 7.8 N•m
NOTE
allowed.
(b) Connect odometer sensor connector.
9. LOWER VEHICLE.
ENGINE CONTROL SYSTEM - IGNITION CONTROL MODULE 11A-65
IGNITION CONTROL MODULE

PRINCIPLE
11A
1. PRINCIPLE OF IGNITION CONTROL MODULE.
。
(a) Adopting group ignition technology, taking advantage of

the theory that the mutual induction of the
electromagnetic coils can generate high energy,
controlling the switch-on/switch-off time of the primary
coil, and taking advantage of the high voltage power of
the secondary coil to puncture the spark plug gap so as
to generate strong spark to ignite the mixed air. Since the
air ionization is very great and the resistance is very low 11A
during the engine exhaust process, then only low voltage
power is required to puncture the spark plug gap.
Therefore, this system adopts group ignition technology
so as not to waste the energy.
MEMO
FUEL
12A
FUEL SYSTEM................................................................................. 12A-1
PRECAUTION............................................................................ 12A-1
PROBLEM SYMPTOMS TABLE................................................ 12A-3
COMPONENTS ......................................................................... 12A-4 12A
FUEL TANK ASSY........................................................................... 12A-5
REPLACEMENT ........................................................................ 12A-5
FUEL FILTER ASSY ...................................................................... 12A-10
REPLACMENT......................................................................... 12A-10 12A
FUEL LEVEL SENSOR ASSY ....................................................... 12A-11
REPLACMENT......................................................................... 12A-11 12A
FUEL PUMP ASSY ........................................................................ 12A-12
OVERHAUL ............................................................................. 12A-12
FUEL INJECTOR ASSY................................................................. 12A-13
OVERHAUL ............................................................................. 12A-13
FUEL FILLING DOOR.................................................................... 12A-18
REPLACEMENT ...................................................................... 12A-18
FUEL - FUEL SYSTEM 12A-1
FUEL SYSTEM
FUEL
PRECAUTION
1. FUEL SYSTEM PRECAUTION. 12A
(a) Before working on fuel system, disconnect battery negative cable.
(b) When removing the fuel hose, use a suitable container to hold the fuel.
(c) Do not smoke, carry lighted tobacco or work near an open flame when working on fuel system.
Equipment with ventilator at woking area can avoid personal injury.
(d) Fuel in the fuel pump, railway and tubes remain under high pressure. In order to avoid personal injury,
do not loosen tube connector while engine is running.
(e) Keep gasoline away from rubber and leather parts.
(f) Before disconncting any of the fuel system tubes or fuel system components, relieve the fuel system
pressure to prevent accidental spraying of fuel, even when the engine is not running. Failure to follow
12A
this instruction may result in serious personal injury.
(g) Check if there is any dirt like mud around the fuel tube connector before this work and clean dirt away,
otherwise it can damage fuel system or engine.
(h) Keep cleaner away from the O-ring of tube connector. Cleaner can corrode the seal of fuel system.
(i) Do not bend or twist the fuel system tube and pipe by force.
(j) Before connceting fuel system tube, be sure there is no damage to tube, connecto. If there are
damages, cracks or dirt on surface, replace it with a new tube assy.
12A-2 FUEL - FUEL SYSTEM
FUEL SYSTEM PRESSURE RELIEF PROCESS

(a) Disconnect the fuel pump connector.
(b) Start and idle the engine till it stops on its own. Turn the ignition switch to lock.
(c) Start the engine again for 5 seconds. Ensure that fuel manifold branch pressure relief is complete.
(d) Connect the fuel pump connector.
DRAIN FUEL TANK PROCESS

(a) Disconnect battery negative terminal.
(b) Open the fuel filling door.
(c) Lift the vehicle in place.
(d) Remove the fuel tank drain bolt and drain the fuel to the
suitable container.
FUEL TUBE CLEAN

(a) Use fuel treatment that Foton recommends to clean fuel system.
(b) Use fuel additives that Foton recommends to clean fuel system.
FUEL - FUEL SYSTEM 12A-3
PROBLEM SYMPTOMS TABLE

Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in the order shown. If necessary, repair or replace these parts.
12A
Symptom Suspect Area Reference
1. Fuel pump (Damaged) Chapter 12A fuel - fuel pump, overhaul
2. Fuel tube (Choke) Chapter 12A fuel - precaution
3. Fuel pressure regulator (Fuel -

Engine does not start pressure too low)
4. Fuel tank (No fuel) -
5. Fuel pump relay(Damaged) -

12A
6. Fuel injector (Damaged) Chapter 12A fuel - fuel injector, overhaul
1. Fuel tube (Obstructed) Chapter 12A fuel - precaution

pressure too low)
3. Fuel injector (Leakage or Chapter 12A fuel - fuel injector, overhaul

obstructed)
Engine start hard 4. Fuel pump (Out of order) Chapter 12A fuel - fuel pump, overhaul
5. Fuel injector control system (Out Chapter 04 diagnostics - engine control

of order) system
6. Fuel injector (Out of order) Chapter 12A fuel - fuel injector, overhaul
7. Fuel pressure regulator or fuel -

pump (Return valve damaged)

pressure too low)
Engine idles rough 2. Fuel injector (Leakage or Chapter 12A fuel - fuel injector, overhaul
obstructed)

pressure too low)
2. Fuel injector (Leakage or Chapter 12A fuel - fuel injector, overhaul

obstructed)
Engine loss of power
3. Fuel pump (Out of order) Chapter 12A fuel - fuel pump, overhaul
5. Fuel (Poor quality) -

12A-4 FUEL - FUEL SYSTEM
COMPONENTS
1 Fuel Filter 7 Fuel Tank
2 Fuel Tube 8 Fuel Tank Retaining Belt
3 Fuel Level Sensor 9 Fuel Tank Front Fender
4 Fuel Pump Assy 10 Fuel Tank Filler Cap
5 Fuel Gravity Valve 11 Fuel Filling Guid Assy
6 Rear Fuel Tank Bracket

FUEL - FUEL TANK ASSY 12A-5
FUEL TANK ASSY

REPLACEMENT
1. RELIEVE FUEL PRESSURE. (Refer to “Chapter 12A fuel - precaution”) 12A
2. DRAIN FUEL TANK. (Refer to “Chapter 12A fuel - precaution”)
4. LIFT VEHICLE IN PLACE.
5. SUPPORT FUEL TANK BY A JACK.
6. DISCONNECT CONNECTOR OF FUEL FILTER INLET

PIPE.
NOTE
There is some dirt like mud around the fuel pipe connector, 12A
slightly rap connector by suitable tools when disconnection
is in difficutly.
7. LOOSEN RETURN PIPE CLIP, DISCONNECT RETURN

PIPE AND HOSE.
8. LOOSEN FUEL VAPOR HOSE CLIP, DISCONNECT

FUEL VAPOR HOSE AND CHARCOAL CANISTER
HOSE.
9. LOOSEN FUEL FILLING HOSE CLIP AND DISCONNECT

IT FROM FUEL TANK.
12A-6 FUEL - FUEL TANK ASSY
10. LOOSEN FUEL TANK BREATHER HOSE CLIP AND

DISCONNECT HOSE FROM FUEL TANK.
11. DISCONNECT FUEL LEVEL SENSOR AND FUEL

PUMP CONNECTORS.
12. REMOVE REAR FUEL TANK BRACKET.

(a) Remove 2 rear fuel tank bracket retaining bolts.
(b) Take off the rear fuel tank bracket.
13. REMOVE FUEL TANK ASSY.

(a) Remove 2 fuel tank belt retaining bolts.
(b) Take off the fuel tank retaining belt.
(c) Take off the fuel tank assy.
NOTE
• Check if there is any dirt like mud and tube, harness
around the fuel tank. Clean the dirt if necessary.
• When removing fuel tank, as fuel tank is large and
heavy, it is necessary to use sutiable tool or need
others help.
14. REMOVE FUEL LEVEL SENSOR ASSY.

(a) Remove 5 fuel level sensor sealing cover retaining
screws.
(b) Separate fuel level sensor from the sealing cover. 12A
NOTE
• Check if there is any dirt or other material around
fuel level sensor before this work and clean the dirt if
necessary.
• There is a O-ring in sealing cover. Be careful not to
damage the O-ring when removing.
15. REMOVE FUEL PUMP ASSY.

(a) Remove 6 fuel pump sealing cover retaining screws.
12A
(b) Separate fuel pump from the sealing cover.
NOTE
• Check if there is any dirty or other material around
fuel pump before this work and clean the dirt if
necessary.
16. INSTALL FUEL LEVEL SENSOR ASSY.

(a) Tighten 5 fuel level sensor sealing cover retaining
screws.
Touque: 8 ~ 10 N•m
17. INSTALL FUEL PUMP ASSY.

(a) Tighten 6 fuel pump sealing cover retaining screws.
12A-8 FUEL - FUEL TANK ASSY
18. INSTALL FUEL TANK.

(a) Lift the fuel tank assy to satiable position by jack.
(b) Tighten 2 rear fuel tank bracket retaining bolts.
(c) Install 2 fuel tank retaining belt and tighten the bolts.
NOTE
• The fuel tank should be fastened and without
abnormal viberation.
• The fuel tank retaining belt should be uniform and
flat.
19. CONNECT FUEL FILTER INLET CONNECTOR.

NOTE
Follow the arrow on the fuel filter to install the fuel filter.
20. CONNECT RETURN HOSE AND PIPE, THEN

TIGHTEN CLIP.
21. CONNECT FUEL VAPOR HOSE AND CHARCOAL

CANISTER HOSE, THEN TIGHTEN CLIP.
22. CONNECT FUEL TANK BREATHER HOSE AND

FUEL TANK, THEN TIGHTEN CLIP.
12A
23. CONNECT FUEL FILLING HOSE AND FUEL TANK,

THEN TIGHTEN CLIP.
12A
24. CONNECT FUEL PUMP AND FUEL LEVEL SENSOR

CONNECTOR.
25. LOWER VEHICLE.

27. CHECK FUEL TUBE.
(a) After connecting, check if the fuel tube connector and pipe are securely connected by pulling them.
Turn ignition switch ON and inspect the fuel gauge display normal or not. Start engine, inspect if there is
fuel leakage from pipe connection.
28. CHECK FUEL TANK.
(a) After installing fuel tank, inspect if fuel tank damaged, it shoud be repaired on time.
29. CHECK FUEL TANK FILLER CAP.
(a) Check fuel filler cap conditions. If cap spring is damaged or corroded, repair or replace with a new one.
12A-10 FUEL - FUEL FILTER ASSY
FUEL FILTER ASSY

REPLACMENT
1. RELIEVE FUEL PRESSURE. (Refer to “Chapter 12A fuel - precaution”)
3. LOOSEN 2 FUEL FILTER CLIPS.
4. REMOVE THE FUEL FILTER.

(a) Loosen the fuel filter retaing belt bolt.
(b) Take off the fuel filter.
5. INSTALL NEW FUEL FILTER.

(a) Tighten the fuel filter retaining belt bolt.
6. CONNECT FUEL FILTER INLET HOSE AND TIGHTEN

CLIPS.
NOTE
Follow the arrow on the fuel filter to install the fuel filter.
7. CHECK FUEL TUBE.

Turn ignition switch on, inspect if the fuel gauge display is normal or not. Start engine, inspect if there is
fuel leakage from pipe connection.
FUEL - FUEL LEVEL SENSOR ASSY 12A-11
FUEL LEVEL SENSOR ASSY

REPLACMENT
4. REMOVE FUEL TANK. (Refer to “Chapter 12A fuel - fuel tank, replacment”)

screws.
(b) Separate fuel level sensor from sealing cover.
NOTE 12A
fuel level sensor before this work and clean the dirt
if necessary.
6. REPLACE FUEL LEVEL SENSOR ASSY.

(a) Install fuel level sensor to sealing cover.
(b) Tighten 5 fuel level sensor sealing cover retaining
screws.
8. INSTALL FUEL TANK. (Refer to “Chapter 12A fuel - fuel tank, replacment”)

CONNECTOR.
10. CHECK.
(a) After disconnecting fuel pump connector, connect fuel level sensor connector and turn ignition switch
ON. Slide fuel level sensor position manually and then check the fuel gauge’s conditions in instrument
panel.
(b) In condition that all connectors are connected properly, turn the ignition switch ON and check fuel
gauge’s conditions. Start the engine to check if there is any fuel leakage in fuel system.
12A-12 FUEL - FUEL PUMP ASSY
FUEL PUMP ASSY

OVERHAUL
1. RELIEVE FUEL PRESSURE. (Refer to “Chapter 12A fuel - precaution”)
4. REMOVE FUEL TANK. (Refer to “Chapter 12A fuel - fuel tank, replacment”)
5. REMOVE FUEL PUMP ASSY.

(a) Remove 6 fuel pump sealing cover retaining screws.
(b) Separate fuel pump from sealing cover.
NOTE
fuel pump before this work and clean the dirt if
necessary.
6. INSPECT FUEL PUMP RESISTANCE.

(a) Give two terminals electricity, check the pump injection
flow. If the fuel pump injection flow less than stardand,
replace it.
Stardand: ≥ 16 g/s
(b) Apply battery voltage to both terminals. Check that the
pump’s operation. If the fuel pump has abnormal noise,
replace it.
NOTE
• Keep fuel pump as far away from the battery as
possible.
• These tests must be done quickly (within 10
seconds) to prevent the coil from burning out.
• Always do the switching at the battery side.
7. REPLACE FUEL PUMP ASSY.
8. INSTALL FUEL PUMP ASSY.

(a) Install fuel pump to sealing cover.
(b) Tighten 6 fuel pump sealing cover retaining screws.
9. INSTALL FUEL TANK. (Refer to“Chapter 12A fuel - fuel tank, replacment”)
10. CHECK.
(a) In condition that all connectors are connected properly, turn the ignition switch ON and check fuel
FUEL - FUEL INJECTOR ASSY 12A-13
FUEL INJECTOR ASSY

OVERHAUL

(b) Remove 2 intake air duct retaining bolts.
12A
4. REMOVE THROAT ELBOW.

(a) Loosen the throat elbow clip.
(b) Take off the throat elbow.

(a) Loosen the accelerator cable adjustment bolt on the
throttle body.
(b) Remove the end block of accelerator cable.
(c) Remove the accelerator cable.
6. DISCONNECT 4 FUEL INJECTOR CONNECTORS.

12A-14 FUEL - FUEL INJECTOR ASSY
7. REMOVE FUEL INLET HOSE FROM FUEL RAIL.
8. DISCONNECT FUEL RETURN HOSE FROM FUEL

RAIL.
NOTE
After disconnecting the fuel hose, use the plastic bag to
seal up the fuel hose connector, avoid the dust entering the
fuel hose.
9. REMOVE FUEL INJECTOR ASSY.

(a) Remove 2 fuel rail retaining bolts.
(b) Take off the injector assy lightly.
10. REMOVE 4 INJECTORS FROM FUEL RAIL.

11. PULL CLIP AND REMOVE FUEL PRESSURE REGULATOR.
12A
12. USE AN OHMMETER TO MEASURE RESISTANCE BETWEEN TWO TERMINALS OF INJECTOR.

Resistance: 12 ~ 15 Ω
13. CHECK IF THERE IS ANY CARBON DEPOSITION OR DIRTY AROUD INJECTOR NOZZLE.
CLEAR IT AWAY IF BLOCKED.
12A
14. IF NECESSARY, TAKE INJECTOR ON INJECTOR TEST

TABLE TO CHECK IF INJECTOR LEAKS OR NOT.
15. INSPECT RETURN SPRING OF FUEL PRESSURE REGULATOR OPERATION.
16. INSTALL NEW INSULATOR TO EACH FUEL INJECTOR.
17. APPLY A LIGHT COAT OF SPINDLE OIL OR GASOLINE TO A NEW O-RING AND INSTALL IT TO
EACH FUEL INJECTOR.
NOTE
Do not use engine oil or brake fluid.
18. INSTALL EACH FUEL INJECTOR TO FUEL RAIL.
19. INSTALL FUEL PRESSURE REGULATORS.
NOTE
Inspect if fuel pressure regulator turns smoothly. If not, it means that O-ring is clamped. Reinstall it
with a new O-ring.
12A-16 FUEL - FUEL INJECTOR ASSY
20. INSTALL FUEL INJECTOR ASSY.

(a) Slightly push each injector into cylinder hole till position.
(b) Install 2 fuel injector assy retaining bolts.
21. CONNECT FUEL INLET HOSE AND FUEL RAIL,

THEN TIGHTEN CLIP.
22. CONNECT RETURN HOSE AND RAIL RETURN.
23. CONNECT 4 INJECTOR ELECTRICAL CONNECTORS.
24. INSTALL ACCELERATOR CABLE.

(a) Tighten the accelerator cable adjustment bolt on the
throttle body.
(b) Install the end block of accelerator cable.
25. INSTALL THROAT ELBOW.

(a) Tighten the throat elbow clip.
12A

12A
27. CHECK.
(a) In condition that all connectors are connected properly, turn the ignition switch ON and check fuel
12A-18 FUEL - FUEL FILLING DOOR
FUEL FILLING DOOR

REPLACEMENT
1. PULL FUEL FILLING DOOR OPENING CABLE UNDER
DRIVER SEAT.
2. REMOVE FUEL FILLING DOOR RETAINING BOLT.
3. ADJUST FUEL FILLING DOOR POSITION MANUALLY IF

FUEL FILLING DOOR IS NOT CLOSED COMPLETELY.
4. TIGHTEN FUEL FILLING DOOR RETAINING BOLTS.

EMISSION CONTROL
13A
FUEL TANK CAP .............................................................................13A-1
INSPECTION ............................................................................. 13A-1
CHARCOAL CANISTER .................................................................. 13A-2
OVERHAUL ............................................................................... 13A-2 13A
CHARCOAL CANISTER SOLENOID VALVE ................................. 13A-4
OVERHAUL ............................................................................... 13A-4
POSITIVE CRANKCASE VENTILATION VALVE (PCV VALVE).... 13A-7
OVERHAUL ............................................................................... 13A-7 13A
13A
EMISSION CONTROL - FUEL TANK CAP 13A-1
FUEL TANK CAP

EMISSION CONTROL
INSPECTION
13A
1. OPEN FUEL TANK FILLER CAP.
2. INSPECT FUEL TANK FILLER CAP ASSY.

(a) Visually inspect fuel tank cap and gasket if deformed or 13A
damaged. Replace it with a new one if necessary.
(b) Termly lubricate the rotating part.
13A-2 EMISSION CONTROL - CHARCOAL CANISTER
CHARCOAL CANISTER
OVERHAUL
(b) Remove 2 intake air duct bolts.
2. LOOSEN CLIP OF CHARCOAL CANISTER THAT

LOCATED AT BOTTOM OF BATTERY.
3. LOOSEN INTAKE CLIP OF CHARCOAL CANISTER

AND DISCONNECT HOSE (CONNECT FUEL TANK).
NOTE
When disconnecting these hoses which used for a long
time, twist hose first and confirm loosened, then operate
disconnection.
4. LOOSEN OUTPUT CLIP OF CHARCOAL CANISTER

AND DISCONNECT HOSE (CONNECT SOLENOID
VALVE OF CHARCOAL CANISTER).
5. REMOVE CHAROCAL CANISTER.

6. VISUALLY CHECK CHARCOAL CANISTER FOR CRACK OR DAMAGE AND REPLACE IT WITH A
NEW ONE IF NECESSARY.
EMISSION CONTROL - CHARCOAL CANISTER 13A-3
7. BLOW COMPRESSED AIR INTO INTAKE OR VENT

PORT. AND CHECK WHETHER AIR FLOWS FROM
OTHER PORT.
NOTE 13A
If no air flows from the other port, charcoal canister is
blocked. Replace it if necessary.
8. INSTALL CHARCOAL CANISTER ON BRACKET.
13A
9. INSTALL CLIP OF CHARCOAL CANISTER INTAKE

HOSE (CONNECT FUEL TANK).
10. INSTALL CLIP OF CHARCOAL CANISTER VENT PORT

HOSE (CONNECT SOLENOID VALVE OF CHARCOAL
CANISTER).

13A-4 EMISSION CONTROL - CHARCOAL CANISTER SOLENOID VALVE
CHARCOAL CANISTER SOLENOID VALVE

OVERHAUL
2. REMOVE CHARCOAL CANISTER SOLENIOD VALVE

RETAINING BOLT.
3. DISCONNECT CHARCOAL CANISTER SOLENOID VALVE CONNECTOR.
4. LOOSEN CLIP OF CHAROCAL CANISTER SOLE-

NOID VALVE INLET PORT AND DISCONNCET HOSE
(CONNECT CHAROCAL CANISTER).
NOTE
When disconnecting these hoses which are used for a long
time, twist hose first and confirm loosened, then operate
disconnection.
EMISSION CONTROL - CHARCOAL CANISTER SOLENOID VALVE 13A-5
5. LOOSEN CLIP OF CHARCOAL CANISTER SOLE-

NIOD VALVE VENT PORT AND DISCONNECT HOSE
(CONNECT THROTTLE VALVE INTAKE MANIFOLD).
13A
13A
6. REMOVE CHARCOAL CANISTER SOLENOID VALVE.
7. APPLY BATTERY POSITIVE VOLTAGE ACROSS TER-

MINALS. CHECK THAT AIR FLOWS FROM VENT
PORT (CONNECT INTAKE MANIFOLD). THEN SOLE-
NOID VALVE WORK NORMAL. IF OPERATION IS NOT
AS SPECIFIED, REPLACE IT WITH A NEW ONE.
8. TIGHTEN CHARCOAL CANISTER SOLENOID VALVE

RETAINING BOLT.
Torque: 7 ~ 9 N•m
13A-6 EMISSION CONTROL - CHARCOAL CANISTER SOLENOID VALVE
9. CONNECT CLIP OF CHARCOAL CARNITER SOLE-

NOID VALVE VENT PORT HOSE (CONNECT THROT-
TLE VALVE INSTAKE MANIFOLD).
10. CONNECT CLIP OF CHARCOAL CARNITER SOLE-

NOID VALVE INLET PORT HOSE (CONNECT CHAR-
COAL CARNITER ).
11. CONNECT CHARCOAL CARNITER SOLENIOD VALVE CONNECTOR.

EMISSION CONTROL - POSITIVE CRANKCASE VENTILATION VALVE (PCV VALVE) 13A-7
POSITIVE CRANKCASE VENTILATION VALVE (PCV VALVE)

OVERHAUL
13A
2. REMOVE INTAKE AIR HOSE. (Refer to “Chapter 14A intake air system - intake air hose, replace-
ment”) 13A
3. REMOVE PCV VALVE.

(a) Disconnect PCV hose from engine cylinder head.
(b) Separate PCV valve and hose.
4. DISCONNECT PCV HOSE FROM ENGINE CYLINDER HEAD AND START ENGINE AT IDEAL
SPEED. PUT FINGER AT PCV PORT, CHECK IF VACUUM OF AIR INTAKE MANIFOLD EXITS.
CLEAN OR REPLACE IT WITH A NEW ONE IF NOT.
5. INSPECT PCV VALVE.

(a) Blow air from port that connect cylinder. Air can flow out
from the other port.
(b) Blow air from port that connect air intake mainfold. Air
can not flow out from the other port.
13A-8 EMISSION CONTROL - POSITIVE CRANKCASE VENTILATION VALVE (PCV VALVE)
6. INSTALL PCV VALVE.
7. INSTALL INTAKE AIR HOSE. (Refer to“Chapter 14A intake air - intake air hose, replacement”)

INTAKE AIR
11A
INTAKE AIR SYSTEM...................................................................... 14A-1
PRECAUTION............................................................................ 14A-1
COMPONENTS ......................................................................... 14A-2
INTAKE AIR HOSE .......................................................................... 14A-3 11A
REPLACEMENT ........................................................................ 14A-3
AIR FILTER ASSY ........................................................................... 14A-7
REPLACEMENT ........................................................................ 14A-7
INTAKE RESONATOR ASSY....................................................... 14A-10 11A
REPLACEMENT ...................................................................... 14A-10
INTAKE MANIFOLD....................................................................... 14A-12
REPLACEMENT ...................................................................... 14A-12
14A
INTAKE AIR - INTAKE AIR SYSTEM 14A-1
INTAKE AIR SYSTEM

INTAKE AIR
PRECAUTION
1. INTAKE AIR SYSTEM PRECAUTION. 14A
(a) To avoid impuriy entry, the intake air must be filtered before entrying the engine. If the intake manifold
hose is broken or loosen, the unfilter air will enter and abrade.
(b) The intake manifold hose connection must be reliable enough to avoid gaps and looseness, etc.
(c) Each cushion and bracket connection with intake manifold hose must be reliable. There are no cracks
on the apperance or gaps in the connection portion.
(d) The connection between cushion and intake manifold bracket must be reliable.
14A
14A-2 INTAKE AIR - INTAKE AIR SYSTEM
COMPONENTS
1 Intake Resonator Assy (With Cushion) 5 Throat Elbow
2 Air Filter Assy 6 Air Intake Duct
3 Pressurizer Tank Intake Hose 7 Intake Three Way Pipe
4 Intake Pressurizer Tank

INTAKE AIR - INTAKE AIR HOSE 14A-3
INTAKE AIR HOSE

REPLACEMENT
14A
2. LOOSEN PRESSURIZER TANK INTAKE HOSE CLIPS.
14A
3. REMOVE PRESSURIZER TANK INTAKE HOSE AND CHECK IT. IF FIND ANY ABNORMAL,
REPLACE IT WITH NEW ONE.
4. LOOSEN THROAT ELBOW CLIPS.
5. REMOVE THROAT ELBOW.

14A-4 INTAKE AIR - INTAKE AIR HOSE
6. REMOVE INTAKE PRESSURIZER TANK RETAINING

BOLTS.
7. DISCONNECT CLIPS ATTACHING INTAKE PRESSURIZER

TANK TO CRANKCASE VENTILATION HOSE.
NOTE
Remove the crankcase ventilation hose and check it, if find
any abnormal such as broken, replace it with new one.
8. REMOVE INTAKE PRESSURIZER TANK.
9. CONNECT CLIPS ATTACHING INTAKE PRESSURIZER

TANK TO CRANKCASE VENTILATION HOSE.
INTAKE AIR - INTAKE AIR HOSE 14A-5
10. TIGHTEN INTAKE PRESSURIZER TANK RETAINING

BOLTS.
14A
11. INSTALL THROAT ELBOW HOSE.
12. TIGHTEN THROAT ELBOW HOSE CLIPS. 14A
13. INSTALL PRESSURIZER TANK INTAKE HOSE.
14. TIGHTEN INTAKE PRESSURIZER TANK HOSE CLIPS.
15. AFTER INSTALLING AIR INTAKE HOSE, CHECK ALL PARTS AND PARTS CONNECTION AGAIN
TO MAKE SURE ENGINE OPERATES PROPERLY.
14A-6 INTAKE AIR - INTAKE AIR HOSE

INTAKE AIR - AIR FILTER ASSY 14A-7
AIR FILTER ASSY

REPLACEMENT
14A
1. REMOVE 2 AIR FILTER INTAKE DUCT RETAINING
BOLTS AND TAKE IT AWAY.
2. LOOSEN INTAKE THREE-WAY PIPE CONNECTING

CLIPS.
14A
3. LOOSEN PRESSURIZER TANK INTAKE HOSE CLIPS.
4. REMOVE 3 RETAINING BOLTS FROM AIR FILTER

ASSY.
5. REMOVE AIR FILTER ASSY.

14A-8 INTAKE AIR - AIR FILTER ASSY
6. LOSSEN AIR FILTER UPPER COVER CLIP.
7. OPEN AIR FILTER UPPER COVER AND TAKE OUT

AIR FILTER.
NOTE
Air filter is made from paper. If necessary, clear the air filter
with high pressure air gun. Do not clean it with water.
8. CLEAN OR REPLACE THE AIR FILTER.
9. INSTALL AIR FILTER UPPER COVER AND TIGHTEN

CLIP.
NOTE
Before installing the air filter upper cover clip, adjust the
position attaching the air filter upper cover to the pressur-
izer tank intake hose.
10. POSITION AIR FILTER ASSY.

INTAKE AIR - AIR FILTER ASSY 14A-9
11. TIGHTEN 3 AIR FILTER ASSY RETAINING BOLTS.

14A
12. INSTALL AND TIGHTEN CLIPS ATTACHING INTAKE

PRESSURIZER TANK HOSE TO AIR FILTER ASSY.
14A
13. POSITION INTAKE THREE-WAY PIPES AND

CONNECTING CLIPS.
14. TIGHTEN AIR FILTER INTAKE DUCT AND TIGHTEN

RETAINING BOLTS.
14A-10 INTAKE AIR - INTAKE RESONATOR ASSY
INTAKE RESONATOR ASSY

REPLACEMENT
1. REMOVE AIR FILTER ASSY. (Refer to “Chapter 14A intake air - air filter assy, replacement”)
2. REMOVE FRONT BUMPER ASSY. (Refer to “Chapter 88 exterior and interior trim - front bumper,
replacement”)
3. REMOVE FRONT COMBINATION LAMP RH ASSY. (Refer to “Chapter 64 lighting - front combina-
tion lamp assy, replacement”)
4. REMOVE BOLT ATTACHING INTAKE RESONATOR

TO VEHICLE BODY.
5. REMOVE BOLT ATTACHING INTAKE RESONATOR

TO ABS PUMP.
6. REMOVE ABS PUMP RETAINING BOLTS. (Refer to "Chapter 35 brake - ABS pump, overhaul")
7. MOVE PIPES OF ABS PUMP TO SUITABLE POSITION AND TAKE OUT INTAKE RESONATOR
ASSY.
CAUTION
When removing the position of ABS pipe, do not curve the pipe avoid to damaging the pipe and
leaking the brake fluid.
8. POSITION INTAKE RESONATOR.
9. RESTORE POSITION OF ABS PIPE AND TIGHTEN ABS PUMP RETAINING BOLT.
10. TIGHTEN BOLT ATTACHING INTAKE RESONATOR
AND ABS PUMP.
INTAKE AIR - INTAKE RESONATOR ASSY 14A-11
11. TIGHTEN BOLT ATTACHING INTAKE RESONATOR

TO VEHICLE BODY.
14A
12. INSTALL FRONT COMBINATION LAMP RH ASSY. (Refer to “Chapter 64 lighting - front combina-
tion lamp assy, replacement”)
13. INSTALL FRONT BUMPER ASSY. (Refer to “Chapter 88 exterior and interior trim - front bumper,
replacement”)
14. INSTALL AIR FILTER ASSY. (Refer to “Chapter 14A intake air - air filter assy, replacement”)
14A
14A-12 INTAKE AIR - INTAKE MANIFOLD
INTAKE MANIFOLD
REPLACEMENT
2. LOOSEN THROAT ELBOW CLIPS AND REMOVE

THROAT ELBOW.

(a) Loosen accelerator cable adjustable nut on the throttle
body.
(b) Remove accelerator cable clip.
(c) Remove accelerator cable.
4. REMOVE 4 THROTTLE BODY RETAINING BOLTS.
5. REMOVE FUEL INJECTOR ASSY. (Refer to “Chapter 12A fuel-fuel injector assy, overhaul”)
6. DISCONNECT PCV VALVE AND VALVE CHAMBER

COVER.
INTAKE AIR - INTAKE MANIFOLD 14A-13
7. DISCONNECT CANISTER CONTROL SOLENOID

VALVE INTAKE HOSE CLIPS AND TAKE AWAY HOSE.
NOTE
When disconnect these hoses used for a long time. Twist 14A
hoses first to make sure it loosen, then proceed disconnection.
8. DISCONNECT CANISTER CONTROL SOLENOID VALVE CONNECTOR.

9. DISCONNECT MAP SENSOR CONNECTOR. 14A
10. REMOVE INTAKE MANIFOLD LOWER BRACKET
RETAINING BOLTS.
11. DRAIN COOLANT. (Refer to “Chapter 17A cooling - precaution”)

12. REMOVE RADIATOR UPPER OUTLET HOSE. (Refer to “Chapter 17A cooling - radiator assy,
overhaul”)
13. REMOVE 2 ENGINE COOLANT TEMPERATURE SENSOR

BRACKET RETAINING BOLTS.
14. REMOVE 8 INTAKE MANIFOLD RETAINING BOLTS

(NUTS), THEN TAKE AWAY INTAKE MANIFOLD.
15. REMOVE INTAKE MANIFOLD GASKET.

NOTE
After removing the intake manifold, replace the intake manifold gasket.
16. INSTALL A NEW INTAKE MANIFOLD GASKET.
17. TIGHTEN 6 INTAKE MANIFOLD RETAINING BOLTS AND

2 NUTS.
18. TIGHTEN 2 ENGINE COOLANT TEMPERATURE SENSOR

BRACKET RETAINING BOLTS.
19. INSTALL RADIATOR UPPER OUTLET HOSE. (Refer to “Chapter 17A cooling - radiator assy,
overhaul”)
INTAKE AIR - INTAKE MANIFOLD 14A-15
20. TIGHTEN INTAKE MANIFOLD LOWER BRACKET

RETAINING BOLTS.
14A
21. CONNECT CANISTER CONTROL SOLENOID VALVE CONNECTOR.
22. CONNECT CANISTER CONTROL SOLENOID VALVE

INTAKE HOSE AND TIGHTEN CLIPS.
14A
23. CONNECT MAP SENSOR CONNECTOR.

24. INSTALL FUEL INJECTOR ASSY. (Refer to “Chapter 12A fuel-fuel injector assy, overhaul”)
25. CONNECT PCV VALVE AND VALVE CHAMBER COVER.
26. TIGHTEN 4 THROTTLE BODY RETAINING BOLTS.


(a) Tighten accelerator cable adjustable nut on the throttle
body.
(b) Install accelerator cable clip.
28. INSTALL THROAT ELBOW AND TIGHTEN THROAT

ELBOW CLIP.

30. FILL REASONABLE COOLANT. (Refer to “Chapter 17A cooling - precaution”)
ENGINE MECHANICAL
15A
ENGINE MECHANICAL PART ........................................................ 15A-1
PRECAUTION............................................................................ 15A-1
ENGINE ASSY ................................................................................. 15A-4 15A
REPLACEMENT ........................................................................ 15A-4
ENGINE ACCESSORY BELT ........................................................ 15A-20
OVERHAUL ............................................................................. 15A-20
ENGINE TIMING BELT COVER .................................................... 15A-23 15A
REPLACENEMT ...................................................................... 15A-23
ENGINE TIMING BELT .................................................................. 15A-26
COMPONENTS ....................................................................... 15A-26
OVERHAUL ............................................................................. 15A-27
ROCKER ARM/ROCKER SHAFT/HYDRAULIC ADJUSTER ....... 15A-41
COMPONENTS ....................................................................... 15A-41
OVERHAUL ............................................................................. 15A-43
CAMSHAFT.................................................................................... 15A-53
OVERHAUL ............................................................................. 15A-53 15A
CYLINDER HEAD/VALVE .............................................................15A-55
COMPONENTS ....................................................................... 15A-55
CYLINDER HEAD OVERHAUL ............................................... 15A-56
VALVE OVERHAUL................................................................. 15A-59
PISTON AND CONNECTING RODS ............................................. 15A-63
COMPONENTS ....................................................................... 15A-63
OVERHAUL ............................................................................. 15A-64
CRANKSHAFT/ENGINE BLOCK/FLYWHEEL.............................. 15A-72
COMPONENTS ....................................................................... 15A-72
OVERHAUL ............................................................................. 15A-74
ENGINE MECHANICAL - ENGINE MECHANICAL PART 15A-1
ENGINE MECHANICAL PART

ENGINE MECHANICAL
PRECAUTION
1. ENGINE MECHANICAL PART PRECAUTION. 15A
(a) When using, should follow the instructions of maintenance methods and regulations to adjust or main-
tain.
(b) Before starting the engine, check the coolant level, filling or drain the coolant if necessary. check the
engine oil level, fill the engine oil if necessary.
(c) Do not adjust the position of throttle valve screw. it will cause the throttle valve closed angle change and
make the engine work abnormal.
(d) Do not pull up the spark plug wire when the engine is running.
(e) The clearance between ckp sensor and flywheel is 0.5 ～ 1.5 mm. do not try to adjust it.
(f) The fuel should use ron ≥ 93 unleaded gasoline， otherwise the catalytic converter will be damaged.
(g) Use the oil as requirement. otherwise exacerbate engine wear.
(h) Use the original fittings, otherwise it will damage the engine or affect the engine working condition.
(i) Do not use the high pressure water cannons to wash the ecm shell though it is waterproof.
(j) The engine starting time should be less than 5s.
(k) Keep the normal coolant temperature 85 ～ 105 ℃ .
(l) When the engine in high speed or high load, do not turn the ignition switch off. 15A
(m) Before opening the radiator cap, must ensure the engine is cool.
(n) Use the sealant scraper to clear the sundries in seal surface. confirm seal surface flat and smooth, no
oil stain there.
15A-2 ENGINE MECHANICAL - ENGINE MECHANICAL PART
REGULAR MAINTENANCE TABLE

Maintenance Intervals
Month - 6 12 18 24 30 36 42 48 54 60
Item
10
Odometer X1000 Km 1 10 20 30 40 50 60 70 80 90
0
Engine room check
Check the accessory blets wear and adjust

X X X X X X
the tension
Check spark plug wire X X
Replace engine timing belt Each 100000 Km
Check crankcase ventilation system X X
Relpace spark plug O O O O O
Check radiator X X
Check engine coolant level X X X X X X
Replace engine coolant O O
General using condition X X X X X

Check air filter
Darsh using condition X X X X X X X X X
Other check
Replace engine General using condition Each 5000 Km or each 6 months

oil
Darsh using condition Each 2500 Km
General using condition O O O O O O O O O O

Replace oil filter
Darsh using condition Each 5000 Km
Check engine idling X X X X X X
Check crankcase breather hose X X
NOTE
• “X” means check fluid level, tighten or adjust.
• “O” means replacement.
• “Empty” means not suitable.
• “Darsh using condition” includes following items.
(a) Drive in the dust or vehicle often be exposed in the salty environment.
(b) The uneven, water or mountain path driving.
(c) Drive in cold areas.
(d) Often brake while driving.
(e) Towing.
(f) Drive in congestion area above 32 ℃ .
(g) Overload driving.
ENGINE MECHANICAL - ENGINE MECHANICAL PART 15A-3

15A
1. Battery (Low voltage or loose Chapter 20A starting and charging - battery,
connect) precaution
2. Fuel pump (Damage) Chapter 12A fuel - fuel pump, overhaul
Chapter 20A starting and charging - starter,

3. Starting (Damage) overhaul
Chapter 19A ignition - ignition coil/spark plug

4. Ignition system (Damage) wire/spark plug, overhaul
Engine does not start
5. Spark plug (Over clearance) wire/spark plug, overhaul
6. Fuel system (Block) Chapter 12A fuel - precaution
Chapter 15A engine mechanical - timing belt,

7. Engine timing (Mistake) overhaul 15A
8. Cylinder compressure -
Chapter 04 diagnostics - engine control

1. Air-fuel mixing ratio system
2. Intake air hose (Leakage) Chapter 14A intake air - precaution
Engine idles rough Chapter 19A ignition - ignition coil/spark plug

3. Ignition coil (Damage) wire/spark plug, overhaul
5. Idle control motor (Out of order) -
1. Spark plug (Carbon deposition Chapter 19A ignition - ignition coil/spark plug
over clearance) wire/spark plug, overhaul
Chapter 15A engine mechanical - timing belt,

3. Engine timing (Mistake) overhaul
4. Cylinder gasket (leakage) -
5. Cylinder compressure -
Engine loss of power
6. Valve (Burned, warped, Chapter 15A engine mechanical - cylinder
excessive clearance, or pitted head/valve, overhaul
valves)
7. Exhaust system (block) Chapter 16A exhaust - precaution

9. Ignition system (Out of order) wire/spark plug, overhaul
15A-4 ENGINE MECHANICAL - ENGINE ASSY
ENGINE ASSY
REPLACEMENT
NOTE
• Before raising the vehicle, ensure the support position on the vehicle.
• Turn ignition switch off and lock the steering column assy.
• Use the fender protection cover to avoid damaging paint surface.
• Avoid damaging, should hold the head of the connector, carefully connect wire.
• Mark in all wires and hoses and confirm have not touched with the other wire or hose, or
interfered with other parts.
• Drain coolant. (Refer to “Chapter 17A cooling - coolant, replacement”)
1. REMOVE ENGINE HOOD. (Refer to “Chapter 87 engine hood and doors - engine hood,
replacement”)

3. DISCONNECT BATTERY NEGATIVE CABLE, THEN BATTERY POSITIVE CABLE.
4. REMOVE BATTERY HOLD DOWN RETAINING BOLTS AND

TAKE IT AWAY.
5. REMOVE BATTERY.
6. REMOVE INTAKE AIR HOSE. (Refer to “Chapter 14A intake air - intake air hose, replacement”)
7. DISCONNECT ENGINE ROOM JUNCTION BOX WIRE CONNECTORS.
8. DISCONNECT ENGINE ROOM A JUNCTION BOX LOAD OF ELECTRICAL EQUIPMENT
CONNECTORS (IF EFFECT ENGINE MOUNT REMOVAL) .
9. REMOVE ENGINE CONTROL WIRE HARNESS CLIP.
10. TAKE ENGINE ROOM JUNCTION BOX AWAY.
ENGINE MECHANICAL - ENGINE ASSY 15A-5

(a) Loosen accelerator cable and adjust nut on the throttle
body.
(b) Take off accelerator cable clip. 15A
12. REMOVE FUEL INLET HOSE FROM FUEL RAIL.
15A
13. DISCONNECT FUEL RETURN HOSE FROM FUEL RAIL.
NOTE
After disconnecting the fuel hose, use the plastic bag seal
up the fuel hose connector, prevent the dust entering the
fuel hose.
14. LOOSEN OUTPUT PORT CLIP OF CHARCOAL CAN-

ISTER AND DISCONNECT HOSE (CONNECT SOLE-
NOID VALVE OF CHARCOAL CANISTER).
15. REMOVE VACUUM BOOSTER ASSY HOSE.
16. DRAIN CLUTH/BRAKE FLUID.
17. DISCONNECT CLUTCH CYLINDER AND CLUTCH

HYDRAULIC PIPELINE CONNECTOR.
18. REMOVE NUT ATTACHING TRANSMISSION CONTROL

UNIT TO RETAINING ROD.
19. DISCONNECT TRANSMISSION CONTROL UNIT WITH

GEAR SELECTOR ROD ASSY AND GEARSHIFT ASSY.
(a) Remove the nut attaching gear selector rod arm to gear
selector rod assy. 15A
(b) Remove the nut attaching gearshift arm to gearshift assy.
15A
20. DRAIN STEERING FLUID, DISCONNECT STEERING

FLUID RESERVOIR INLET HOSE AND OUTLET PIPE.
NOTE
Do not splash the steering fluid on the engine parts, erase
the fluid immediately if did.
21. DISCONNECT THE HEATER INLET/OUTLET HOSES ON

THE VEHICLE.
22. DISCONNECT RADIATOR UPPER COOLANT HOSE.
23. DISCONNECT RADIATOR LOWER COOLANT HOSE.
24. DRAIN REFRIGERANT. (Refer to “Chapter 61 heater and air conditioning - refrigerant,
replacement”)
25. REMOVE 2 BOLTS ATTACHING A/C PIPE TO A/C

COMPRESSOR.
NOTE
Using clean cloth, block the A/C pipe and A/C compressor
hole to avoid dust entering.
26. INSTALL ENGINE LIFT CHAIN HANGERS.

27. RAISE THE VEHICLE TO TOP PLACE.
28. REMOVE THE FRONT WHEEL. (Refer to “Chapter 33 tire and wheel - front tire and wheel,
replacement”)
29. REMOVE LOWER GUARD PLATE RETAINING BOLT.

30. REMOVE EXHAUST PIPE RETAINING BELT BOLT.
15A
31. REMOVE 2 BOLTS ATTACHING CATALYTIC CONVERTER

TO EXHAUST PIPE.
15A
32. REMOVE LOWER CONTROL ARM. (Refer to “Chapter 31 front suspension - lower control arm,
replacement”)
33. REMOVE STEERING GEAR ASSY. (Refer to “Chapter 52 steering - steering gear assy,
replacement”)
34. SEPARATE TRANSMISSION TO PROPELLER SHAFT ASSY. (Refer to “Chapter 34 axle and
propeller shaft - propeller shaft, overhaul”)
35. DISCONNECT FOLLOWING ELECTRICAL CONNECTORS:
• MAP Sensor
• TP Sensor
• Idle Control Motor
• Generator
• Generator Positive Cable
• Fuel Injector
• Ignition Coil
• KS Sensor
• Engine Oil Pressure Switch
• ECT Sensor
• ECM
• Charcoal Canister Solenoid Valve
• Front/rear Oxygen Sensor
• CKP Sensor
• Reverse Gear Switch
• A/C Compressor
• Starter Positive Cable
• Cooling Fan
• Engine Ground Cable
36. USING A JACK, SUPPORT VEHICLE.
37. REMOVE BOLT ATTACHING ENGINE MOUNT TO

SUB-FRAME.
38. REMOVE NUTS ATTACHING TRANSMISSION MOUNT

TO VEHICLE BODY.
39. REMOVE 4 BOLTS ATTACHING SUB-FRAME TO

VEHICLE BODY AND TAKE AWAY SUB-FRAME.
NOTE
Before removing sub-frame, mark on the sub-frame and
sub-frame retaining bolts.
40. LOWER ENGINE SUPPORT JACK AND RELEASE ENGINE LIFT CHAIN HANGERS SLOWLY.
41. VERIFY ALL VACUUM HOSES, FUEL AND COOLANT HOSES, ELECTRICAL CONNECTORS
BETWEEN ENGINE/TRANSMISSION AND VEHICLE ARE DISCONNECTED.
42. LOWER ENGINE ABOUT 150 MM SLOWLY. VERIFY ALL COMPONENTS BETWEEN THE
ENGINE/TRANSMISSION AND VEHICLE ARE DISCONNECTED AGAIN.
43. REMOVE ENGINE AND TRANSMISSION FROM VEHICLE.
44. REMOVE BOLTS ATTACHING ENGINE TO SUB-

FRAME AND SEPARATE THEM.
15A
45. REMOVE STARTER RETAINING BOLTS AND

SEPARATE STARTER FROM TRANSMISSION.
15A
46. REMOVE BOLTS ATTACHING ENGINE TO TRANSMISSION

AND SEPARATE TRANSMISSION FROM ENGINE.
47. REMOVE CLUTCH PRESSURE PLATE RETAINING BOLTS. (Refer to “Chapter 42 clutch - clutch
pressure plate, overhaul”)
48. REMOVE ENGINE ACCESSORY BELTS. (Refer to “Chapter 15A engine mechanical - engine
accessory belt, overhaul”)
49. REMOVE GENERATOR RETAINING BOLTS AND

SEPARATE GENERATOR FROM BRACKET.
50. REMOVE BOLTS ATTACHING A/C COMPRESSOR TO ENGINE AND TAKE AWAY A/C
COMPRESSOR. (Refer to “Chapter 61 heater and air conditioning - compressor, overhaul”)
51. TIGHTEN GENERATOR RETAINING BOLTS.

52. INSTALL A/C COMPRESSOR RETAINING BOLTS. (Refer to “Chapter 61 heater and air
conditioning - compressor, overhaul”)
53. INSTALL CLUTCH PRESSURE PLATE RETAINING BOLTS. (Refer to “Chapter 42 clutch - clutch
54. INSTALL ENGINE ACCESSORY BELT. (Refer to “Chapter 15A engine mechanical - engine
55. TIGHTEN BOLTS ATTACHING ENGINE TO TRANSMISSION.

56. TIGHTEN STARTER RETAINING BOLTS.

15A
57. TIGHTEN BOLTS ATTACHING ENGINE TO SUB-

FRAME.
15A
58. INSTALL ENGINE WITH TRANSMISSION FROM BOTTOM OF VEHICLE, INSTALL ENGINE LIFT
CHAIN HANGERS.
59. TIGHTEN 4 BOLTS ATTACHING SUB-FRAME TO

VEHICLE BODY.
Torque: 205 ~ 215 N•m
NOTE
According to the mark on the sub-frame retaining bolt,
position the sub-frame.
60. TIGHTEN BOLT ATTACHING ENGINE MOUNT TO

SUB-FRAME.
61. TIGHTEN NUTS ATTACHING TRANSMISSION MOUNT TO

VEHICLE BODY.
Torque: 110 ~ 130 N•m
62. TIGHTEN 2 BOLTS ATTACHING CATALYTIC CONVERTER

TO EXHAUST PIPE.
63. TIGHTEN EXHAUST PIPE RETAINING BELT BOLT.

64. INSTALL LOWER CONTROL ARM. (Refer to “Chapter 31 front suspension - lower control arm,
replacement”)
65. INSTALL STEERING GEAR ASSY. (Refer to “Chapter 52 steering - steering gear assy,
replacement”)
66. CONNECT TRANSMISSION TO PROPELLER SHAFT ASSY. (Refer to “Chapter 34 axle and
67. INSTALL THE FRONT WHEEL. (Refer to“Chapter 33 tire and wheel - front tire and wheel,
replacement”)
68. LOWER VEHICLE AND LOSSEN ENGINE LIFT CHAIN HANGERS.
69. TIGHTEN 2 BOLTS ATTACHING A/C PIPE TO A/C

COMPRESSOR.
NOTE
Install a new o-ring.
70. CONNECT THE HEATER INLET/OUTLET HOSES ON

THE VEHICLE.
15A
71. CONNECT RADIATOR UPPER COOLANT HOSE AND

TIGHTEN THE CLIP.
15A
72. CONNECT RADIATOR LOWER COOLANT HOSE AND
TIGHTEN THE CLIP.
73. CONNECT POWER STEERING RESERVOIR INLET

HOSE AND OUTLET PIPE.
74. TIGHTEN NUT ATTACHING GEAR SELECTOR ROD ARM

TO GEAR SELECTER ROD ASSY.
75. TIGHTEN NUT ATTACHING GEARSHIFT ARM TO

GEARSHIFT ASSY.
76. TIGHTEN NUT ATTACHING TRANSMISSION CONTROL

77. CONNECT CLUTCH CYLINDER AND CLUTCH HYDRAULIC

PIPELINE CONNECTOR.
15A
78. TIGHTEN OUTPUT HOSE CLIP OF CHARCOAL CAN-

ISTER (CONNECT SOLENOID VALVE OF CHARCOAL
CANISTER).
15A
79. CONNECT VACUUM BOOSTER ASSY HOSE AND
TIGHTEN CLIP.

(a) Install accelerator cable clip.
(b) Tighten accelerator cable adjust nut on the throttle body.
81. CONNECT FUEL INLET HOSE TO FUEL RAIL.

82. CONNECT FUEL RETURN HOSE TO FUEL RAIL.
83. INSTALL ENGINE ROOM JUNCTION BOX.

84. ACCORDING TO MARK BEFORE REMOVAL, CONNECT FOLLOWING ELECTRICAL
CONNECTORS:
• MAP Sensor
• TP Sensor
• Idle Control Motor
• Generator
• Generator Positive Cable
• Fuel Injector
• Ignition Coil
• Knock Sensor
• ECT Sensor
• ECM
• Charcoal Canister Solenoid Valve
• Front/rear Oxygen Sensor
• CKP Sensor
• A/C Compressor
• Starter Positive Cable
• Cooling Fan
85. TIGHTEN LOWER GUARD PLATE RETAINING BOLTS.

86. FILL COOLANT. (Refer to “Chapter 17A cooling - coolant, replacement”)

87. FILL STEERING FLUID. (Refer to “Chapter 52 power steering - steering fluid, replacement”)
88. FILL CLUTCH FLUID.
89. FILL BRAKE FLUID. (Refer to “Chapter 35 brake - brake fluid, replacement”)

(b) Tighten 2 intake air duct retaining bolts. 15A
91. INSTALL ENGINE HOOD. (Refer to “Chapter 87 engine hood and doors - engine hood,
replacement”)
15A
15A-20 ENGINE MECHANICAL - ENGINE ACCESSORY BELT
ENGINE ACCESSORY BELT

OVERHAUL
1. REFRIGERATE ENGINE, LET BELT SURFACE TEMPERATURE AS CLOSE AS POSSIBLE TO THE
ENVIRONMENT TEMPERATURE.
2. ROTATE GENERATOR BELT AND CHECK CRACK.
3. LOOSEN NUT ATTACHING GENERATOR TO GENER-

ATOR BRACKET.
4. LOOSEN TENSIONER LOCKED NUT.

5. ROTATE TENSIONER BOLT TO ADJUST TENSITY OF
GENERATOR BELT.
6. REPLACE WITH A NEW GENERATOR BELT IF NECESSARY.
7. ADJUST TENSIONER BOLT AND TIGHTEN LOCK NUT.

8. TIGHTEN NUT ATTACHING GENERATOR TO GENER-

ATOR BRACKET.
9. CHECK TENSITY OF GENERATOR BELT, ADJUST IT IF NECESSARY.

ENGINE MECHANICAL - ENGINE ACCESSORY BELT 15A-21
10. USING BELT TENSION DEVICE, INSPECT BELT TEN-

SITY.
Item Standard Tensity 15A

New belt 490 ~ 686 N
Used belt 343 ~ 441 N
11. PRESS 100 N TO MIDDLE OF BELT AND CHECK

DEFLECTION.
Item Deflection
New belt 5.5 ~ 7.5 mm
Used belt 7.5 ~ 8.5 mm
15A
12. LOOSEN IDLE PULLEY RETAINING BOLT OF STEER-

ING BELT AND STEERING BELT TENSIONER BOLT.
13. TAKE AWAY GENERATOR BELT AND CHECK CRACK, REPLACE IT IF NECESSARY.
14. INSTALL STEERING BELT.
15. ROTATE TENSIONER BOLT TO ADJUST BELT TEN-

SITY AND TIGHTEN STEERING BELT IDLE PULLEY
RETAINING BOLT.
15A-22 ENGINE MECHANICAL - ENGINE ACCESSORY BELT

DEFLECTION.
Item Deflection
17. LOOSEN IDLE PULLEY RETAINING BOLT OF A/C

COMPRESSOR AND LOOSEN TENSIONER BOLT.
18. TAKE AWAY A/C COMPRESSOR BELT AND CHECK CRACK, REPLACE IT IF NECESSARY.
19. INSTALL A/C COMPRESSOR BELT.
20. ROTATE A/C COMPRESSOR TENSIONER BOLT TO

ADJUST BELT TENSITY AND TIGHTEN A/C
COMPRESSOR BELT IDLE PULLEY RETAINING
BOLT.

DEFLECTION.
Item Deflection

ENGINE MECHANICAL - ENGINE TIMING BELT COVER 15A-23
ENGINE TIMING BELT COVER

REPLACENEMT
1. REMOVE ENGINE COVER AND INTAKE AIR DUCT. 15A
2. REMOVE IGNITION COIL AND SPARK PLUG WIRE. (Refer to “Chapter 19A ignition - ignition
coil/spark plug wire/spark plug, overhaul”)
3. REMOVE 2 ENGINE TIMING BELT UPPER COVER

RETAINING BOLTS AND TAKE IT AWAY.
15A
4. REMOVE ENGINE ACCESSORY BELT. (Refer to “Chapter 15A engine mechanical - engine
accessory belt, replacement”)
5. LOOSEN STEERING FLUID RESERVOIR RETAINING BOLT AND SET IT ASIDE. (Refer to
“Chapter 52 power steering - steering pump, replacement”)
6. REMOVE 4 ENGINE TIMING BELT MIDDLE COVER

7. REMOVE 4 COOLANT PUMP PULLEY RETAINING

BOLTS.
15A-24 ENGINE MECHANICAL - ENGINE TIMING BELT COVER
8. REMOVE 4 CRANKSHAFT PULLEY RETAINING BOLTS.
9. REMOVE 9 ENGINE TIMING BELT LOWER COVER

10. AFTER REMOVING ENGINE TIMING BELT COVER, USE PRESSURE AIR TO CLEAN THE TIMING
BELT INSIDE IN ORDER TO AVOID RUNNING PARTS BEENING AFFECTED BY PARTICLE
IMPURITIES AND REDUCING USING LIFE OR WEAR.
11. TIGHTEN 9 ENGINE TIMING BELT LOWER COVER

RETAINING BOLTS.
12. TIGHTEN 4 ENGINE TIMING BELT MIDDLE COVER

RETAINING BOLTS.
ENGINE MECHANICAL - ENGINE TIMING BELT COVER 15A-25
13. TIGHTEN 4 CRANKSHAFT PULLEY RETAINING BOLTS.

15A
14. TIGHTEN 4 COOLANT PUMP PULLEY RETAINING

BOLTS.
15A
15. POSITION STEERING FLUID RESERVOIR AND INSTALL RETAINING BOLTS. (Refer to “Chapter
52 power steering - steering pump, replacement”)
16. INSTALL ENGINE ACCESSORY BELT. (Refer to “Chapter 15A engine mechanical - engine acces-
sory belt, replacement”)
17. TIGHTEN 2 ENGINE TIMING BELT UPPER COVER

RETAINING BOLTS.
18. INSTALL IGNITION COIL AND SPARK PLUG WIRE. (Refer to “Chapter 19A ignition - ignition coil/
spark plug wire/spark plug, overhaul”)

15A-26 ENGINE MECHANICAL - ENGINE TIMING BELT
ENGINE TIMING BELT

COMPONENTS
1 Timing Belt Cover (Lower) 10 Balance Shaft Timing Belt
2 Timing Belt Cover (Middle) 11 Engine Timing Belt B
3 Timing Belt Cover (Upper) 12 Flange Ring
4 Camshaft Timing Belt Pulley 13 Idle Pulley
5 Wire Harness Bracket 14 Crankshaft Timing Belt Pulley B
6 Engine Timing Belt 15 Crankshaft Timing Belt Pulley B Washer
7 Tensioner 16 Oil Pump Timing Belt Pulley
8 Automatic Tensioner Arm 17 Crankshaft Timing Belt Pulley
9 Tensioner B 18 Automatic Tensioner

ENGINE MECHANICAL - ENGINE TIMING BELT 15A-27
OVERHAUL
1. RAISE AND SUPPORT VEHICLE.
2. REMOVE ENGINE COVER AND INTAKE AIR DUCT. 15A


4. SET ENGINE WIRE HARNESS ASIDE.
6. REMOVE ENGINE TIMING BELT COVER. (Refer to “Chapter 15A engine mechanical - engine tim-
ing belt cover, replacement”) 15A
7. REMEMBER TO ROTATE DIRECTION OF TIMING

BELT IN ORDER TO AVOID ANY ERROR WHEN
ASSEMBLING.
8. ROTATE THE CRANKSHAFT PULLEY AND ALIGN

TIMING MARKS AS SHOW.
9. INSERT A STEEL PIN INTO THE AUTOMATIC TENSIONER

ALIGNED HOLE.
10. REMOVE 2 TIMING BELT AUTOMATIC TENSIONER

11. INSPECT AUTOMATIC TENSIONER.

(a) Inspect the automatic tensioner for any leakage. Replace the tensioner if happened.
(b) Inspect the automatic tensioner for signs of abrasion. Replace the tensioner if any abrasions are found.
(c) Inspect the length of the rod. If the rod length does not
comply with the standard length, replace the tensioner.
Standard: 12 mm
(d) Using a calibrated force, press the end of the rod with 98
- 196 N·m and measure the rod displacement. If the rod
displacement is 1 mm larger than the standard, replace
the tensioner.
Standard: ≤ 1 mm
(e) Assemble the automatic tensioner with a soft jawed vise.

Rotate the handle of the vise to push the rod of the
automatic tensioner into the tensioner. If the rod is easy
to push in, replace the automatic tensioner. The rod 15A
should have some resistance when you push the rod into
the tensioner.
NOTE
Using an appropriate pad, protect the tensioner bolt from
the jaws of the vise.
12. REMOVE ENGINE TIMING BELT.

NOTE
• Water or oil on the belt shortens its life drastically, so the removed timing belt, sprocket, and
tensioner must be free from oil and water. These parts should not be washed or immersed in
solvent. Replace parts if contaminated.
• If there is oil or water on each part, check the front case oil seals, camshaft oil seal and water
pump for leakage.
13. INSPECT TIMING BELT.
15A
NOTE
Inspect each part of timing belt carefully, if find any damage as following, replace with a new one.
(a) Inspect the timing belt back rubber for signs of aging and
glistening.
(b) Cracks in the back rubber.

(c) Cracks and stripping in the canvas.
(d) Cracks in the grooves.
(e) Cracks in the side of the belt.
(f) Inspect the timing belt for abnormal abrasion in the side
of the belt.
(g) Timing belt for abnormal abrasion.

(h) Teeth missing from the belt.
14. USING SPECIAL TOOLS MD-998719 AND MB-990767,

REMOVE CAMSHAFT TIMING BELT PULLEY BOLT.
15. REMOVE OIL PUMP TIMING BELT PULLEY.

(a) Remove the plug from the cylinder block.
(b) Insert a holder (8 mm diameter) into the hole and lock the
left balance shaft.
(c) Remove oil pump timing belt pulley bolt.
(d) Take oil pump timing belt pulley away.
16. REMOVE CRANKSHAFT PULLEY.

(a) Using special tool MD-998781, attach the tool to the
flywheel.
15A
(b) Remove 4 crankshaft pulley retaining bolts.
15A
17. REMOVE CRANKSHAFT TIMING BELT PULLEY
BOLT.
NOTE
Using special tool MD-998778, remove the crankshaft
timing belt pulley.
18. REMOVE IDLE PULLEY AND TENSIONER.
19. REMOVE AUTOMATIC TENSIONER ARM RETAINING

BOLT.
20. REMEMBER TO ROTATE DIRECTION OF TIMING

BELT B IN ORDER TO AVOID ANY ERROR WHEN
ASSEMBLING.
NOTE
• Water or oil on the belt shortens its life drastically, so the removed timing belt, sprocket, and
• If there is oil or water on each part, check the front case oil seals, camshaft oil seal and water
pump for leakage.
21. ALIGN TIMING MARKS ON CRANKSHAFT PULLEY

AND UPPER BALANCE SHAFT PULLEY WITH TIMING
MARKS ON FRONT ENGINE COVER.
22. LOOSEN TIMING BELT B TENSIONER RETAINING

BOLT.
23. REMOVE TIMING BELT B.


NOTE
15A
glistening.

15A
of the belt.

25. USING SPECIAL TOOL MD-9988785, LOCK LEFT

BALANCE SHAFT TIMING BELT PULLEY IN PLACE.
26. REMOVE LEFT BALANCE SHAFT TIMING BELT PULLEY RETAINING BOLT AND TAKE IT AWAY.
27. REMOVE LEFT BALANCE SHAFT BUSHING.
28. USING SPECIAL TOOL MD-9988778, REMOVE LEFT

BALANCE SHAFT TIMING BELT PULLEY.
29. INSTALL LEFT BALANCE SHAFT BUSHING.

NOTE
Face the beveling to the oil seal when installing the
bushing.
30. INSTALL LEFT BALANCE SHAFT TIMING BELT PULLEY.
31. USING SPECIAL TOOL MD-9988785, LOCK LEFT

BALANCE SHAFT TIMING BELT PULLEY IN PLACE
AND TIGHTEN RETAINING BOLT.
32. ALIGN TIMING MARKS ON CRANKSHAFT PULLEY B

AND UPPER BALANCE SHAFT PULLEY WITH TIMING
MARKS ON FRONT ENGINE COVER.
15A
33. POSITION TIMING BELT B ON CRANKSHAFT PULLEY B AND UPPER BALANCE SHAFT
PULLEY. NO RELAXATION ON TENSIONING SIDE.
34. MAKE SURE THAT BELT TENSIONER AND TENSIONER

RETAINING BOLT POSITION IS AS SHOWN.
15A
35. WHILE APPLYING FINGER PRESSURE TO BELT

TENSIONER IN DIRECTION OF ARROW, TIGHTEN
TENSIONER BOLT.
NOTE
Do not allow the belt tensioner to move while tightening the
bolt. If the tensioner moves, it could cause the belt to be
overtightened.
36. ENSURE THAT TIMING MARKS ARE STILL IN

ALIGNMENT, PRESS CENTER OF TIMING BELT WITH
AN INDEX FINGER AND MEASURE BELT DEFLECTION
(STANDARD DEFLECTION IS 5 ~ 7 MM).
37. LIGHTLY COATED WITH ENGINE OIL ON CRANKSHAFT

TIMING BELT PULLEY BOLT, USING SPECIAL TOOL MD-
998781, FIX FLYWHEEL AND TIGHTEN CRANKSHAFT
TIMING BELT PULLEY BOLT.
Torque: 157 ~ 167 N•m
38. INSTALL OIL PUMP TIMING BELT PULLEY.

(a) Insert a holder (8 mm diameter) into the hole and lock the
left balance shaft.
(b) Position oil pump timing belt pulley.

(c) Lightly coated with engine oil on joint surface between
retaining bolt and bearing.
(d) Tighten the oil pump timing belt pulley retaining bolt.
39. TIGHTEN AUTOMATIC TENSIONER ARM RETAINING

BOLTS.
40. REMOVE IDLE PULLEY AND TENSIONER.

41. INSTALL AUTOMATIC TENSIONER.

NOTE
If the automatic tensioner rod remains in its fully extended position, reset it to the retracted position as
following steps. 15A
(a) Assemble the automatic tensioner with a soft jawed vise.

NOTE
Use an appropriate pad to protect the tensioner bolt from
the jaws of the vise.
(b) Slowly close the vise jaws until the rod hole A and
housing hole B are aligned. Insert a steel wire (1.4 mm
diameter) into the aligned hole.
(c) Istall the automatic tensioner from the vise.
15A
42. POSITION AUTOMATIC TENSIONER ON ENGINE

FRONT COVER AND TIGHTEN 2 TIMING BELT
AUTOMATIC TENSIONER RETAINING BOLTS .
NOTE
Before adjusting the timing belt tension, do not remove the
steel wire.

TIGHTEN CAMSHAFT TIMING BELT PULLEY BOLT.
44. INSTALL TENSIONER PULLEY AND ENSURE 2

HOLES ARE IN LINE.
Torque：29 ~ 41 N•m
45. ROTATE CAMSHAFT PULLEY AND ALIGN TIMING

MARKS WITH CYLINDER HEAD COVER.
46. ROTATE CRANKSHAFT PULLEY AND ALIGN TIMING

MARKS WITH FRONT COVER.
47. ROTATE LOWER BALANCE SHAFT PULLEY AND

ALIGN TIMING MARKS WITH FRONT COVER.
NOTE
Remove the plug from the cylinder block and then insert a holder (8 mm diameter) into the hole. If the
holder can be inserted more than 60 mm, then the timing marks are aligned. If the holder could not be
inserted more than 20 ~ 25 mm, the lower balance shaft pulley should be rotated one revolution and the
timing marks should
be aligned. Adjust the holder until the installation of the timing belt is complete.
48. INSTALL TIMING BELT ON CRANKSHAFT TIMING BELT PULLEY/IDLE PULLEY/CAMSHAFT
TIMING BELT PULLEY AND TENSIONER PULLEY IN PROPER SEQUENCE.
49. ROTATE TENSIONER PULLEY AS DIRECTION OF

ARROW THEN TIGHTEN TENSIONER PULLEY BOLT.
15A
50. MAKE SURE ALL TIMING MARKS ARE ALIGNED PROPERLY.
51. REMOVE HOLDER FROM CYLINDER BLOCK AND

TIGHTEN PLUG.
15A
52. ROTATE THE CRANKSHAFT A QUARTER COUNTER-CLOCKWISE TURN. THEN TURN IT

CLOCKWISE UNTIL THE TIMING MARKS ARE ALIGNED PROPERLY AGAIN.
53. USING SPECIAL TOOLS MD-998767 AND A TORQUE

WRENCH, ADJUST TIMING BELT TENSIONER.
Torque: 3.5 N•m
NOTE
If the special tool is not available, use a commercially
available torque wrench that is capable of measuring 0 ~ 5
N•m.
54. HOLDING TENSIONER PULLEY WITH SPECIAL

TOOL AND TORQUE WRENCH, TIGHTEN RETAINING
BOLT TO SPECIFICATION.
55. AFTER CLOCKWISELY ROTATING 2 TURNS OF

CRANKSHAFT, LET IT ALONE FOR ABOUT 15
MINUTES, THEN MAKE SURE THAT AUTOMATIC
TENSIONER STEEL WIRE MOVES FREELY.
NOTE
If the wire does not move freely, repeat step 40 above until
it moves freely.
56. TAKE AUTOMATIC TENSIONER STEEL WIRE AWAY.
57. MEASURE DISTANCE “A” BETWEEN TENSIONER

ARM AND AUTOMATIC TENSIONER.
Standard: 3.8 ~ 4.5 mm
58. INSTALL ENGINE TIMING BELT COVER. (Refer to “Chapter 15A engine mechanical - engine tim-
ing belt cover, replacement”)
61. POSITION ENGINE WIRE HARNESS.

ENGINE MECHANICAL - ROCKER ARM/ROCKER SHAFT/HYDRAULIC ADJUSTER 15A-41
ROCKER ARM/ROCKER SHAFT/HYDRAULIC ADJUSTER

COMPONENTS
15A
15A
15A-42 ENGINE MECHANICAL - ROCKER ARM/ROCKER SHAFT/HYDRAULIC ADJUSTER
1 Breather Hose 10 Rocker Arm A
2 Filling Oil Cap 11 Hydraulic Adjuster
3 Cylinder Head Cover Bolt 12 Rocker Arm C
4 Cylinder Head Cover 13 O-ring
5 Cylinder Head Cover Gasket 14 Camshaft Thrust Plate
6 Rocker Shaft Bolt 15 Rocker Arm And Rocker Shaft Assy
7 Rocker Shaft 16 Camshaft Oil Seal
8 Rocker Arm B 17 Camshaft
9 Rocker Shaft Spring

OVERHAUL
15A
4. REMOVE INTAKE AIR HOSE. (Refer to “Chapter 14A intake air - intake air hose, replacement”).

15A
(a) Loosen the accelerator cable adjustment bolt on the
throttle body.
(b) Remove the end block of accelerator cable.
(c) Remove the accelerator cable.
7. DISCONNECT PCV HOSE FROM ENGINE CYLINDER

HEAD.
8. REMOVE HEATER CORE PIPE RETAINING BOLT.

9. ROTATE SPARK PLUG WIRE LIGHTLY AND PULL IT

OUT.
10. DISCONNECT IGNITION COIL CONNECTOR.
11. REMOVE IGNITION COIL RETAINING BOLTS.
12. TAKE SPARK PLUG WIRE AWAY.

NOTE
Before removing the spark plug wires from ignition coil, make a mark on each position of spark plug
wire.
13. REMOVE ENGINE TIMING BELT UPPER COVER

RETAINING BOLTS.
14. REMOVE 6 CYLINDER HEAD COVER RETAINING

BOLTS.
NOTE
Cylinder head cover retaining bolt connects the engine 15A
harness wire bracket, please make a mark.
15. TAKE CYLINDER HEAD COVER AND CYLINDER HEAD COVER GASKET AWAY.
NOTE
Cylinder head cover gasket can not be recycled. Replace with a new one before installing.
16. BEFORE DISASSEMBLING ROCKER ARM AND

ROCKER SHAFT ASSY, INSTALL SPECIAL TOOL
MD-998443 AS SHOWN IN ILLUSTRATION TO
PREVENT THE HYDRAULIC ADJUSTERS FROM
DROPPING.
15A
17. REMOVE ROCKER SHAFT ASSY RETAINING BOLTS.
18. TAKE ROCKER SHAFT ASSY AWAY.

19. TAKE ROCKER SHAFT SPRING AWAY, THEN SEPARATE ROCKER ARM AND ROCKER SHAFT.
20. TAKE HYDRAULIC ADJUSTERS AWAY.
21. INSPECT ROCKER ARM.

(a) Inspect the surface of the roller on all rocker arms. If
there is any damage, the rocker arm should be replaced.
(b) Inspect the roller for smooth operation. If the roller does
not revolve smoothly or is loose, the rocker arm should
be replaced.
(c) Inspect the internal diameter of the rocker arms. If there
is any damage, the rocker arm should be replaced.
22. INSPECT AND CLEAN HYDRAULIC ADJUSTER, IF FIND ANY DAMAGE, REPLACE IT.
NOTE
• Hydraulic adjusters are a precision part. There should not be any dust or foreign matter on its
surface.
• Do not disassemble the hydraulic adjusters.
• It is required to use clean diesel oil to clean the hydraulic adjusters.
(a) Prepare three containers and 5L diesel fuel. Pour

enough diesel fuel into each container until each upright
adjuster is completely submerged. Clean the hydraulic
adjusters as the following steps.
(b) Place the hydraulic adjuster in container A and wash its

surface.
NOTE
Using a nylon brush if there are hard-to-remove deposits.
(c) Install special tool MD-998441 to the hydraulic adjuster.

Using special tool MD-998442 press the steel ball in the
hydraulic adjuster, move the plunger up and down 5-10
times until it moves smoothly. This can eliminate the
plunger sliding resistance and expel contaminated oil.
NOTE
• The steel ball spring of the hydraulic adjuster is extremely weak. The hydraulic adjuster's
functionality may be badly affected if the special tool is inserted strongly.
• Use the special tool and check whether the plunger can be pressed. If it is hard to press, the
hydraulic adjuster is normal. If it is easy to press, repeat the previous procedure and then check
the hydraulic adjuster again. If the plunger is still loose, the hydraulic adjuster should be
replaced.
(d) Take the hydraulic adjuster out of the container, then

move the plunger by pushing the steel ball gently to drain
the diesel fuel from the pressure chamber.
15A
(e) Install special tool MD-998441 to the hydraulic adjuster.

Put the hydraulic adjuster into container B. Using special
tool MD-998442 press the steel ball in the hydraulic
adjuster, move the plunger up and down 5-10 times until
it moves smoothly. This operation can wash the hydraulic
adjuster’s pressure chamber.
15A
NOTE
The steel ball spring of the hydraulic adjuster is extremely weak. The hydraulic adjuster's functionality
may be badly affected if the special tool is inserted strongly.
(f) Take the hydraulic adjuster out of the container B, then

move the plunger by pushing the steel ball gently to drain
the diesel fuel from the pressure chamber.
(g) Put the hydraulic adjuster into container C. Using special

adjuster.
NOTE
Do not use container C for cleaning. If cleaning is
performed in container C, foreign matter could enter the
pressure chamber when the chamber is filled with diesel
fuel.
(h) Place the hydraulic adjuster upright with the plunger at

the top. Push the plunger firmly until it makes a full
stroke, then return the plunger slowly and release the
hold of the steel ball to allow the pressure chamber to be
filled with diesel fuel.
(i) Remove special tool MD-998441.
(j) Take the hydraulic adjuster out of the container C, place

it upright with the plunger at the top and push the plunger
firmly. The plunger can not be moved at all. Check the
height between the plunger and new hydraulic adjuster.
NOTE
If the hydraulic adjuster shrinks, perform the steps from (g) to (j) again until pressure chamber has
completely been filled with diesel fuel (air has been bled). Replace the hydraulic adjuster if it still
shrinks even after the operation.
(k) Install hydraulic adjuster on special tool MD-998440.

After plunger has gone down about 0.2 ~ 0.5 mm,
measure the time of going down 1 mm.
Standard: 3 ~ 20 second/1mm (Diesel fuel at 15 ~ 20
℃)
NOTE
If the measured values do not conform to the standards,
replace the hydraulic adjuster.
(l) Install special tool MD-998441 to the hydraulic adjuster,

put the hydraulic adjuster into container C. Use special
adjuster. Place the hydraulic adjuster upright with the
plunger at the top. Push the plunger firmly until it makes
a full stroke, then return the plunger slowly and release
the hold of the steel ball to allow the pressure chamber to
be filled with diesel fuel.
(m) Remove special tool MD-998441.

(n) Take the hydraulic adjuster out of the container C, place

it upright with the plunger at the top and push the plunger
firmly. The plunger can not be moved at all. Check the
height between the plunger and new hydraulic adjuster. 15A
NOTE
If the hydraulic adjuster shrinks, repeat step (i) to (n) until pressure chamber has been completely
filled with diesel fuel. Replace the hydraulic adjuster if it still shrinks even after the operation.
(o) Keep the hydraulic adjuster in their upright position to

prevent diesel fuel from spilling out. Protect them from
dust and other foreign matters. Install the hydraulic
adjusters onto the engine as soon as possible.
15A
NOTE
• Insert the hydraulic adjuster to rocker arm, careful not to spill out the diesel fuel. Then use the
special tool to prevent hydraulic adjuster from falling while installing.
• The hydraulic adjuster must be cleaned if it is reused.
23. INSTALL ROCKER ARM TO ROCKER SHAFT.
24. TEMPORARILY TIGHTEN ROCKER SHAFT RETAINING

BOLT UNTIL ALL ROCKER ARMS HAVE DO PUSH
VALVES.
25. INSTALL ROCKER SHAFT SPRINGS TO ROCKER

SHAFTS FROM UPPER SIDE OF SHAFT AND
VERTICAL WITH SPARK GUIDE.
NOTE
• The rocker shaft springs should be installed first and then install the rocker shaft bolts.
• The oil hole in the rocker shafts should be aligned with the cylinder head to ensure correct
installation position.
26. INSTALL ROCKER SHAFT RETAINING BOLTS.
27. REMOVE THE SPECIAL TOOL MD-998443 FOR SECURING THE HYDRAULIC ADJUSTER.
28. MAKE SURE THAT ROCKER SHAFTS ARE INSTALLED

PROPERLY AS SHOWN IN ILLUSTRATION.
29. POSITION CYLINDER HEAD COVER GASKET AND CYLINDER HEAD COVER.
30. TIGHTEN CYLINDER HEAD COVER RETAINING

BOLTS.
NOTE
Install the cylinder head cover retaining bolt following to
the mark during removal.
31. TIGHTEN ENGINE TIMING BELT UPPER COVER

RETAINING BOLTS.
32. POSITION SPARK PLUG WIRE TO IGNITION COIL.

NOTE
Install the spark plug wire following to the mark during removal.
33. TIGHTEN IGNITION COIL RETAINING BOLTS.

15A
34. CONNECT IGNITION COIL CONNECTOR.
15A
35. INSTALL SPARK PLUG WIRE TO CYLINDER HEAD
COVER.

(a) Tighten the accelerator cable adjustment bolt on the
throttle body.
(b) Install the end block of accelerator cable.
37. CONNECT PCV HOSE AND ENGINE CYLINDER HEAD.

38. TIGHTEN HEATER CORE PIPE RETAINING BOLT.

Torque: 20 ~28 N•m
39. INSTALL INTAKE AIR HOSE. (Refer to “Chapter 14A intake air - intake air hose, replacement”)
42. LOWER VEHICLE.

ENGINE MECHANICAL - CAMSHAFT 15A-53
CAMSHAFT
OVERHAUL
NOTE 15A
Remove the camshaft after take away the cylinder head.
1. REMOVE CYLINDER HEAD. (Refer to “Chapter 15A engine mechanical - cylinder head and
valve, overhaul”)

REMOVE CAMSHAFT TIMING BELT PULLEY BOLT.
3. REMOVE CAMSHAFT THRUST PLATE RETAINING BOLT. 15A

4. PULL OUT CAMSHAFT.
5. INSPECT CAMSHAFT.
(a) Measure the camshaft cam lobe height.
4G63:
Item Standard Limit

Intake Cam Lobe Height 37.50 mm 37.00 mm
Exhaust Cam Lobe Height 37.14 mm 36.49 mm
4G64:
Item Standard Limit

Intake Cam Lobe Height 37.39 mm 36.89 mm
Exhaust Cam Lobe Height 37.14 mm 36.64 mm
(b) If there is any wear or flaw, replace the camshaft.

6. REMOVE CAMSHAFT OIL SEAL.
NOTE
Replace with a new oil seal after moving the camshaft oil seal.
7. LIGHTLY COATED WITH ENGINE OIL ON CAMSHAFT OIL SEAL LIP AREA AND FRONT END OF
CAMSHAFT.
15A-54 ENGINE MECHANICAL - CAMSHAFT
8. USING SPECIAL TOOL MD-998713, INSTALL THE

CAMSHAFT OIL SEAL.
9. INSTALL CAMSHAFT THRUST PLATE O-RING.

10. INSTALL CAMSHAFT THRUST PLATE RETAINING BOLT.

TIGHTEN CAMSHAFT TIMING BELT PULLEY BOLT.
12. INSTALL CYLINDER HEAD. (Refer to “Chapter 15A engine mechanical - cylinder head and valve,
overhaul”)
ENGINE MECHANICAL - CYLINDER HEAD/VALVE 15A-55
CYLINDER HEAD/VALVE
COMPONENTS
15A
15A
1 Cylinder Head Bolt 8 Valve Guide
2 Cylinder Head Assy 9 Valve Seat
3 Valve Spring Lock 10 Exhaust Valve
4 Upper Valve Spring Retainer 11 Cylinder Head
5 Valve Spring 12 Intake Valve
6 Valve Oil Seal 13 Cylinder Head Gasket
7 Lower Valve Spring Retainer 0
去
15A-56 ENGINE MECHANICAL - CYLINDER HEAD/VALVE
CYLINDER HEAD OVERHAUL

3. DRAIN COOLANT. (Refer to “Chapter 17A cooling - coolant, replacement”)

5. REMOVE INTAKE AIR HOSE . (Refer to “Chapter 14A intake air - intake air hose, replacement”)
7. REMOVE ENGINE TIMING BELT. (Refer to “Chapter 15A engine mechanical - engine timing belt,
overhaul”)
8. REMOVE ROCKER ARM AND ROCKER SHAFT. (Refer to “Chapter 15A engine mechanical -
rocker arm and rocker shaft, overhaul”)
9. USING SPECIAL TOOL, LOOSEN CYLINDER HEAD

BOLTS.
10. REMOVE CYLINDER HEAD BOLTS IN SEQUENCE AS

SHOWN.
11. TAKE CYLINDER HEAD AND CYLINDER HEAD GASKET AWAY.

12. CHECK CYLINDER HEAD GASKET SURFACE FOR

FLATNESS BY USING A RULER AND THICKNESS
GAUGE.
Standard: 0.03 mm 15A
Limit: 0.2 mm
NOTE
• If the service limit is exceeded, grind to meet specification.
Grind limit: 0.2 mm (0.2 mm includes combination with cylinder block grinding)
Cylinder head height (new specification): 119.9 ～ 120.1mm
• Check the underside of cylinder head whether corrode or not，replace with a new cylinder head
if find.
13. INSTALL A NEW CYLINDER HEAD GASKET.

CAUTION
15A
Please position the cylinder head gasket according to the
mark on the gasket, align the water and oil way. Otherwise
will damage the engine.
14. POSITION CYLINDER HEAD GASKET TO LOCATE PIN.
15. WHEN INSTALLING CYLINDER HEAD BOLTS, CHECK

LENGTH OF EACH BOLT. IF THE LENGTH LIMIT IS
EXCEEDED, REPLACE BOLT.
Limit: 99.4 mm
16. USING SPECIAL TOOL MB-991654. CYLINDER

HEAD BOLTS SHOULD BE INSTALLED AND
TORQUED IN THE SEQUENCE AS SHOWN.
Tighten steps:
(a) Tighten the bolt to 78 N·m
(b) Completely loosen the bolt.
(c) Retighten the bolt to 20 N·m
(d) Make a paint mark across each cylinder head bolt and
cylinder head.
(e) Tighten the bolt an additional 90°
(f) Finish tightening the bolt an additional 90°， ensure the
paint mark on cylinder head bolt and cylinder head is
aline.
NOTE
• Before installing cylinder head bolts, threads should be lightly coated with engine oil.
• If the bolt is turned less than 90°, proper fastening performance may not be achieved. Be careful
to turn each bolt exact 90°.
• If the bolt is over-tightened, loosen the bolt completely and then retighten it by repeating the
tightening procedure from step (a).
17. INSTALL ROCKER ARM AND ROCKER SHAFT. (Refer to “Chapter 15A engine mechanical -
rocker arm and rocker shaft, overhaul”)
18. INSTALL ENGINE TIMING BELT. (Refer to “Chapter 15A engine mechanical - engine timing belt,
overhaul”)
20. INSTALL INTAKE AIR HOSE. (Refer to “Chapter 14A intake air - intake air hose, replacement”)


VALVE OVERHAUL
1. REMOVE CYLINDER HEAD. (Refer to “Chapter 15A engine mechanical - cylinder head and
valve, overhaul”)
15A
2. USING SPECIAL TOOL MD-998772, COMPRESS
VALVE SPRING AND TAKE VALVE SPRING LOCK
AWAY.
3. REMOVE UPPER VALVE SPRING RETAINER AND VALVE SPRING.

NOTE
Store removed valves, spring and other parts, tag to indicate their cylinder number and location for
assembly.
15A
4. INSPECT VALVE SPRING.
(a) Check the valve spring free length/height， discard the
springs that do not meet specifications.
Standard: 51.0 mm
Limit: 50.0 mm
(b) Check the valve spring center line, discard the springs
that do not meet specifications.
Standard: ≤ 2°
Limit: 4°
5. REMOVE VALVE OIL SEAL.

NOTE
Do not reuse valve oil seal.
6. REMOVE LOWER VALVE SPRING RETAINER.
7. TAKE VALVE AWAY AND CHECK IT.

(a) Check the valve face for correct contection. If incorrect,
reface using valve refacer. Valve seat contaction should
be maintained uniform at the center of valve face.
(b) If the edge thickness exceeds the service limit, replace

the valve.
Edge Thinkness Standard Limit

Intake Valve 1.0 mm 0.5 mm
Exhaust Valve 1.2 mm 0.7 mm
(c) Measure the valve height. If the measurement is less

than specification, replace the valve.
Valve Height Standard Limit

(d) Measure valve stem diameter and valve guide inner

diameter. Check that clearance wheather within
specification or not. If it exceeds the limit, replace valve
or valve guide.
Clearance Standard Limit

Intake Valve 0.02~0.05 mm 0.10 mm
Exhaust Valve 0.03~0.07 mm 0.15 mm
8. HEAT CYLINDER HEAD AND TAKE AWAY VALVE SEAT.

9. USING A PRESSOR, PUSH VALVE GUIDE OUT TOWARD THE CYLINDER BLOCK SIDE.
10. REBORE VALVE GUIDE HOLE IN CYLINDER HEAD.
Valve Guide Hole Diameter

0.05 oversize 11.05~11.068 mm
0.25 oversize 11.25~11.268 mm
0.50 oversize 11.50~11.518 mm
NOTE
Do not install a valve guide of the same size again.
11. INSTALL NEW VALVE GUIDE, PRESS VALVE GUIDE

UNTIL IT PROJECTS BY THE SPECIFIED AMOUNT.
Stardand: 13.7~14.3 mm
NOTE 15A
• The valve guide must be installed from the upper
side of the cylinder head.
• The valve guides differ in length on the intake and
exhaust sides.
Intake valve: 45.5 mm
Exhaust valve: 50.5 mm
12. AFTER INSTALLING VALVE GUIDE, INSERT A NEW VALVE AND CHECK THAT IT SLIDES
SMOOTHLY.
13. ASSEMBLE VALVE, THEN MEASURE VALVE STEM

PROJECTION BETWEEN END OF VALVE STEM AND
SPRING SEATING SURFACE. IF MEASUREMENT
EXCEEDS SPECIFIED LIMIT, REPLACE VALVE SEAT.
Item Standard Limit

15A
14. RECONDITIONING VALVE SEAT.

(a) Before correcting the valve seat, check for clearance
between the valve guide and valve, if necessary, replace
the valve guide.
(b) Using the special tool or seat grinder, correct to obtain
the specified seat width and angle.
(c) After correction, valve and valve seat should be lapped
with a lapping compound. Then, check the valve stem
projection.
15. REPLACE VALVE SEAT.

(a) Cut the valve seat to be replaced from the inside to thin
the wall thickness, then, remove the valve seat.
(b) Rebore the valve seat hole in the cylinder head to match
the selected oversize valve seat diameter.
Valve seat hole diameter:
0.30 Oversize 34.435-34.455 mm

Intake Valve Seat
0.60 Oversize 34.735-34.755 mm
0.30 Oversize 31.935-31.955 mm

Exhaust Valve Seat
0.60 Oversize 32.235-32.255 mm
(c) Before installing the valve seat, heat the cylinder head up to approximate 250 ℃ or cool the valve seat
in liquid nitrogen to prevent the cylinder head bore from galling.
(d) Using a valve seat cutter correct the valve seat to the specified width and angle.
16. FOLLOW MARK BEFORE REMOVAL TO INSTALL VALVE.
17. INSTALL LOWER VALVE SPRING RETAINER.
18. USING SPECIAL TOOL MD-998774, INSTALL NEW VALVE

OIL SEAL. IMPROPER INSTALLATION COULD RESULT IN
OIL LEAKAGE.
19. INSTALL VALVE SPRING.

NOTE
Position the valve spring end with color toward the upper valve spring retainer.
20. INSTALL UPPER VALVE SPRING RETAINER.
21. USING SPECIAL TOOL MD-998772, COMPRESS

VALVE SPRING AND TAKE VALVE SPRING LOCK
AWAY.
22. INSTALL CYLINDER HEAD. (Refer to “Chapter 15A engine mechanical - cylinder head and valve,
overhaul”)
ENGINE MECHANICAL - PISTON AND CONNECTING RODS 15A-63
PISTON AND CONNECTING RODS

COMPONENTS
15A
15A
1 No. 1 Compression Ring 7 Piston
2 No. 2 Compression Ring 8 Piston And Connecting Rod Assy
3 Oil Control Ring 9 Upper Connecting Rod Bearing
4 Piston Pin 10 Lower Connecting Rod Bearing
5 Connecting Rod 11 Connecting Rod Cap
6 Connecting Rod Bolts 12 Connecting Rod Nut

15A-64 ENGINE MECHANICAL - PISTON AND CONNECTING RODS
OVERHAUL
1. REMOVE ENGINE ASSY. (Refer to “Chapter 15A engine mechanical - engine assy, replace-
ment”)
2. REMOVE CYLINDER HEAD ASSY. (Refer to “Chapter 15A engine mechanical - cylinder head,
overhaul”)
3. REMOVE OIL PAN. (Refer to “Chapter 18A lubrication - oil pan, replacement”)
4. REMOVE OIL STRAINER. (Refer to “Chapter 18A lubrication - oil pump, overhaul”)
5. MARK CYLINDER NUMBER ON SIDE OF THE

CONNECTING ROD BIG END FOR CORRECT
ASSEMBLY.
NOTE
Keep the removed connecting rods, caps, and bearings in
order according to the cylinder number.
6. REMOVE CONNECTING ROD CAP NUTS IN

SEQUENCE AS SHOWN.
7. USING A HAMMER HANDLE OR SIMILAR TOOL, PUSH

PISTON AND CONNECTING ROD ASSY OUT THROUGH
THE CYLINDER HEAD SIDE OF ENGINE BLOCK.
8. REMOVE CONNECTING ROD BEARINGS.

9. USING SPECIAL TOOL MD-998780, REMOVE PISTON

PIN.
NOTE
Keep the disassembled pistons, piston pins and 15A
connecting rods in order according to the cylinder number.
1 Push Rod
2 Guide Block B
3 Guide Block C
4 Guide A
5 Guide A
6 Guide A
7 Guide A
8 Base
(a) Insert the push rod (special tool) into the piston from the 15A
side on which the front mark is stamped in the piston
head, and attach the guide C to the push rod end.
(b) Place the piston and connecting rod assy on the piston
pin setting base (special tool) with the mark facing
upward.
(c) Press the piston pin.
10. REMOVE NO.1 COMPRESSION RING, NO.2 COMPRESSION RING AND OIL CONTROL RING BY
HAND.
11. INSPECT PISTON RING.
(a) If the piston needs to be reused, clean the carbon deposition on piston, compression ring and the
greasy dirt on oil ring in clean diesel.
NOTE
Do not damage the piston surface.
(b) Check the piston ring for damage, excessive wear, and breakage. Replace it if happened. If the piston
has been replaced with a new one, the piston rings must also be replaced.
(c) Check piston ring to groove side clearance. If the limit is

exceeded, replace the ring or piston, even both.
Stardand: 0.02 ~ 0.06 mm
Limit: 0.1 mm
12. INSERT PISTON RING INTO CYLINDER BLOCK.

FORCE IT DOWN WITH A PISTON TO CORRECTLY
POSITION IT. THEN MEASURE END GAP WITH A
FEELER GAUGE. IF RING GAP IS EXCESSIVE,
REPLACE PISTON RING.
Item First Ring Second Ring Oil Ring

Standard 0.25 ~ 0.35 mm 0.40 ~ 0.55 mm 0.10 ~ 0.40 mm
Limit 0.8 mm 0.8 mm 0.1 mm
13. CHECK OIL CLEARANCE OF CONNECTING RODS AND

CRANKSHAFT.
(a) Clean all engine oil off of the connecting rod bearing and
the crankshaft journal.
(b) Cut the plastigauge into length as wide as the crankshaft
journal. Lay the plastigauge across the crankshaft
journal.
(c) Carefully install the connecting rod cap. Tighten the
connecting rod cap nuts to 20 N·m.
(d) Carefully disassemble the connecting rod cap.
(e) Using a measuring ruler imprinted on the plastigauge
package, measure the width of the widest part of the
plastigauge.
Stardand: 0.02 ~ 0.05 mm
Limit: 0.1 mm
14. INSTALL PISTON PIN.

(a) Measure the following dimensions of each piston, piston
pin and connecting rod.
• A: Length of piston pin in hole 15A
• B: Width of pin socket
• C: Length of piston pin
• D: Width of small end of connecting rod
(b) Put measured values above into following formula to
calculate L.
L ＝ ((A - C) - (B - D)) / 2
(c) After inserting the push rod of the special tool into piston
pin, install pipe A in the top of the push rod.
(d) Install forward marks of piston and connecting rod in the

same direction.
(e) Lubricate the external diameter of piston pin with engine
oil.
15A
(f) Through pipe A, insert the push rod, piston pin and pipe
component into piston pin hole from the side with the
forward mark.
(g) Screw on guide block B into guide pipe A to gain

clearance between guide block A and guide block B
equal to the value of value L (L=((A-C)-(B-D)) / 2) plus 3
mm.
(h) Keep the forward mark of piston upward. Install piston

and connecting rod in tool base of piston pin installer.
(i) Press the piston pin into the piston. When the pressure is
less than standard value, replace piston pin and piston
component or replace connecting rod.
Standard: 7350 ～ 17200 N
15. CHECK TO MAKE SURE PISTON CAN ROTATE FREELY AFTER INSTALLING.
16. INSTALL OIL CONTROL RING.
(a) Install oil control ring spacer into the piston ring groove.
NOTE
• There is no difference between the upper and lower oil control rings.
• New spacers and oil control rings are colorful for identification of their sizes.
Standard: none
0.50 mm oversize diameter: Red
1.00 mm oversize diameter: Yellow
(b) Install the top oil control ring. When installing the ring,
force one side of the piston ring into the piston oil ring
groove. Then force the ring into oil ring groove with the
thumb as shown.
NOTE
Do not use a piston ring expander when installing oil
control ring. Using ring expander, expand the oil control
ring end gap can break the oil control ring, unlike other pis-
ton rings.
(c) Install the bottom oil control ring as step (b).

(d) Ensure the ring can turn from the left to the right freely
after installation.
17. INSTALL NO. 1 COMPRESSION RING AND NO. 2

COMPRESSION RING.
(a) Using a piston ring expander, install the NO. 2
compression ring, then install the NO. 1 compression
ring.
(b) The compression rings have an identification mark on

the top of the ring.
• NO. 1 compression ring: 1R
• NO. 2 compression ring: 2R
• When installing piston ring, keep the mark upward
and toward the top of piston.
• Size marks of pistons shown as the following:
Size Identification
Standard None
0.50 mm Oversize 50
1.00 mm Oversize 100
18. INSTALL PISTON AND CONNECTING ROD.

(a) Oil the piston rings and the side of the piston.
(b) Position the piston rings in the proper alignment with the
piston pin as shown:
1 Top Oil Control Ring

15A
2 Piston Pin
3 Bottom Oil Control Ring
No. 2 Compression Ring And Oil Control

4
Ring Spacer
5 No. 1 Compression Ring
6 Crankshaft Pulley Side
(c) Rotate the crankshaft journal to the lowest position.

(d) Install protective coverings over the connecting rod bolts.
Be careful, do not damage the crank journal.
(e) Using a suitable piston ring compressor, insert the piston

and connecting rod assembly into cylinder.
NOTE 15A
• Make sure the forward mark on the top of the piston
is facing the front of the engine.
• Using a suitable tool, tap the piston and connecting
rod assembly into cylinder.
19. INSTALL CONNECTING ROD BEARING.

Perform the following steps when replacing the connecting rod bearings.
(a) Measure and record the external diameter of the

connecting rod journals. Use the connecting rod bearing
identification table to pick up the desired bearing. In the
case of a crankshaft supplied as a service part, size
differences are painted with color at the positions shown
in the illustration.
(b) The bearing will have an identification mark in the

position as shown.
Crank Journal Connecting Rod Bearing

Identification Identification Identification
Group External Diameter Thickness
Color Number Color
I Yellow 44.995~45.000 mm 1 Yellow 1.487~1.491 mm
II None 44.985~44.995 mm 2 None 1.491~1.495 mm
III White 44.980~44.985 mm 3 Blue 1.495~1.499 mm
Internal diameter of connecting rods (without bearing): 48.000 mm~48.015 mm
(c) Select a bearing from the above table according to assured group number in step (a) and step (b).
(d) For example
If the measurement of the external diameter of the connecting rod journal is 44.996 mm, it will be
identified as group 1 in the table. If the crankshaft has been replaced, check the identification color
applied to the new crankshaft journal. If the journal is yellow, the crankshaft bearing will be from group
1, and the connecting rod bearing will be identified as 1.
20. VERIFY MARK MADE DURING DISASSEMBLY,

INSTALL BEARING CAP TO THE CONNECTING ROD.
IF CONNECTING ROD IS NEW WITH NO INDEX
MARK, MAKE SURE THAT BEARING LOCK
NOTCHES COME ON THE SAME SIDE AS SHOWN.
21. CHECK AXIAL CLEARANCE OF CONNECTING RODS.

Limit: 0.4 mm
15A
22. INSTALL CONNECTING ROD CAP NUTS.

(a) Before installing connecting rod cap, remove the spark plug, then tighten the connecting rod cap nut if
cylinder head installed.
(b) Since the connecting rod bolts and nuts are torqued using a new procedure, they should be examined
before reuse. If the bolt threads are “necked down”, the bolts should be replaced. Necking can be
checked by running a nut with fingers to the full length of the bolt’s thread. If the nut does not run down
smoothly, the bolt should be replaced.
(c) Apply engine oil to the connecting rod bolts.
(d) Install each nut to the bolt and tighten it by hand. Then tighten the nuts alternately to install the cap 15A
properly.
(e) Make a paint mark on the head of each nut.
• Make a paint mark on the bolt at the position 90° ~
100° from the paint mark made on the nut in the
direction of tightening the nut.
• Turn additional 90° ~ 100° to the nut and make sure
that the paint mark on the nut and that on the bolt are
in alignment.
NOTE
• If the nuts are tightened less than 90°, they may not hold the caps with sufficient strength. Be
careful to tighten the nut at exact 90°.
• If a nut is tightened exceeding 100°, completely remove all nuts and carry out the installation
procedure again from step (a).
23. INSTALL OIL STRAINER. (Refer to “Chapter 18A lubrication - oil pump, overhaul”)
24. INSTALL OIL PAN. (Refer to “Chapter 18A lubrication - oil pan, replacement”)
25. INSTALL CYLINDER HEAD ASSY. (Refer to “Chapter 15A engine mechanical - cylinder head,
overhaul”)
26. INSTALL ENGINE ASSY. (Refer to “Chapter 15A engine mechanical - engine assy, replacement”)
15A-72 ENGINE MECHANICAL - CRANKSHAFT/ENGINE BLOCK/FLYWHEEL
CRANKSHAFT/ENGINE BLOCK/FLYWHEEL
COMPONENTS
1 Cylinder Block 6 Crankshaft
2 Crankshaft Rear Oil Seal Housing 7 Lower Crankshaft Bearing
3 Crankshaft Rear Oil Seal 8 Bearing Cap
4 Crankshaft Thrust Bearing 9 Bearing Cap Bolt
5 Upper Crankshaft Bearing

ENGINE MECHANICAL - CRANKSHAFT/ENGINE BLOCK/FLYWHEEL 15A-73
15A
15A
1 Flywheel Bolt 6 Rear Cover
2 Joint Plate 7 Engine Block Rear Cover
3 Flywheel 8 Crankshaft Rear Oil Seal
4 Joint Plate 9 Crankshaft Rear Oil Seal Housing
5 Crankshaft Bushing 10 Engine Block

OVERHAUL
1. REMOVE ENGINE ASSY. (Refer to “Chapter 15A engine mechanical - engine assy, replace-
ment”)
2. REMOVE CYLINDER HEAD ASSY. (Refer to “Chapter 15A engine mechanical - cylinder head,
overhaul”)
3. REMOVE OIL PAN. (Refer to “Chapter 18A lubrication - oil pan, replacement”)
4. REMOVE OIL STRAINER. (Refer to “Chapter 18A lubrication - oil pump, overhaul”)
5. REMOVE OIL PUMP FRONT COVER. (Refer to “Chapter 18A lubrication - oil pump, overhaul”)
6. FIX ENGINE BLOCK ASSY TO FLIP FRAME AND DISASSEMBLY IT.
7. USING SPECIAL TOOL MD-998781, TO FIX FLYWHEEL.
8. REMOVE 6 FLYWHEEL RETAINING BOLTS.
9. REMOVE REAR COVER RETAINING BOLTS.
10. TAKE REAR COVER AWAY.

11. REMOVE ENGINE BLOCK REAR COVER RETAINING

BOLTS.
15A
12. TAKE ENGINE BLOCK REAR COVER AWAY.

13. REMOVE THE CRANKSHAFT REAR OIL SEAL USING A SUITABLE TOOL.
14. REMOVE CRANKSHAFT REAR OIL SEAL HOUSING

RETAINING BOLTS.
15A
15. TAKE CRANKSHAFT REAR OIL SEAL HOUSING AWAY.

16. ROTATE ENGINE BLOCK, MAKE OIL PAN PART UP.
17. REMOVE CRANKSHAFT MAIN BEARING CAP

BOLTS IN SEQUENCE AS SHOWN.
18. REMOVE CRANKSHAFT MAIN BEARING CAP AND DISASSEMBLE LOWER CRANKSHAFT
BEARING.
19. INSPECT THE CRANKSHAFT.

(a) Using plastigauge, check the oil clearance of the
crankshaft as following.
(b) Clean all engine oil off of the crankshaft journals.

(c) Install the crankshaft.

(d) Cut the plastigauge into length as wide as the crankshaft
journal. Lay the plastigauge across the crankshaft
journal.
(e) Carefully install the main bearing cap. Tighten the main
bearing cap to the specified torque.
Torque: 23 ~ 27 N•m + 90°~100°
(f) Carefully disassemble the main bearing cap.
(g) Use the measuring ruler imprinted on the plastigauge

package to measure the width of the widest part of the
plastigauge.
Limit: 0.1 mm
20. REMOVE UPPER CRANKSHAFT BEARING AND CRANKSHAFT THRUST BEARING.
21. TAKE ENGINE BLOCK FROM FLIP FRAME AND

INSPECT IT.
(a) Check for scratches, rust, and corrosion. Visually or with
flaw detecting agent. If defects are evident, correct or
replace it.
(b) Use a straightedge and feeler gauge to check the block
top surface for warpage. Make sure that the surface is
free from gasket chips and other foreign matters.
Standard: 0.05 mm
Limit: 0.1 mm
(c) If the warpage is excessive, correct within the allowable
limit or replace.
Grinding limit: 0.2 mm
(d) The total thickness of the stock allowed to be removed
from cylinder block and mating cylinder head is 0.2mm at
maximum.
Cylinder block height (new): 4G63: 284 mm
4G64: 290 mm
(e) The cylinder walls should be checked for out-of-round
and taper with cylinder indicator or equivalent. If the
cylinder walls are badly scuffed or scored, the cylinder
block should be replaced, and new pistons and rings
should be fitted.
(f) Measure the cylinder bore at three levels in directions A

and B. Top measurement should be 12 mm down and
bottom measurement should be 12 mm up from bottom
of bore. 15A
Standard:
Cylinder Size: 4G63 85.00 ~ 85.03 mm
4G64 86.50 ~ 86.53 mm
Cylinder Cylindrically: ≤ 0.01 mm
(g) Oversize pistons using should be determined on the
basis of the largest bore cylinder.
Piston size identification
Size Identification Mark

0.50 Oversize 0.50
1.00 Oversize 1.00
NOTE
Size mark is stamped on piston top.
15A
(h) Measure piston outside diameter is in thrust direction as
shown.
(i) Follow the piston external diameter to calculate cylinder
bore dimension.
Cylinder bore dimension = W + F - 0.02 mm
Check clearance between piston and cylinder bore.
NOTE
• “W” means “piston outside diameter”， “F” means “clearance between piston outside diameter
and cylinder bore”. Bore all cylinder to calculated cylinder bore dimension.
• To prevent distortion that may result from temperature rising during honing, bore cylinders to
follow the sequence of No.2, No.4, No.1 then No.3. Honing dimension (piston E.D. + clearance
between piston E.D. and cylinder).
• When boring cylinders, make all of four cylinders same oversize. Do not bore only one cylinder.
22. ROTATE ENGINE BLOCK, MAKE OIL PAN PART UP.
23. INSTALL CRANKSHAFT BEARING.

(a) Select the proper size bearing for crankshaft journal
according to the following table.
Combination of Crankshaft Main Journal and Spindle Bore

Crankshaft Main Journal Identification Identification
Identification
Mark And Color Mark And Color
Identification External Mark Of Spindle
Group Of No. 1, 2, 4, 5 Of No. 3 Journal
Color Diameter Group Bore
Journal Bearing Bearing
0 1. Green 0. Black
I Yellow 56.994~57.000 mm 1 2. Yellow 1. Green
2 3. None 2. Yellow
0 2. Yellow 1. Green
II None 56.988~56.994 mm 1 3. None 2. Yellow
2 4. Blue 3. None
0 3. None 2. Yellow
III White 56.982~56.988 mm 1 4. Blue 3. None
2 5. Red 4. Blue
For example:
• If the identification color of the crankshaft main journal is
yellow and the identification mark of spindle bore is “1”,
choose the No. 1, 2, 4, 5 bearing of which identification
mark is “2” and identification color is “yellow” and No.3
bearing of which identification mark is “1” and
identification color is “green”.
24. INSTALL MAIN BEARING AND THRUST BEARING.

(a) Install the main bearings with oil grooves on the cylinder
block side.
(b) Install the main bearings without oil grooves on the
bearing cap.
(c) Install the 2 thrust bearings on crankshaft journal No.3.
Apply clean oil to the surface of thrust bearing.
25. INSTALL MAIN BEARING CAPS.

(a) Install the main bearing caps with the arrow on the main
caps facing the front of the engine.
26. INSTALL THE MAIN BEARING CAP BOLTS.

(a) When installing the bearing cap bolts, check that the
shank length of each bolt meets the limit. If the limit is
15A
excessive, replace the bolt.
Limit: 71.1 mm
(b) Apply engine oil to the threaded portion bearing surface

of the bolt.
(c) Tighten the bearing cap bolts in the sequence as shown.

Torque: 25 N•m
15A
(d) Make a paint mark on the head of each nut.

(e) Make a paint mark on the area around the bolt bearing
surface at location 90° ~ 100° in the direction of
tightening the bolt.
(f) Turn additional 90° ~ 100° to the nut and make sure that
the paint mark on the nut and on the bolt are in
alignment.
NOTE
• If the nuts are tightened less than 90°, they may not
hold the caps with sufficient strength. Be careful to
tighten the nut at exact 90°.
• If a nut is tightened exceeding 100°, completely
remove all nuts and carry out the installation
procedure again from step (a).
27. After installing main bearing caps, assure that
crankshaft rotates smoothly and inspect crankshaft
axial clearance. If the crankshaft axial clearance
exceeds the maximum limit, replace the No.3
crankshaft thrust bearing.
Limit: 0.25 mm
28. USING SPECIAL TOOL MD-990938 AND MD-998376,

INSTALL REAR CRANKSHAFT OIL SEAL.
29. INSTALL REAR CRANKSHAFT OIL SEAL HOUSING.

NOTE
• Before installation, please use scraper to clear seal surface dirt, do not damage the surface.
• Use specified sealant. (MITSUBISHI genuine part number MD-970389 or equivalent)
• Be sure to install the case quickly while the sealant is wet (within 15 minutes).
• After installation, keep the sealant area away from the oil for one hour.
30. INSTALL REAR COVER AND ENGINE BLOCK REAR COVER .
31. USING SPECIAL TOOL MD-998781, FIX FLYWHEEL.
32. TIGHTEN 6 FLYWHEEL RETAINING BOLTS.

Torque: 130 ~ 140 N•m
33. INSTALL OIL PUMP FRONT COVER. (Refer to “Chapter 18A lubrication - oil pump, overhaul”)
34. INSTALL OIL STRAINER. (Refer to “Chapter 18A lubrication - oil pump, overhaul”)
35. INSTALL OIL PAN. (Refer to “Chapter 18A lubrication - oil pan, replacement”)
36. INSTALL CYLINDER HEAD ASSY. (Refer to “Chapter 15A engine mechanical - cylinder head,
overhaul”)
37. INSTALL ENGINE ASSY. (Refer to “Chapter 15A engine mechanical - engine assy, replacement”)
EXHAUST
16A
EXHAUST PIPE ............................................................................... 16A-1
COMPONENTS ......................................................................... 16A-1
REPLACEMENT ........................................................................ 16A-2
EXHAUST MANIFOLD..................................................................... 16A-7 16A
REPLACEMENT ........................................................................ 16A-7
16A
16A
EXHAUST - EXHAUST PIPE 16A-1
EXHAUST PIPE
EXHAUST
COMPONENTS
16A
16A
1 Clamp 5 Heat Shield
2 Exhaust Gasket 6 Middle Exhaust Pipe With Muffler Assy
Front Exhaust Pipe With Catalytic 7 Joint Rubber

3
Converter Assy
Rear Exhaust Pipe With 2-stage Muffler
8
4 Rear Oxygen Sensor Assy
16A-2 EXHAUST - EXHAUST PIPE
REPLACEMENT

WARNING
Exhaust pipe is a high temperature part. Never work around or attempt to service any parts of the
exhaust system until it cools down.
4. REMOVE LOWER GUARD PLATE RETAINING BOLTS.
5. REMOVE FRONT EXHAUST PIPE WITH CATALYTIC

CONVERTER ASSY RETAINING BELT BOLTS.
6. REMOVE BOLTS ATTACHING FRONT EXHAUST

PIPE WITH CATALYTIC CONVERTER ASSY TO
EXHAUST MANIFOLD.
7. DISCONNECT REAR OXYGEN SENSOR CONNEC-

TOR.
16A

MIDDLE EXHAUST PIPE WITH MUFFLER ASSY.
9. REMOVE FRONT EXHAUST PIPE WITH CATALYTIC CONVERTER ASSY. 16A

10. INSPECT CATALYTIC CONVERTER.
(a) Tap the catalytic converter, if hear any noise, replace with a new one.
(b) Using a scan tool, check the oxygen sensor signal fluctuation range. If the catalytic converter damage,
oxygen sensor signal fluctuation range will become larger.
11. REMOVE BOLTS ATTACHING MIDDLE EXHAUST

PIPE WITH MUFFLER ASSY TO REAR EXHAUST
PIPE WITH 2-STAGE MUFFLER ASSY.
12. DISCONNECT MIDDLE EXHAUST PIPE WITH MUFFLER

ASSY JOINT RUBBER.
13. DISCONNECT REAR EXHAUST PIPE WITH 2-STAGE

MUFFLER ASSY JOINT RUBBER.
14. REMOVE REAR EXHAUST PIPE WITH 2-STAGE MUFFLER ASSY.

NOTE
After a long-time used, the exhaust pipe gasket will be adhered to exhaust pipe. After remove the
muffler, using the scraper, clean the surface of exhaust pipe and replace with a new gasket to avoid
exhaust leakage.


17. CHECK WHETHER THERE ARE CORROSION, EXHAUST LEAKAGE. REPLACE IT IF
NECESSARY.
18. INSTALL MIDDLE EXHAUST PIPE WITH MUFFLER

ASSY JOINT RUBBER.
19. INSTALL REAR EXHAUST PIPE WITH 2-STAGE

20. POSITION A NEW EXHAUST PIPE GASKET.

21. POSITION FRONT EXHAUST PIPE WITH CATALYTIC CONVERTER ASSY.
22. TIGHTEN BOLTS ATTACHING FRONT EXHAUST 16A

EXHAUST MANIFOLD.
23. TIGHTEN FRONT EXHAUST PIPE WITH CATALYTIC

CONVERTER ASSY RETAINING BELT BOLTS.
16A
25. TIGHTEN BOLTS ATTACHING FRONT EXHAUST

MIDDLE EXHAUST PIPE WITH MUFFLER ASSY.
26. CONNECT REAR EXHAUST PIPE WITH 2-STAGE

27. TIGHTEN BOLTS ATTACHING MIDDLE EXHAUST PIPE

WITH MUFFLER ASSY TO REAR EXHAUST PIPE WITH 2-
STAGE MUFFLER ASSY.
28. CONNECT REAR OXYGEN SENSOR CONNECTOR.
29. INSTALL LOWER GUARD PLATE RETAINING BOLTS.
30. LOWER VEHICLE.

EXHAUST - EXHAUST MANIFOLD 16A-7
EXHAUST MANIFOLD
REPLACEMENT
16A

WARNING
Exhaust pipe is a high temperature part. Never work around, or attempt to service any parts of the
3. REMOVE INTAKE AIR HOSE. (Refer to “Chapter 14A intake air - intake air hose, replacement”)
4. DISCONNECT FRONT OXYGEN SENSOR

CONNECTOR. 16A
5. REMOVE 3 EXHAUST MANIFOLD HEAT SHIELD

RETAINING BOLTS.
6. REMOVE HEAT SHIELD.

16A-8 EXHAUST - EXHAUST MANIFOLD
7. REMOVE EXHAUST MANIFOLD RETAINING NUTS.

NOTE
The exhaust manifold retaining nuts will be rusted after a
long-time drive. Use derusting spray when loosen the nuts.
8. REMOVE EXHAUST MANIFOLD.

9. REMOVE EXHAUST MANIFOLD GASKET.
NOTE
• Check whether parts have any damage or crack.
• Check exhaust manifold and cylinder head surface for flatness by using a ruler and thickness
gauge.
Standard: 0.15 mm or less
Limit value: 0.20 mm
• Clean the dirt on exhaust manifold and cylinder head connect surface.
10. INSTALL A NEW EXHAUST MANIFOLD GASKET.
NOTE
If do not replace with a new gasket, use exhaust sealant to avoid exhaust leakage.
11. TIGHTEN EXHAUST MANIFOLD RETAINING NUTS.

NOTE
• Daub rust-inhibiting lubricant on nuts for next
removing conveniently.
• Install the exhaust manifold retaining bolts
diagonally.
EXHAUST - EXHAUST MANIFOLD 16A-9
12. TIGHTEN 3 EXHAUST MANIFOLD HEAT SHIELD

RETAINING BOLTS.
16A
13. CONNECT FRONT OXYGEN SENSOR CONNECTOR.
14. INSTALL INTAKE AIR HOSE. (Refer to “Chapter 14A intake air - intake air hose, replacement”) 16A
MEMO
COOLING
17A
COOLING SYSTEM ......................................................................... 17A-1
PRECAUTION............................................................................ 17A-1
ON-VEHICLE INSPECT............................................................. 17A-3 17A
COOLANT ........................................................................................ 17A-5
REPLACEMENT ........................................................................ 17A-5
RADIATOR ....................................................................................... 17A-8
COMPONENTS ......................................................................... 17A-8 17A
REPLACEMENT ........................................................................ 17A-9
COOLING FAN............................................................................... 17A-14
REPLACEMENT ...................................................................... 17A-14
THERMOSTAT ............................................................................... 17A-16
OVERHAUL ............................................................................. 17A-16
COOLANT PUMP...........................................................................17A-19
OVERHAUL ............................................................................. 17A-19
17A
COOLING - COOLING SYSTEM 17A-1
COOLING SYSTEM
COOLING
PRECAUTION
1. COOL SYSTEM PRECAUTION. 17A
(a) When removing the cooling hose, use a suitable container to recycle the retains of coolant. If not
continue to use, according to regulations for disposal.
(b) When disconnecting the pipes of cooling system, do not let debris into the pipes of cooling system. It
may damage the cooling system and engine.
(c) When disconnecting the cooling system pipes connectors, a special plug must be used to cover the
nozzle to prevent dirt or impurities.
(d) Coolant is poisonous, always keep it away from children and pets. If not continue to use, according to
regulations for disposal.
(e) Do not open the radiator cap when the engine is hot. Such as coolant temperature should be reduced
to 50 ° c (120 ° f) below, remove the radiator cap. Otherwise, the cooling liquid or vapor emitting heat
may cause personal injury.
(f) Use FOTON specified coolant, do not only use water as coolant. Water will damage the engine
because of corrosion.
(g) Regular clean radiator outside, and prevent mud or dust deposition to affect radiator.
17A
17A-2 COOLING - COOLING SYSTEM

1. Coolant (Lack or leakage) Chapter 17A cooling - coolant, replacement
2. Coolant (Non-standard) Chapter 17A cooling - coolant, replacement
3. Thermostat (Damaged) Chapter 17A cooling - thermostat, overhaul
Engine overheating 4. Engine (Rough work) -
Chapter 17A cooling - cooling system,

5. Radiator (Poor cooling) precaution
6. Cooling fan (Damaged) Chapter 17A cooling - cooling fan, overhaul
7. Cooling system (Block) -
1. Radiator Chapter 17A cooling - radiator, replacement
2. Cooling system hose (Broken) -
Coolant leakage Chapter 17A cooling - coolant pump,

3. Coolant pump replacement
Chapter 17A cooling - coolant reservoir,

4. Coolant reservoir replacement
1. Cooling fan Chapter 17A cooling - cooling fan, overhaul

Engine room noise
Chapter 17A cooling - coolant pump,
COOLING - COOLING SYSTEM 17A-3
ON-VEHICLE INSPECT
1. CHECK WHETHER COOLANT LEVEL IS NORMAL. IF NOT, CHECK COOLING SYSTEM
LEAKAGE.
17A
WARNING
Never remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be
blown out under pressure.
(a) Fill the radiator with coolant and attach a radiator cap
tester.
(b) Warm up the engine.
(c) Pump it to 110 kPa, and check that the pressure does not
drop.
NOTE
If the pressure drops, check the hoses, radiator or water pump for leakage. If no external leakage is
found, check the heater core, cylinder block and head.
2. CHECK ENGINE COOLANT LEVEL IN COOLANT RESERVOIR.
(a) When the engine is cool, the engine coolant level should be between the ”LOW” and ”FULL” line.
(b) If low, check for leakage and add ”FOTON Long-effective coolant” or equivalent up to the ”FULL” line. 17A
NOTE
Do not use water as coolant.
3. CHECK ENGINE COOLANT QUALITY.
WARNING
Never remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be
blown out under pressure.
(a) Remove the radiator cap.
(b) Place a container under the radiator to bloom the coolant from the coolant drain hole.
(c) Loosen the coolant drain plug to drain the coolant and check if there is any excessive deposits of rust or
scale around the radiator cap and radiator filler hole. The coolant should be free from oil. If excessively
dirty, replace the coolant.
(d) Tighten the drain plug and check the coolant level in the coolant reservoir. Fill the coolant if necessary.
4. INSPECT FINS BLOCKAGE.
(a) If fins are clogged, wash them with water or a steam cleaner and dry them with compressed air.
NOTE
If the distance between the steam cleaner and core is too close, there is a possibility of damaging the
fins. So keep the following injection distance.
(b) Be careful not to spary water directly onto electronic components.
17A-4 COOLING - COOLING SYSTEM
5. INSPECT COOLING FAN.

(a) Disconnect the cooling fan connector.
(b) Connect battery and ammeter to the connector.
(c) Check that the cooling fan rotates smoothly, and check the reading on the ammeter.
Standard amperage:
Approx. 8.0 ~ 12.0 A at 20°C (68°F)
(d) Connect the cooling fan connector.
(e) No abnormal noise except fan itself when the fan is rotating at a high speed.
COOLING - COOLANT 17A-5
COOLANT
REPLACEMENT
WARNING 17A
Do not open the radiator cap when the engine is hot. Such as coolant temperature should be reduced
to 50 ° C (120 ° F) below, remove the radiator cap. Otherwise, the cooling liquid or vapor emitting heat
1. COOL ENGINE TO NORMAL INDOOR TEMPERATURE.

3. REMOVE RADIATOR CAP.

NOTE
Press the radiator cap and counterclockwise rotate to open radiator cap.
17A
4. REMOVE CLAMP ATTACHING COOLANT RESERVOIR
HOSE TO RADIATOR.
5. REMOVE COOLANT RESERVOIR RETAINING BOLT.
6. DISCONNECT COOLANT LEVEL SENSOR CONNECTOR.

7. REMOVE COOLANT RESERVOIR AND DRAIN COOLANT.
17A-6 COOLING - COOLANT
10. LOOSEN COOLANT DRAIN PLUG AT RADIATOR

BOTTOM.
11. INSTALL CONDUIT BETWEEN RADIATOR DRAIN

PLUG AND CONTAINER.
NOTE
Using a suitable container, hold the coolant. If do not
12. TIGHTEN COOLANT DRAIN PLUG AT RADIATOR

BOTTOM.
13. INSTALL LOWER GUARD PLATE AND TIGHTEN

RETAINING BOLTS.
COOLING - COOLANT 17A-7
14. LOWER VEHICLE.
15. INSTALL COOLANT RESERVOIR AND TIGHTEN

BOLT.
17A
16. CONNECT COOLANT LEVEL SENSOR CONNECTOR.
17. CONNECT CLAMP ATTACHING COOLANT RESERVOIR

HOSE TO RADIATOR.
17A
18. FILL COOLANT FROM RADIATOR FILLING HOLE.
19. FILL COOLANT TO STANDARD LEVEL.
20. START ENGINE AND ACCELERATE TO 2500 RPM. FILL RADIATOR WITH COOLANT.
21. INSTALL RADIATOR CAP, RUNNING ENGINE UNTIL COOLING FAN RUN AT HIGH SPEED.
CHECK COOLANT LEVEL IN COOLANT RESERVOIR.
NOTE
The air in cooling system can be bled automatic.

17A-8 COOLING - RADIATOR
RADIATOR
COMPONENTS
1 Rubber Cushion 6 Engine Outlet Coolant Hose
2 Radiator 7 Coolant Reservoir Hose
3 Radiator Support 8 Coolant Reservoir
4 Cooling Fan 9 Coolant Level Sensor
5 Engine Inlet Coolant Hose 10 Radiator Cap

COOLING - RADIATOR 17A-9
REPLACEMENT
WARNING
17A
1. COOL THE ENGINE TO NORMAL INDOOR TEMPERATURE.


5. DISCONNECT UPPER RADIATOR COOLANT HOSE

CLAMP.
17A
6. DISCONNECT COOLING FAN CONNECTOR.
7. REMOVE COOLING FAN CIRCUIT BREAKER BOX.

10. DISCONNECT LOWER RADIATOR COOLANT HOSE

CLAMP.
11. LOOSEN 2 RADIATOR LOWER SUPPORT RETAINING

BOLTS.
12. LOWER VEHICLE.
13. REMOVE 2 RADIATOR UPPER SUPPORT RETAINING

BOLTS.
14. REMOVE RADIATOR AND COOLING FAN ASSY.

15. REMOVE 4 COOLING FAN RETAINING BOLTS.
17A
16. REMOVE RADIATOR AND CLEAN IT IF NECESSARY.
17. INSTALL COOLING FAN AND TIGHTEN 4 COOLING

FAN RETAINING BOLTS.
18. INSTALL RADIATOR AND COOLING FAN ASSY TO RADIATOR FRAME.

17A
NOTE
Before installing radiator, position the rubber cushion.
19. RAISE VEHICLE.
20. TIGHTEN 2 LOWER RADIATOR SUPPORT RETAINING

BOLTS.
21. CONNECT LOWER RADIATOR COOLANT HOSE AND

TIGHTEN CLAMP.
23. LOWER VEHICLE.
24. TIGHTEN 2 UPPER RADIATOR SUPPORT RETAINING

BOLTS.
25. CONNECT UPPER RADIATOR COOLANT HOSE AND

TIGHTEN CLAMP.
26. CONNECT COOLING FAN CONNECTOR.

27. INSTALL COOLING FAN CIRCUIT BREAKER BOX.
17A


17A
31. AFTER INSTALLING RADIATOR, START ENGINE UNTIL COOLING FAN RUNNING AT HIGH
SPEED. CHECK COOLANT FOR LEAKAGE.
17A-14 COOLING - COOLING FAN
COOLING FAN
REPLACEMENT
6. CHOOSE A SUITABLE POSITION TO REMOVE COOLING FAN.

COOLING - COOLING FAN 17A-15

(a) Using an ohmmeter, measure the resistance between the terminals.
Resistance: 1.17 - 1.43 Ω at 20 ℃ .
(b) Rotate cooling fan by hand, the blades should be rotated smoothly. 17A
8. POSITION COOLING FAN PROPERLY.
9. TIGHTEN 4 COOLING FAN RETAINING BOLTS.

17A

17A-16 COOLING - THERMOSTAT
THERMOSTAT
OVERHAUL
WARNING
1. COOLING THE ENGINE TO NORMAL ROOM TEMPERATURE.


5. REMOVE THERMOSTAT HOUSING RETAINING

BOLTS.
6. REMOVE THERMOSTAT.
COOLING - THERMOSTAT 17A-17
7. INSPECT THERMOSTAT.
(a) The thermostat is numbered with the valve opening
temperature.
17A
(b) Immerse the thermostat in water and gradually heat the

water.
(c) Check the valve opening temperature.
Valve opening temperature: 80 - 84 ℃
NOTE
If the valve opening temperature is not as specified, replace
the thermostat.
(d) Check the valve lift.

Valve lift: 8 mm or more, at 95 ℃ . 17A
NOTE
If the valve lift is not as specified, replace the thermostat.
• Check that the valve is fully closed when the thermostat is at low temperatures (below 77 ℃ ).
• If it does not closed, replace the thermostat.
8. INSTALL THERMOSTAT.
17A-18 COOLING - THERMOSTAT
9. TIGHTEN THERMOSTAT HOUSING RETAINING

BOLTS.

11. FILL COOLANT. (Refer to “Chapter 17A cooling - coolant， replacement”)

13. AFTER INSTALLING THERMOSTAT, START ENGINE UNTIL COOLING FAN RUNNING AT HIGH
COOLING - COOLANT PUMP 17A-19
COOLANT PUMP
OVERHAUL
WARNING 17A
1. COOLING THE ENGINE TO NORMAL INDOOR TEMPERATURE.


accessory belt, overhaul”) 17A
6. REMOVE COOLANT PUMP PULLEY RETAINING

BOLTS.
7. REMOVE ENGINE TIMING BELT COVER. (Refer to “Chapter 15A engine mechanical - engine
timing belt cover, replacement”)
overhaul”)
9. REMOVE COOLANT PUMP RETAINING BOLTS.
10. REMOVE COOLANT PUMP GASKET.

17A-20 COOLING - COOLANT PUMP
11. USING A SCRAPER, CLEAN DIRT ON COOLANT PUMP AND ENGINE BLOCK CONNECT
SURFACE.
NOTE
Clean the dirt, do not damage coolant pump and engine block connect surface.
12. INSPECT COOLANT PUMP.
(a) Rotate coolant pump and it should turn smoothly.
(b) There should be no clearance between coolant pump shaft and coolant punp bearing, and no abnormal
noise when it turns.
(c) No coolant leaks around coolant pump.
13. INSTALL COOLANT PUMP GASKET. TO AVOID COOLANT LEAKAGE, USE COOLANT PUMP
SEALANT IF NECESSARY.
NOTE
After using the coolant pump sealant, wait for 15 minutes then fill the coolant.
14. TIGHTEN COOLANT PUMP RETAINING BOLTS.

Torque: 14 N•m
15. INSTALL ENGINE TIMING BELT. (Refer to “Chapter 15A engine mechanical - engine timing belt,
overhaul”)
16. INSTALL ENGINE TIMING BELT COVER. (Refer to “Chapter 15A engine mechanical - engine
17. TIGHTEN COOLANT PUMP PULLEY RETAINING

BOLTS.
Torque: 25 N•m
COOLING - COOLANT PUMP 17A-21

17A
22. AFTER REPLACING COOLANT PUMP, START ENGINE UNTIL COOLING FAN RUNNING AT HIGH
17A
MEMO
LUBRICATION
18A
LUBRICATION SYSTEM ................................................................. 18A-1
PRECAUTION............................................................................ 18A-1
COMPONENTS ......................................................................... 18A-2
ENGINE OIL ..................................................................................... 18A-4 18A
REPLACEMENT ........................................................................ 18A-4
OIL FILTER ...................................................................................... 18A-6
REPLACEMENT ........................................................................ 18A-6
OIL PAN ...........................................................................................18A-9 18A
REPLACEMENT ........................................................................ 18A-9
OIL PUMP ...................................................................................... 18A-11
OVERHAUL ............................................................................. 18A-11
18A
LUBRICATION - LUBRICATION SYSTEM 18A-1
LUBRICATION SYSTEM
LUBRICATION
PRECAUTION
1. LUBRICATION SYSTEM PRECAUTION. 18A
(a) 4G6 series engine lubrication system is a full-flow filtration, pressure feed type. The oil pump body is
mounted to the engine block. The pump inner rotor is driven by the crankshaft.
WARNING
Prolonged and repeated contact with engine oil will cause the skin fat to be removed, resulting in dry
skin, allergies and dermatitis. In addition, used engine oil contains potentially harmful pollutants which
may cause skin cancer. Therefore, the skin must be protected in appropriate methods and with
cleaning equipment.
(b) Avoid contacting with oil for a long time, especially the used engine oil.
(c) Wear protective clothing including waterproof work gloves.
(d) Avoid contaminated clothing, especially underwear containing the oil.
(e) Never put rags contaminated with oil in pockets.
(f) Avoid eyes contacting with oil, must wear goggles, In addition, equipment must be prepared to clean
the eye. And wrapping the wound must be dealt with immediately.
(g) Frequent use of soap and water can clean, especially before meals, and make sure all the oil has been
removed (skin cleansers can also be used to assist with the nail brush). After cleaning, it is
recommended to replace the natural skin oils cotton suet.
(h) Do not use gasoline, kerosene, diesel, thinner or solvent to clean skin.
(i) Before each work, apply cream to help skin cleaning after work.
(j) If your skin is abnormal, consult a doctor immediately.
18A
18A-2 LUBRICATION - LUBRICATION SYSTEM
COMPONENTS
LUBRICATION - LUBRICATION SYSTEM 18A-3
1 Drain Plug 16 O-ring
2 Oil Pan Bolts 17 Front Case Inside Bolt
3 Oil Filter 18 Front Case 18A
4 Oil Pan 19 Front Case Gasket
5 Oil Strainer 20 Oil Pump Cover
6 Oil Strainer Gasket 21 Oil Pump Driven Gear
7 Oil Pump Cover Bolt 22 Oil Pump Drive Gear
8 Engine Oil Pressure Switch 23 Front Crankshaft Oil Seal
9 Relief Plug 24 Balance Shaft Oil Seal
10 Gasket 25 Oil Pump Oil Seal
11 Relief Spring 26 Right Balance Shaft
12 Relief Plug 27 Left Balance Shaft
13 Oil Filter Bracket 28 Right Balance Shaft Front Bearing
14 Oil Filter Bracket Gasket 29 Right Balance Shaft Rear Bearing
15 Front Case Plug 30 Left Balance Shaft Bearing
18A
18A-4 LUBRICATION - ENGINE OIL
ENGINE OIL
REPLACEMENT
1. PARK VEHICLE IN LEVEL ROAD, SLOWLY PULL OUT OIL DIPSTICK, AND CHECK OIL LEVEL.
OIL LEVEL MUST BE LOCATED WITHIN THE OIL DIPSTICK MARK.
2. CHECK OIL WITHOUT EXCESSIVE POLLUTION, NO PETROL AND COOLING LIQUID MIXED.
THERE MUST BE ENOUGH CONCENTRATIONS AND LUBRICATION DEGREE.
3. START ENGINE AND ENSURE ENGINE COOLANT TEMPERATURE WITHIN 80 ~ 90 ℃ .
4. OPEN OIL FILLER CAP.
7. REMOVE OIL DRAIN PLUG.

WARNING
The engine oil maybe hot, be careful.
8. USING A SPECIAL CONTAINER, COLLECT USED OIL, DISPOSAL AS REQUIRED.

LUBRICATION - ENGINE OIL 18A-5
9. REPLACE WITH NEW DRAIN PLUG GASKET AND

TIGHTEN PLUG.
Torque: 34 ~ 45 N.m
18A
11. LOWER VEHICLE.

12. FILL ENGINE OIL.
Engine oil: 4 L
Oil filter oil: 0.3 L
NOTE 18A
Engine oil with ACEA A3/B3 and API SL (or higher) specifications of SAE 0W-30, 5W-30, 5W-40 are
allowed.
13. INSTALL OIL FILLER CAP.
14. PARK VEHICLE IN LEVEL ROAD, START ENGINE AND RUN FOR 5 MINUTES.
15. CHECK AND ENSURE THERE IS NO OIL LEAKAGE.
17. AFTER 8 MINUTES, PULL OUT OIL DIPSTICK,

ENSURE OIL LEVEL IS BETWEEN “MAX” MARK
AND THE “MIN” MARK.
18A-6 LUBRICATION - OIL FILTER
OIL FILTER
REPLACEMENT
NOTE
Without special circumstances, the oil filter should be replaced with engine oil replacement, which can
avoid oil pollution and keep engine operation.
4. REMOVE LOWER GUARD PLATE RETAINING

BOLTS.

WARNING
Be careful, the engine oil may be hot.
7. USING SPECIAL TOOL MD-991396 OR TOOLS SOLD

ON MARKET, REMOVE OIL FILTER.
8. CLEAN INTERFACE OF OIL FILTER AND OIL FILTER BRACKET.

LUBRICATION - OIL FILTER 18A-7
9. APPLY OIL TO NEW OIL FILTER O-RING.
18A
10. TIGHTEN OIL FILTER BY HAND UNTIL O-RING

TOUCHES OIL FILTER BRACKET. USE SUITABLE
TOOL TO TIGHTEN OIL FILTER.
11. TIGHTEN DRAIN PLUG.

18A
13. LOWER VEHICLE.

14. FILL ENGINE OIL TO SPECIFIED LEVEL.
18A-8 LUBRICATION - OIL FILTER
16. PARK VEHICLE IN LEVEL ROAD, START ENGINE AND BE RUNNING FOR 5 MINUTES.
19. AFTER 8 MINUTES, PULL OUT OIL DIPSTICK

LUBRICATION - OIL PAN 18A-9
OIL PAN
REPLACEMENT
18A
18A
WARNING

6. REMOVE OIL PAN RETAINING BOLTS.
7. DRIVE IN SPECIAL TOOL MD-998727 BETWEEN

CYLINDER BLOCK AND OIL PAN, THEN SEPARATE
THEM BY HAMMER.
NOTE
Never use screwdriver or chisel to remove the oil pan. It will
damage the oil pan flange and cause oil leakage.
8. CLEAN THE INTERFACE OF OIL PAN AND ENGINE BLOCK.

18A-10 LUBRICATION - OIL PAN
9. APPLY A 4MM WIDE BEAD OF SEALANT TO THE

ENTIRE CIRCUMFERENCE OF OIL PAN FLANGE.
NOTE
Circle the bolt hole with sealant strips around.
10. POSITION OIL PAN.

NOTE
Be sure to install the oil pan quickly while the sealant is wet (within 15 minutes).
11. TIGHTEN OIL PAN RETAINING BOLTS DIAGONALLY.
Torque: 6 ~ 7 N•m
NOTE
After installation, keep the sealant area away from the oil for about one hour.

13. INSTALL LOWER GUARD PLATE AND TIGHTEN

RETAINING BOLTS.

LUBRICATION - OIL PUMP 18A-11
OIL PUMP
OVERHAUL
18A

4. REMOVE OIL PAN. (Refer to “Chapter 15A, engine mechanical - oil pan, replacement”)
5. REMOVE OIL STRAINER RETAINING BOLTS.
18A
overhaul”)
7. REMOVE OIL FILTER BRACKET RETAINING BOLTS.
8. TAKE OIL FILTER BRACKET GASKET AWAY.

NOTE
If the gasket adheres to the interface, using soft squeegee, remove the residue. Be careful not to
damage the interface.
18A-12 LUBRICATION - OIL PUMP
9. DISCONNECT ENGNIE OIL PRESSURE WIRE HARNESS.

USING SPECIAL TOOL MD-998012, REMOVE ENGINE
OIL PRESSURE SWITCH.
10. USING SPECIAL TOOL MD-998162, REMOVE FRONT

CASE PLUG.
NOTE
If the plug is too tight, hit the plug head with a
hammer two or three times, and the plug will be easily
loosened.
11. REMOVE PLUG ON THE LEFT SIDE OF CYLINDER

BLOCK. INSERT A SCREWDRIVER (SHANK
DIAMETER 8 MM) INTO PLUG HOLE TO LOCK
BALANCE SHAFT.
12. REMOVE FRONT CASE INSIDE BOLT.
13. REMOVE FRONT CASE RETAINING BOLTS.

14. TAKE FRONT CASE AWAY AND INSPECT IT.

• Check oil holes for blocking and clean if necessary.
• Check left balance shaft front bearing section for wear, damage and seizure. If there are anything
damaged with the section, replace the front case. 18A
• Check the front case for cracks and other damage. Replace cracked or damaged front case if neces-
sary.
• Check the oil seal lip for wear and damage. Replace oil seal if necessary.
15. REMOVE OIL PUMP COVER RETAINING BOLTS.
16. INSPECT OIL PUMP GEAR.

• Using rules and feeler gauge, measure the gear
clearance.
Standard:
Drive gear: 0.08 ~ 0.14 mm
Dirven gear: 0.06 ~ 0.12 mm
18A
• Assemble the oil pump gear to the front case and rotate it
to ensure smooth rotation with no looseness.
• Ensure that there is no ridge wear on the contact surface
between the front case and the gear surface of the oil
pump cover.
17. TAKE OIL PUMP DRIVE GEAR AND DRIVEN GEAR AWAY.
18. REMOVE FRONT CRANKSHAFT OIL SEAL, BALANCE SHAFT OIL SEAL AND PUMP OIL SEAL.
NOTE
Oil seal can not be reused after removal.
19. USING SPECIAL TOOL MD-998371, REMOVE RIGHT

BLANCE SHAFT FRONT BEARING FROM
CYLINDER BLOCK.
NOTE
Be sure to remove the front bearing first, otherwise the rear
bearing puller cannot be used.
20. USING SPECIAL TOOL MD-998372, REMOVE LEFT

BALANCE SHAFT REAR BEARING FROM THE
CYLINDER BLOCK.
NOTE
Before removing left balance shaft rear bearing, install
special tool MB-991603 in front of cylinder block.
21. TAKE RIGHT AND LEFT BALANCE SHAFT AWAY AND INSPECT THEM.
(a) Check oil holes for blocking.
(b) Check journal for seizure, damage and contact with

bearing. If there is anything damaged with the journal,
replace balance shaft, bearing or front case assembly.
22. INSTALL LEFT BALANCE SHAFT REAR BEARING.

(a) Install special tools MD-998372 and MB-991603 to
cylinder block.
(b) Apply engine oil to the outer surface of bearing.
(c) Using special tool MD-998705, install the rear bearing.

NOTE
The left rear bearing hasn’t oil holes.
23. INSTALL RIGHT BALANCE SHAFT REAR.

(a) Align the ratchet ball of the special tool MD-998705 with
the oil hole in the rear bearing to install the bearing of the
special tool. 18A
(b) Apply engine oil to the front bearing outer surface and
bearing hole in the cylinder.
(c) Using special tool MD-998705, install the rear bearing.

Make sure that the oil hole of the bearing is aligned with
the oil hole of the cylinder block.
18A
24. REMOVE REAR BEARING INSTALLING PORTION

FROM SPECIAL TOOL MD-998705.
25. USING SPECIAL TOOL MD-998705, INSTALL FRONT

BEARING.
26. INSTALL OIL PUMP DRIVEN GEAR AND OIL PUMP

DRIVE GEAR.
(a) Apply engine oil generously to the gears and line up the
alignment marks.
27. TIGHTEN OIL PUMP COVER RETAINING BOLTS.

Torque: 10 N•m
28. USING AN APPROPRIATE SOCKET WRENCH,

INSTALL OIL PUMP SEAL.
29. USING AN APPROPRIATE SOCKET WRENCH,

INSTALL BALANCER SHAFT OIL SEAL.
30. USING SPECIAL TOOL MD-998375, INSTALL

CRANKSHAFT OIL SEAL.
31. INSTALL SPECIAL TOOL MD-998285 ON FRONT END

OF CRANKSHAFT AND APPLY A THIN COAT OF
ENGINE OIL TO THE OUTER SURFACE OF SPECIAL
TOOL. 18A
NOTE
Be sure to use the special tool when the front case is fitted
with an oil seal.
32. INSTALL A NEW FRONT CASE GASKET.
33. POSITION FRONT CASE AND TIGHTEN RETAINING

BOLTS TEMPORARILY.
34. INSTALL OIL FILTER BRACKET GASKET.
35. POSITION OIL FILTER BRACKET AND TIGHTEN

RETAINING BOLTS TEMPORARILY. 18A
36. REMOVE PLUG ON THE LEFT SIDE OF CYLINDER

BLOCK. INSERT A SCREWDRIVER (SHANK
DIAMETER 8 MM) INTO PLUG HOLE TO LOCK
BALANCE SHAFT.
37. TIGHTEN FRONT CASE INSIDE BOLT.

Torque: 36 N•m
38. TIGHTEN FRONT CASE RETAINING BOLTS.

Torque: 24 N•m
39. TIGHTEN OIL FILTER BRACKET RETAINING BOLTS.
Torque: 19 N•m
40. INSTALL NEW O-RING.
41. USING SPECIAL TOOL MD-998162, TIGHTEN FRONT

CASE PLUG.
42. APPLY SEALANT TO THE THREADED PORTION.

NOTE
• Specified Sealant: 3M ATD Part No.8660 or
equivalent
• Keep the end of threaded portion clean.
• Avoid an over tightening.
• Be careful not to block the oil passage with sealant.
43. USING SPECIAL TOOL MD-998012, TIGHTEN

ENGINE OIL PRESSURE SWITCH. CONNECT
ENGINE OIL PRESSURE SWITCH WIRE HARNESS.
44. TIGHTEN OIL STRAINER RETAINING BOLTS.
18A
45. INSTALL OIL PAN. (Refer to “Chapter 15A, engine mechanical, replacement”)
46. LOWER VEHICLE.

18A
MEMO
IGNITION
19A
IGNITION SYSTEM .......................................................................... 19A-1
COMPONENTS ......................................................................... 19A-1
IGNITION COIL/SPARK PLUG WIRE/SPARK PLUG
OVERHAUL ............................................................................... 19A-2 19A
19A
19A
IGNITION - IGNITION SYSTEM 19A-1
IGNITION SYSTEM
IGNITION
COMPONENTS
19A
19A
1 Ignition Coil Bracket 3 Spark Plug Wire
2 Ignition Coil 4 Spark Plug

19A-2 IGNITION - IGNITION SYSTEM
IGNITION COIL/SPARK PLUG WIRE/SPARK PLUG OVERHAUL


4. REMOVE THROAT ELBOW CLAMP.
5. PULL OUT SPARK PLUG WIRE BY SLIGHTLY

TURNING.
6. DISCONNECT IGNITION COIL CONNECTOR.

7. REMOVE IGNITION COIL RETAINING BOLTS.
19A
8. REMOVE AND INSPECT SPARK PLUG WIRE.

NOTE
Before disconnecting the spark plug wire on the ignition coil, confirm the spark plug position on the
ignition coil and mark it.
• Check if there is spark plug wire break down traces.
• Check if the spark plug wire resistance ≥ 4 KΩ.
9. REMOVE AND CHECK IGNITION COIL.
• Check if the ignition module crack exists.
• Check ignition coil condition.
(a) Using KT600, ensure there is no DTC. If there is DTC, record it. Ensure that the DTC fault is resolved
even the DTC is unrelated with ignition system.
(b) Pull out fuel pump relay.
(c) Lightly pull out spark plug wire and remove the spark plug.
(d) Install a new spark plug to the spark plug wire, touch spark plug negative to the engine cylinder block.
(e) Start engine, check the flash over.
(f) If the flash over is weak or no flash over, replace with a new ignition coil. After replacing with the new 19A
ignition coil, the flash over become strong, we can ensure the ignition coil has damage. If there is still
no flash over, check the ignition circuit and inspect the spark plug.
(g) Using KT600, clear DTC.
10. INSPECT SPARK PLUG.

(a) Check spark plug insulator outer surface for the
existence of cracks.
(b) Check spark plug flash over for the existence of carbon
deposition.
(c) Check spark plugs for the existence of positive and
negative ablation.
(d) Check spark plug gap.
Stardand value: 0.7 ~ 0.8 mm
11. INSTALL SPARK PLUG.

12. INSTALL SPARK PLUG WIRE TO IGNITION COIL AS THE MARKS BEFORE REMOVING.
19A-4 IGNITION - IGNITION SYSTEM
13. TIGHTEN IGNITION COIL RETAINING BOLTS.

Torque: 5 ~ 8 N.m
14. INSTALL SPARK PLUG WIRE TO SPARK PLUG.
15. CONNECT IGNITION COIL CONNECTOR.
16. INSTALL THROAT ELBOW CLAMP.


19A
19. LOWER VEHICLE.

20. START ENGINE AND INSPECT ENGINE OPERATION CONDITION.
19A
MEMO
STARTING AND CHARGING
20A
STARTING AND CHARGING SYSTEM .......................................... 20A-1
PRECAUTION............................................................................ 20A-1
GENERATOR ................................................................................... 20A-4 20A
COMPONENTS ......................................................................... 20A-4
OVERHAUL ............................................................................... 20A-5
STARTER ....................................................................................... 20A-12
COMPONENTS ....................................................................... 20A-12 20A
OVERHAUL ............................................................................. 20A-13
BATTERY ....................................................................................... 20A-22
COMPONENTS ....................................................................... 20A-22
USE AND MAINTENANCE ...................................................... 20A-23
INSPECTION ........................................................................... 20A-25
BATTERY COMMON PROBLEMS, THE CAUSES ANALYSES AND
TROUBLESHOOTING ............................................................. 20A-26
REPLACEMENT ...................................................................... 20A-27
20A
STARTING AND CHARGING - STARTING AND CHARGING SYSTEM 20A-1
STARTING AND CHARGING SYSTEM

PRECAUTION
1. STARTING AND CHARGING SYSTEM PRECAUTION. 20A
(a) Battery may have escaping explosive gas. In order to avoid personal injury, before maintaining battery,
keep ventilated in engine room. To avoid electric arc, disconnect battery negative cable first and
connect the negative cable last.
(b) Battery electrolyte is very dangerous. It can damage the machine and cause serious burns. when
maintaining battery, prepare neutralizers concentration soda water, wear safety eyepiece and wear
protective clothing, which can avoid personal injury.
(c) When using compressed air, wear appropriate goggles and protective mask. Dust particles and dirt can
cause injury.
(d) Don't tighten the electrical connectors excessive, which may damage the starter.
(e) Never short two cables of the battery, it will cause a rapid battery fever even a explosion occur. The
escaping gas from battery is easily be burned by the spark, so do not use fire near battery.
(f) After the generator operation, do not try to use spark check whether the generator works. use bulb or
multimeter to perform the test. Otherwise it will damage the generator diode.
(g) Check the generator silicon rectifier devices, multimeter and 220 V check is strictly forbidden to check
generator insulation, otherwise it will make diode breakdown and damaged.
20A
20A-2 STARTING AND CHARGING - STARTING AND CHARGING SYSTEM

cause of the problem. Check each part in order. If necessary, replace these parts.
1. Starter switch control circuit -

(Open)
2. Brush and rectifier (Poor Chapter 20A starting and charging -

Starter out of operation
connection) starter, overhaul
3. Starter inside circuit (Open or Chapter 20A starting and charging -

short) starter, overhaul
Chapter 20A starting and charging - bat-

1. Battery (Low voltage) tery, use and maintenance
2. Starter wire (Poor connection) -
3. Rectifier (Surface damage or -

stains)
Starter loss power, can not
srart engine 4. Brush (Wear) or Brush spring Chapter 20A starting and charging -
(Loss elastic force) starter, overhaul
5. Solenoid switch (Contacts Chapter 20A starting and charging -

ablation) starter, overhaul
6. Bearing (Wear)， commutator Chapter 20A starting and charging -

(Wipe shell) starter, overhaul
1. Starter relay (Copper contacts Chapter 20A starting and charging -

bond) starter, overhaul
Starter keep working after 2. Starter commutator (Bend or Chapter 20A starting and charging -
engine start break) starter, overhaul
3. Starter gear tooth surface contact Chapter 20A starting and charging -
(Roughening or stuck) starter, overhaul
1. Generator connect wire -
Chapter 20A starting and charging -

2. Rotor winding (Open) generator, overhaul

Generator out of operation 3. Rectifier diode (Damaged) generator, overhaul

4. Brush (Poor connection) generator, overhaul

5. Regulator (Damaged) generator, overhaul
STARTING AND CHARGING - STARTING AND CHARGING SYSTEM 20A-3

Chapter 15A engine mechanical -
1. Belt losing tensity engine accessory belt, overhaul
20A
2. Brush (Poor connection) or collec- Chapter 20A starting and charging -
Generator loss enough tor ring (Burn) generator, overhaul
electricity
3. Regulator (Damaged) generator, overhaul
Chapter 20A starting and charging - bat-

4. Battery lose electrolyte tery, use and maintenance
20A
20A-4 STARTING AND CHARGING - GENERATOR
GENERATOR
COMPONENTS
1 Generator Belt Pulley 8 Anchor Plate
2 Rotator Component 9 Regulator And Brush Carriage
3 Rear Bearing 10 Brush
4 Bearing Carrier 11 Brush Ring
5 Front Bearing 12 Rectifier Component
6 Front Cover 13 Back Cover
7 Stator Component
STARTING AND CHARGING - GENERATOR 20A-5
OVERHAUL
(a) Remove 4 engine cover retaining bolts. 20A
2. COOL ENGINE, MAKE BELT TEMPERATURE BE CLOSED TO NORMAL TEMPERATURE.

3. ROTATE GENERATOR BELT AND CHECK FOR CRACK.
4. LOOSEN NUT ATTACHING GENERATOR TO GENERATOR

BRACKET.
5. LOOSEN TENSIONER LOCKED NUT.

6. ROTATE TENSIONER BOLT ASJUST TENSITY OF
GENERATOR BELT.
20A
7. REMOVE GENERATOR BELT.

8. LOOSEN GENERATOR POSITIVE CABLE CONNECT NUT.
9. DISCONNECT GENERATOR CONNECTOR.
10. REMOVE GENERATOR RETAINING BOLTS.
11. REMOVE GENERATOR.

12. USING PNEUMATIC TOOLS, REMOVE GENERATOR

BELT PULLEY RETAINING NUT.
13. REMOVE RETAINING BOLTS ATTACHING GENERATOR

FRONT COVER TO STATOR COMPONENT.
14. INSERT SCREWDRIVER TO THE INTERVAL BETWEEN FRONT COVER AND STATOR AND
SEPARATE THEM.
NOTE
• If they are difficult to be separated, slap the front cover slightly with rubber hammer and pry it
with screwdriver.
• Do not insert screwdriver too deep to prevent stator component damaged.
15. USING A ELECTRIC IRON (180 ~ 250 W), REMOVE

STATOR. THIS OPERATION SHOULD BE WITHIN 4
SECONDS TO PREVENT TRANSMITTING HEAT TO
DIODE.
16. REMOVE 4 RETAINING BOLTS FROM RECTIFIER.

17. USING A ELECTRIC IRON, REMOVE RECTIFIER FROM

REGULATOR.
20A
NOTE
• Ensure that heat is not transmitted from electric iron to diode for long time.
• Do not let diode pin bear too much force.
18. REMOVE AND INSPECT ROTOR.

(a) Check the rotor coil is conductive, and confirm that the
collector rings are conductive. Measure the resistance of
rotor. If the resistance is less than specified value, it
means the rotor is short circuit. If it is not conductive or it
is short circuit, replace the rotor assy.
Specified value: 3 ~ 5 Ω
(b) Check that rotor coil ground. Confirm that it is insulative

between collector ring and core. If not insulative, replace
the rotor assy.
20A
(c) Using a vernier caliper, measure the slip ring diameter.

Limit: 12.8 mm
19. REMOVE AND INSPECT STATOR.

(a) Check the stator for continuity. Confirm that the coil lead
is conductive. If not, replace the stator assy.
(b) Check the coil ground. Confirm that it is conductive

between coil and stator core. Replace the stator assy if
not conductive.
20. INSPECT STATOR RECTIFIER.

(a) Diode group (three diodes) check: Using an ammeter
connect two ends of each diode, check if three diodes
are conductive. If it is not conductive in both directions, it
means the diodes are broke down, and it is required to
replace the rectifier assy.
21. GET RID OF WELDING POINT OF BRUSH LEAD, THEN

TAKE OUT THE BRUSH.
22. IF BRUSH IS SO WORN TO REACH WEARING LIMIT

LINE, REPLACE BRUSH.
23. WHEN INSTALLING NEW BRUSH, WELD BRUSH

LEAD IN THE CONDITION WHEN BRUSH IS
PRESSING DOWN BRUSH BRACKET AS SHOWN.
20A
24. TIGHTEN 4 RETAINING BOLTS FROM RECTIFIER.

Torque: 6 ~ 8 N•m
25. WELD RECTIFIERS AND STATOR CONNECTION.
20A
26. BEFORE MOUNTING ROTOR ON REAR COVER,

INSERT A STEEL WIRE INTO SMALL HOLE ON
REAR CAP, THEN ERECT MOUNTED ROTOR BY
BRUSH, PULL OUT STEEL WIRE.
27. INSTALL ROTOR.

28. INSTALL RETAINING BOLTS ATTACHING GENERATOR

29. POSITION GENERATOR BELT PULLY. USING PNEUMATIC TOOLS, INSTALL GENERATOR BELT
PULLEY RETAINING NUT.
30. POSITION GENERATOR.
31. POSITION GENERATOR BELT.
32. ADJUST TENSIONER BOLT AND TIGHTEN LOCK NUT.

33. TIGHTEN NUT ATTACHING GENERATOR TO GENERA-

TOR BRACKET.

20A
20A
20A-12 STARTING AND CHARGING - STARTER
STARTER
COMPONENTS
1 Front Bracket 11 Overdrive Clutch
2 Spring 12 Locating Snap Ring
3 Starter Drive Lever 13 Magnet Yoke Assy
4 Rubber Washer 14 Commutator
5 Planetary Gear Bracket 15 Brush
6 Solenoid Component 16 Brush Bracket
7 Rubber Washer 17 Starter Shell Bolt
8 Steel Ball 18 Rear Bearing
9 Planetary Gear 19 Rear Bracket
10 Internal Gear
STARTING AND CHARGING - STARTER 20A-13
OVERHAUL

4. REMOVE 2 STARTER RETAINING BOLTS.
5. REMOVE STARTER ELECTRICAL WIRE CONNECTING

NUT.
20A
6. DISCONNECT STARTER CONTROL WIRE CONNEC-

TOR.
7. REMOVE STARTER AND INSPECT IT.

(a) Pinion gap adjustment.
• Disconnect the field coil wire from the M-terminal of the
magnetic switch.
• Connect a 12-volt battery between the S-terminal and M-
terminal.
NOTE
This test must be performed quickly (less than 10 seconds)
to prevent the coil from burning.
• When the 12-volt battery is connected between the S-

terminal and M-terminal, the pinion will move out.
• Check the pinion-to-stopper clearance (pinion gap) with

a feeler gauge.
• If the pinion gap is out of specification, adjust by adding

or removing gasket(s) between the magnetic switch and
front bracket.
(b) Magnetic switch pull-in test.

magnetic switch.
terminal.
NOTE
• If the pinion moves out, the pull-in coil is good. If it

doesn't, replace the magnetic switch.
(c) Magnetic switch hold-in test.

magnetic switch.
• Connect a 12-volt battery between the S-terminal and 20A
body.
NOTE
• Manually pull out the pinion as far as the pinion stopper

position.
• If the pinion remains out, everything is operating prop-
erly. If the pinion moves in, the hold-in circuit is open.
Replace the magnetic switch.
(d) Magnetic switch return test.

magnetic switch.
• Connect a 12-volt battery between the M-terminal and
body.
NOTE
• Pull the pinion out and release. If the pinion quickly

returns to its original position, everything is operating
properly. If it doesn't, replace the magnetic switch.
20A
WARNING
Be careful not to get your fingers caught when pulling out
the pinion.
8. DISCONNECT MAGNETIC COIL LEAD NUT FROM

MAGNETIC SWITCH.
9. REMOVE MAGNETIC SWITCH RETAINING BOLTS.
10. REMOVE STARTER SHELL RETAINING BOLTS.
11. DISASSEMBLY STARTER AS COMPONENTS ART SHOWN.

NOTE
When removing commutator, do not lose the steel ball mounted in the bearing ends.
(a) Using a proper control sleeve, push and press the

locating snap ring to the overdrive clutch side, and make
it brake away from the clip spring.
(b) Remove the snap spring with snap ring pliers, then
remove the locating snap ring and overdrive clutch.
12. CLEAN STARTER PARTS.

NOTE
• Do not put the parts in the detergent for cleaning. If the magnet yoke, excitation winding lead or
rotor is immerged in detergent, their insulating ability is damaged.
• Clean starter parts with cloth.
• Drive parts can not be immerged in detergent for cleaning. Before delivering out of factory, the
overdrive clutch is greased. If clean it by detergent, its grease might be removed.
• Using a brush and dipping with detergent, clean drive parts then dry them with a cloth.
20A
13. INSPECT COMMUTATOR.
(a) Support the commutator with a pair of V block and turn it
to measure the runout of the surface using a dial gauge.
Standard: ≤ 0.05 mm
Limit: 0.1 mm
(b) Measure the diameter of the commutator.

Standard: 29.4 mm
Limit: 28.4 mm
(c) Measure the depth of the undercut between segments.

Standard: 0.5 mm
Limit: 0.2 mm
20A
14. INSPECT BRUSH AND BRUSH BRACKET.

(a) Check that it is conductive between brush plate and brush bracket, if not conductive, it is normal.
(b) Check the commutator contact surface of each brush for abnormal roughness. Also check the height of
the brush. Replace the brush holder if the height is lower than the limit.
Limit: 7.0 mm
(c) When the contact surface of the brush is rectified or the brush holder is replaced, recondition the
contact surface with sandpaper wrapping around the commutator.
15. INSPECT OVERDRIVE CLUTCH.

(a) Make sure that the pinion can not be turned
counterclockwise and can be turned clockwise freely.
(b) Check the pinion for abnormal ware and damage.
16. INSPECT ARMATURE COIL.

(a) Set the armature in a growler.
(b) While holding a thin strip of iron against the armature in
parallel with its axis, turn the armature slowly. The
armature is normal if the iron strip is not attracted to the
armature or it does not vibrate.
NOTE
Clean the surface of the armature thoroughly before
performing the test.
(c) Check the insulation between commutator segments and

armature coils. The armature coils are properly insulated
if no continuity is present.
(d) Check continuity between a segment and another. It is

normal if there is continuity.
17. INSPECT MAGNETIC SWITCH.

(a) Coil open circuit test.
• Check that there is continuity between the M terminal
and body A.
• If there is no continuity, replace the magnetic switch.
(b) Contact fusion check.

• Check that there is no continuity between the B terminal
and M terminal.
20A
• If there is continuity, replace the magnetic switch.
(c) Switch contact check.

• Push the indicated end of the magnetic switch with a
strong force to close the internal contacts. Without
releasing the switch end, check that there is continuity
between the B terminal and M terminal.
18. USING A SUITABLE PULLER, PULL STOP RING UNTIL

IT GETS OVER SNAP RING.
20A
19. INSTALL LOCATING SNAP RING AND OVERDRIVE

CLUTCH.
20. ASSEMBLY STARTER AS COMPONENTS ART SHOWN.

21. TIGHTEN STARTER SHELL RETAINING BOLTS.

22. TIGHTEN MAGNETIC SWITCH RETAINING BOLTS.

23. CONNECT MAGNETIC COIL LEAD NUT FROM

MAGNETIC SWITCH.
24. CONNECT STARTER ELECTRICAL WIRE CONNECTING

NUT.
25. CONNECT STARTER CONTROL WIRE CONNECTOR.

26. TIGHTEN 2 STARTER RETAINING BOLTS.

20A
27. LOWER VEHICLE.


20A
20A-22 STARTING AND CHARGING - BATTERY
BATTERY
COMPONENTS
Lead-acid battery consists of plus and minus plate, partition, sulfuric acid electrolyte, battery shell.
1 Negative Terminal 5 Overall Groove
2 Battery Cover 6 Negative Plate
3 Cross Wall Connect 7 Partition
4 Bus Bars 8 Positive Plate

STARTING AND CHARGING - BATTERY 20A-23
USE AND MAINTENANCE

1. CHARGING DEVICE.
NOTE 20A
DC power supply must be used for battery charging, howerever, what is supplied by power plant is AC
that it must be transformed into DC, After transform, the charging can be performed.
(a) Rectifier.
(b) Controllable silicone voltage regulation charger.
2. CHARGE PRECAUTIONS
(a) Charging should choose in ventilated dry room, indoor temperature in 5 ℃ ~ 40 ℃ is advisable.
(b) Battery can not be overlap shelved, also do not put them on the ground directly. It should be put on the
wooden support, and cannot be set with alkaline battery or other chemicals.
(c) Charging in field should be far away from fire and heat.
(d) Liquid temperature should not exceed 45 ℃ and otherwise cooling measures shouldl be taken(by
reducing filling current or stopping sharge or being cooled down in water tank)
3. CHARGE CONNECTION.
(a) The positive pole of charger is to be connected with the positive pole of battery, while the negative pole
of charger should be connected with the negative pole of battery. Never connect them reversely.
(b) Charge of most batteries may be determined based on the size of moter power. Connection for charge
must be firm.
4. CHARGING MODES.
(a) Constant current charge.
(b) Constant voltage charge.
(c) Quick charge.
5. AFTER CHARGING, USING THE BELOW METHODS, CHECK THE BATTERY CAPACITY IS
RESTORED TO STANDARD.
(a) Voltage method
20A
Voltage Determination Treatment
Above 12.5 v Normal Go on using
11.5 ～ 12.5 v Undercharge Additional charge
Below 11.5 v Over-discharge or internal failure To be further checked after charging
(b) Capacity method
Capacity Tester Display Determination Treatment

White zone Fully charged Go on using
Green zone Normal Go on using
Yellow zone Undercharge Additional charge
Red zone Over-discharge To be further checked after charging

6. USING AND MAINTENANCE OF BATTERY IN WINTER.

(a) Keep the battery is to be maintained under full charge status, avoid the electrolyte from being frozen
arising from drop in density, which may give rise to breakage of container, curve of pole plats, as well as
smash and dropout of active substances, and other failures.
(b) Because the battery capacity reduced in winter, when start the engine in cold status, preheated the
engine and each time start the engine should not more than 15 seconds, two starting interval 2 ~ 3
minutes, if can not start the engine in three times, troubleshooting, then restarting.
INSPECTION
1. APPEARANCE INSPECTION.
(a) Observe whether the battery appearance in good condition. Check if fixed terminal and wires are
connected firmly. 20A
(b) Observe whether the battery shell and the center partition cracks, and use a wooden beat shell and
center partitions respectively, listen to the sound without breaking, especially the central baffle and shell
side of shell wall at the junction of four, prone to crack, should be carefully examined.
(c) Through mirrors, green for fully charged, red and white said lack of electricity and no electricity. Need of
the following capacity, voltage detection.
2. CAPACITY TEST.
(a) The excel tester is also known as the discharging tongs.

It consists of a DC voltmeter of three volts and one load
resistance.
(b) The tips of the two tongs shall be press on the anode and
the cathode tightly and maintain for five seconds in the
measurement. Observe the terminal voltage in the state
of the big load discharging and the discharging content
and the starting ability can be judged correctly.
(c) For the excel tester of different brands, the readings of
the current and the voltage shall be read according to the
regulations of the factory manual. Generally, the single
voltage of the battery in good state shall be above 1.5 V
and keep steady within five seconds. If the voltage drops
rapidly within five minutes or the voltage of one single
cell is 0.1 V lower than that of others, it indicates there
are troubles in the battery and it shall be repaired.
Below is the use of excel tester of discharge plan detection income cross-references.
20A
Display Zone Determination Treatment
3. VOLTAGE TEST.
The following table is derived using the digital multimeter test table.

Above 12.5 V Normal Go on using
11.5 ~ 12.5 V Undercharge Additional charge
Under 112.5 V Over-discharge or internal fault To be further checked after charging


TROUBLESHOOTING
1. Electrical quality of one full-charged battery reduce without use for a long period.
• Causes analyses:
The full-charged battery without use will lose its electrical quality gradually and this phenomenon is
known as “self-discharge”. The important cause of self-discharge is the impure materials. If there are
impurities in the material of the polar plate or in the electrolyte, there will be a potential difference
between the impurity and the polar plate and between the impurities. A closed “local current” is formed
and would make the discharge of the battery.
• Troubleshooting:
For the battery which has discharged seriously, it can be discharged completely or excessively. This will
enable the impurities on the polar plate into the electrolyte. Then, pour the electrolyte out and clean the
battery with distilled water. Finally, inject the new electrolyte and re-charge the battery.
2. Battery explode.
The water in the electrolyte hydrolyzes into hydrogen or oxygen and a lot of bubbles are generated;
there are short circuit and vulcanization troubles in the battery; the temperature increases while
charging and large amount of water are evaporated. Then if the vent holes of the injection hole cover
are plugged or there are a lot of gases which are unable to escape, the battery will explode when the
inner pressure comes to a limit (or there are sparks).
(a) The vent holes of the injection hole cover shall be cleared.
(b) In order to avoid sparks, the wirings on the polar stud shall be fastened.
(c) The injection hole cover shall be opened first when check with the excel tester.
(d) Control the charging amount and do not over-charge in order to reduce the releasing amount of the
gases. Open flames are prohibited and the ventilation shall be ensured in the charging room.
3. Rapid decrease of the liquid level during the use process of the battery.
(a) Excessive charging current lead to evaporation of water.
(b) Battery shell broken.
(a) Add distilled water.
(b) Repair shell, add the electrolyte.
4. Battery cover produce a yellow or white paste.
The yellow or white paste surrounding the battery cover and the polar stud is caused by the corrosion of
the polar studs, wiring clip and the fixed frame by the sulfuric acid sprayed.
In order to avoid these pastes, clean the electrolyte sprayed on the battery cover and the shell with a
cloth soaked with the soda solution of 10 percents. Then wipe with water and dry with a clean cloth.
The paste on the wire ends and the studs shall be wiped with the cloth soaked with soda solution. If
there are oxides of poor conductivity, scrape them with a little knife and clean them. It would be best to
smear a coat of Vaseline or butter on the cover after the polar studs and wiring clips are fastened.
REPLACEMENT
3. LOOSEN BATTERY CABLE RETAINING BOLTS AND

DISCONNECT BATTERY NEGATIVE / POSITIVE CABLE.
NOTE
Take off the battery negative cable first.
4. LOOSEN BATTERY HOLD DOWN RETAINING BOLTS.
20A
5. REMOVE BATTERY HOLD DOWN.
6. REMOVE BATTERY.
NOTE
Battery should be put up, placing upside down the battery is avoided.
7. REMOVE 4 BATTERY TRAY RETAINING BOLTS.
8. REMOVE 4 BATTERY TRAY BRACKET RETAINING

BOLTS.
9. TIGHTEN 4 BATTERY TRAY BRACKET RETAINING

BOLTS.
10. TIGHTEN 4 BATTERY TRAY RETAINING BOLTS.

11. POSITION BATTERY.

12. TIGHTEN BATTERY HOLD DOWN RETAINING BOLTS.

20A
13. CONNECT BATTERY NEGATIVE/POSITIVE CABLE AND

TIGHTEN BATTERY CABLE RETAINING BOLTS.
NOTE
• If terminals has sediments, remove the impurities
then apply thin layer of grease to terminal.
• Connect positive battery cable first when installing.

20A
MEMO
11B
ENGINE CONTROL SYSTEM.......................................................... 11B-1
PRECAUTION............................................................................ 11B-1
SYSTEM OVERVIEW ................................................................ 11B-2
SYSTEM FUNCTION INTRODUCTION .................................... 11B-7 11B
BASIC PRINCIPLE .................................................................... 11B-9
MAIN COMPNNENTS.............................................................. 11B-14
ENGINE CONTROL MODULE (ECM) ........................................... 11B-16
PRINCIPLE .............................................................................. 11B-16 11B
REPLACEMENT ...................................................................... 11B-17
ENGINE COOLANT TEMPERATURE SENSOR........................... 11B-23
PRINCIPLE .............................................................................. 11B-23
OVERHAUL ............................................................................. 11B-24
CAMSHAFT POSITION SENSOR ................................................. 11B-27
PRINCIPLE .............................................................................. 11B-27
ON-VEHICLE INSPECTION .................................................... 11B-28
OVERHAUL ............................................................................. 11B-29
ACCELEARTOR PEDAL POSITION SENSOR............................. 11B-31
PRINCIPLE .............................................................................. 11B-31
INSPECTION ON VEHICLE .................................................... 11B-32
REPLACEMENT ...................................................................... 11B-33
MAF SENSOR ................................................................................ 11B-38
PRINCIPLE .............................................................................. 11B-38
OVERHAUL ............................................................................. 11B-39
CKP SENSOR ................................................................................ 11B-41
PRINCIPLE .............................................................................. 11B-41
OVERHAUL ............................................................................. 11B-42
ODOMETER SENSOR ................................................................... 11B-44
PRINCIPLE .............................................................................. 11B-44
ON-VEHICLE INSPECTION .................................................... 11B-45
11B
OVERHAUL ............................................................................. 11B-46
COMMON RAIL PRESSURE SENSOR......................................... 11B-48
PRINCIPLE .............................................................................. 11B-48
REPLACEMENT ...................................................................... 11B-49
ENGINE CONTROL SYSTEM - ENGINE CONTROL SYSTEM 11B-1

PRECAUTION
1. POWER OFF. 11B
• The battery negative cable must be disconnected first before removing or installing any electric
appliance and when tools or facilities will touch the exposed terminals. It should be connected
eventually. This will prevent person injured and vehicle damaged.
• The ignition switch must be OFF without any special descriptions.
WARNING
The ignition and illuminatioin switches must be shut off before removing or installing the battery nega-
tive cable (the semiconductor maybe damaged without doing that).
2. THE PRECAUTION OF OPERATION.
(a) Please do disassembly and assembly and testing in accordance with the provisions introduced in this
manual during maintenance.
(b) Clear off the sundries on the mounting surface with a sealant scraper or a wire brush and confirm the
sealing face is level and smooth and no greasy dirt on it before the installation. Don’t forget to remove
the sealant on the mounting hole, the threaded hole and the thread.
(c) Paint some sealant evenly on the prescribed diameters to surround the mounting hole. The sealant not
hardened yet can be scraped away. Install it in place when the sealant is wet (within 15 minutes). Take
care not to stick the sealant to the place where it's not desired during installation. Wait the sealant to be
very hardened (1 hour or so) after installation. Don’t apply oil on the painted parts or wet or start the
engine during this time.
(d) Tighten the straining bolts with prescribed torque during installing the sensors, actuators or other parts.
Ensure the diesel engine always in clean and complete state. Clean or wipe up the parts to ensure the
clean parts and the assembly quality before removing and assembling the parts. The complicated
adjustment and maintenance should be taken indoors to avoid the diesel engine polluted by the
environment.
(e) Don’t test the ecm or the sensor with an analogue multimeter but with a digital multimeter with high
impedance unless specified otherwise during the testing.
(f) When installing and handling sensors, handle them gently to avoid damage, any impact or falling may
cause severe damage. 11B
(g) Don’t start the engine in a long time to avoid damaging the three-way catalyst at under voltage battery
or engine failure.
(h) Don’t test the system electrical signal by use of a fine needle to pierce the harness.
(i) Take a visual inspection to check if the sensing element at the head of sensor is damaged or color
changed; Replace it if it's damaged or the color is severe changed.
(j) As most electric sprayed parts are un-repairable, after confirm the part is damaged, replace it generally.
(k) Prevent ecm form static electricity. The static electricity can damage or even destroy ecm and other
electronic elements, making the device damaged completely and unable to work or hard to determine
the cause of failure. ecm installed on the whole vehicle has a function of preventing static electricity. but
if removed from the whole vehicle, it doesn't have the function of preventing static electricity. So, do
take care to ground when removing ecm from the whole vehicle.
(l) The connector on ecm can be unplugged only 90 seconds after the ignition switch OFF.
(m) ECM should be firmly installed and the installation position should be waterproof and dustproof and not
allowed to be soaked in water or other liquid.
(n) ECM can’t be disassembled for testing and maintenance, but basic testing can be done.
11B-2 ENGINE CONTROL SYSTEM - ENGINE CONTROL SYSTEM
SYSTEM OVERVIEW
1. INTRODUCTION.
BJ493ZQ3 diesel engine adopts the second generation common rail Electronic Fuel Injection (EFI) system
with 3 times injections capacity made by Bosch corporation. The max injection pressure is 145 MPa and 3
times injections can be done, including pre-injection, main injection and post-injection. The main contribution of
the common rail fuel injection system is to separate the generation of injection pressure with the injection pro-
cess completely and to disassociate the high pressure oil pipe pressure with the engine speed through the pre-
cise control of oil pressure in the common rail pipe. But the injection pressure of common rail is lower than that
of pump injector system. As the wide regulation of fuel injection pressure, the vehicle with diesel engine adopt-
ing common rail technology can be better adapted to every condition and the starting is easy.
Bosch the second generation common rail system can change its output pressure based on the engine
requirements. Equipped with oil pump controlling the fuel delivery, even in condition of low pressure, the sys-
tem also can provide proper injection pressure in accordance with actual conditions. It can not only help
reduce the fuel consumption and make the exhaust clean, but also reduce the fuel temperature so as to make
the fuel cooling device unnecessary. Pre-injection reduces the engine noise: Within a millionth of a second
before the pre-injection, a small quantity of fuel is injected into the cylinder for compression ignition, preheating
the combustion chamber. The cylinder after preheated makes the compression ignition after main injection
easier and the pressure and temperature in the cylinder no longer increased suddenly, helpful to reducing the
combustion noise. Post-injection takes place in expansion process and secondary combustion occurs, increas-
ing the temperature in the cylinder by 200 ～ 250 ℃ and reducing the hydrocarbon in the exhaust gas. The fea-
tures of this technology are:
(a) Adopts advanced electronic control device and equipped with high-speed solenoid switch valve, makes
the control of injection process quite convenient. A good many controllable variables are good for the
whole process optimization of the diesel engine combustion process.
(b) Adopts the common rail type for fuel supply, with small pressure fluctuation of fuel injection system, little
interaction between injection nozzles, high precision of injection pressure control and accurate control
of injected fuel quantity.
(c) High frequency response and flexible control of high-speed solenoid switch valve enlarges the
adjustable range of injection pressure of the fuel injection system and realizes the function of pre-
injection and post-injection conveniently, provides efficient methods for optimizing the diesel engine fuel
delivery law, improving its performance and reducing exhaust emission.
2. DIESEL ENGINE COMMON RAIL CONTROL SYSTEM.
• Preheating control
• Mileage memory 11B
• Over voltage pretection
• High pressure fuel pum pcontrol
• Exhaust Gas Recirculation (EGR)
• Speed control
ECM control function
• Totally main power relay control
• A/C, cooling fan control
• Common rail pressure control
• Electric fuel injection control (Include camshaft position sensor judgment)
• Mass Air Flow (MAF) sensor
• Trouble self diagnosis
11B
3. ECM CONTROL STRUCTURE.

4. ENGINE CONTROL SYSTEM DIRGRAM.
11B
1 Engine Control Module (ECM) 9 Sensor
2 Crankshaft Position (CKP) Sensor 10 High Pressure Common Rail
3 Camshaft Position (CMP) Sensor 11 Common Rail Pressure Sensor

11B
4 Accelerator Pedal Position (APP) Sensor 12 High Pressure Pump
Engine Coolant Temperature (ECT)/ 13 Secondary Filter

5
Cooling Fan Temperature Sensor
14 First Filter With Manual Fuel Pump
6 Mass Air Flow (MAF) Sensor
15 Tank With First Filter
7 Injector
16 High Pressure Part
8 Actuator
17 Low Pressure Part
5. ENGINE CONTROL SYSTEM MAIN COMPONENTS DISTRIBUTION GRAPH.
1 Injector 8 Camshaft Position (CMP) Sensor
2 Intake Manifold Assy 9 Timing Belt Cover
3 Common Rail Pressure Sensor 10 Engine Coolant Temperature Sensor
4 Crankshaft Position (CKP) Sensor 11 Coolant Fan Temperature Sensor
5 High Pressure Common Rail 12 Turbocharge
6 Left Mount 13 High Pressure Pipe
7 High Pressure Pump 14 EGR Valve

SYSTEM FUNCTION INTRODUCTION

1. IDLING-SPEED CONTROL.
(a) It takes full advantage of the high pressure common rail fuel injection system, adopts multi-section
injection method to reduce the diesel engine running noise, overcomes the individual difference of 11B
injector through cylinder equilibrium strategy and combines PID control idea to realize stable idle-speed
control.
2. AIR FLOW SENSOR.
(a) There is a heating platinum wire exposed in the intake air flow in the mass air flow sensor.
(b) ECM heats platinum wire to designated temperature by applying prescribed current flow on it. The
intake air flow can cool the platinum wire and inner thermistor so as to change their electric resistance
value. In order to keep steady current value, ECM changes the voltage applied on the parts in the air
flow meter. The voltage value is proportional to the air rate through the sensor and ECM uses this value
to calculate the air intake.
(c) ECM calculates the air amount into the cylinder through the intake air temperature and the mass air
flow sensor, determines the air amount into the cylinder, and makes the air/fuel ratio in accordance with
the requirements of various conditions by controlling the injected fuel quantity.
3. SEQUENCE CONTROL FOR IDENTIFYING TOP DEAD CENTER.
Camshaft Position (CMP) sensor consists of the magnet and the iron core wrapped in copper wire and
is installed on the cylinder head. When the camshaft is rotated, the teeth on the camshaft pass the CMP
sensor, activate the magnet inside the sensor and produce voltage in the copper wire. As receiving this
signal, ECM identifies the signal of compression top dead center through analysis processing with
software.
4. INJECTION CONTROL.
(a) ECM controls the quantity of fuel injected by injectors and the quantity of fuel injected depends on the
fuel rail pressure and the injector opening period.
(b) The control of rail pressure is a close-loop control. ECM issues an order to request the rail pressure
controlled to the set value and the rail pressure sensor on the high pressure fuel rail feeds back current
rail pressure information to ECM, which form a close-loop.
(c) The fuel system of electrically controlled high pressure common rail diesel engine eliminates the
interaction between the pressure generation and the fuel injection in traditional fuel supply system. The
11B
generation of injection pressure doesn’t depend on the engine speed and the quantity of fuel injected.
The fuel under pressure is stored in the high pressure common rail for being injected at any time,
making the injection control more precise.
5. INJECTION TIMING CONTROL (CAMSHAFT POSITION SENSOR).

(a) The camshaft rotates synchronously with the crankshaft. The crankshaft rotates and the voltage is
produced in CMP sensor. The voltage produced in the sensor is a kind of signal which can enable ECM
to find the crankshaft position. The signal is used to control the fuel injection timing.
6. SELF-DIAGNOSTICS.
(a) The self-diagnostics of system failure is a function necessary for the engine control system. When one
or several parts in the system work abnormally, the system can remind the vehicle owner to do
necessary checking and maintenance by lighting the malfunction indicator lamp. When a failure occurs,
the system can control the engine running by use of temporary emergency plan to ensure the owner
can drive the vehicle for maintenance.
(b) If an abnormality is detected for one sensor or actuator, the engine malfunction indicator lamp is lighted
to remind the driver.
(c) If an abnormality is detected for one sensor or actuator, the DTC corresponding to the failure condition
will be output.
(d) The RAM data in ECM related with the sensor and actuator can be read by the scan tool. Additional,
the actuator can be positive driven in a particular situation.
7. OVERVOLTAGE PROTECTION.
If the charging system fails and causes the overvoltage, the system enters the protection state to limit
the engine speed and prevent ECM from damage.
8. A/C COMPRESSOR CONTROL.
When the A/C switch is turned on, the system will receive the signal named A/C request and do the
preparation before loading the A/C according to current engine running condition, then connect the A/C
compressor. The system controls the connection or disconnection of the A/C based on the requirement
of A/C protection. In order to ensure the power output and protect the engine, the system can
disconnect the running of A/C in particular conditions.
9. RADIATOR FAN CONTROL.
(a) The vehicle is equipped with two electric two-speed cooling fans.
(b) Electro-drive fan control function.
BASIC PRINCIPLE
1. ECM CONTROL.
(a) The function of ECM is: To sample all sensor signals in specified order and determine the output data
through mathematical calculation and logical judgment according to the stored empirical data and 11B
control program inside ECM. ECM converts the calculated or determined results into signals that can
received by the actuators and these signals are sent to corresponding actuators separately. ECM also
has the function of system failure self-diagnostic. Once the parts inside and outside ECM fail, the
malfunction indicator lamp on the instrument panel is lighted for alarming.
(b) Based on the driver's requests (position of electronic accelerator pedal) collected by the sensors ECM
and current engine and vehicle conditions, ECM calculates the injected fuel quantity required by the
driver, the injection point, the injection frequency and the injection pressure, gives out an order to
control the rail pressure within required value range and makes the injector inject fuel in accordance
with the calculation results.
2. STARTING CONTROL PRINCIPLE.
(a) Necessary conditions for injector starting to inject (the injector must meet all the following conditions for
starting to inject):
• The rail pressure is less than the minimum setting value.
• Synchronization signal is normal (crankshaft position sensor and camshaft phase sensor signal ≥
trigger threshold) (related with the air gap and the speed; the phase is correct).
(b) Process of identifying top dead center at starting:
• Starting in normal mode (crankshaft position sensor and camshaft position sensor are normal).
• Starting in spare mode 1 (only with camshaft position sensor).
• Starting in spare mode 2 (only with crankshaft position sensor).
(c) Control of injected fuel quantity at starting:
• Calculation of injected fuel quantity at starting: Injected fuel quantity at starting is equal to injected fuel
quantity at basic torque plus injected fuel quantity at compensating torque.
• Function of diesel engine speed and cooling water

Injected fuel quantity at basic torque temperature; the lower water temperature or the
speed, the large fuel quantity at starting.
11B
Injected fuel quantity at compensating torque • Related with the altitude where the vehicle runs,
namely plateau compensation.
(d) During the starting, ECM increases the injected fuel quantity gradually to help the smooth starting of
diesel engine. In order to form the rail pressure rapidly, ECM first adopts the open-loop control mode
with large pulse width, then changes to the PID close-loop control when the rail pressure and the speed
reach certain set values.
3. FUEL INJECTION CONTROL PRINCIPLE.
(a) BJ493ZQ3 diesel engine common rail close-loop control system consists of the high pressure fuel
pump, the common rail pressure sensor and ECM, the task of which is to do the electronic control for
the fuel injection system and realize the real-time control for the quantity of fuel injected and injection
timing along with the running conditions. The fuel system adopts a kind of technology which separates
the injection pressure generation and the injection process completely. It transfers the high pressure
fuel to the common rail by the high pressure pump, disassociates the high pressure rail pressure with
the engine speed through the accuracy control of the fuel pressure in the common rail, sharply reducing
the change of the diesel engine oil supply pressure with the engine speed so as to reduce defects of
traditional diesel engine.
(b) Based on sensors of the crankshaft position, the camshaft posiion, the coolant temperature, the
electronic accelerator pedal, ECM determines the injection point, the injection frequency, the injection
pressure and the quantity of fuel injected at the engine running, inputs the parameters real-detected
into ECM synchronously and compares them with stored parameter values. Through processing and
calculating, ECM controls the actuating mechanisms such as injection pump, the exhaust-gas
recirculation valve and the heating plug based on the optimal values, drives the fuel injection system,
makes the oil supply system with perfect injection characteristics and the engine obtain the air/fuel
mixture with best strength and ideal fuel economy in every condition.
(c) Ejection characteristic chart:
• Calculate fuel-injection pressure depending on RPM,

fuel-injection quantity and ECT.
1 RPM
2 ECT
• Calculate fuel-injection pressure depending on RPM,

fuel-injection.
1 RPM
2 Fuel-injection Quantuty Raise
• Calculate fuel-injection quantity depending on RPM and

ECT.
1 Engine Starting Speed
2 ECT
• Calculate the standard fuel-injection quantity depending

on RPM and accelerator pedal position.
1 RPM
2 Accelerator Pedal Position

• Calculate the maximum fuel-injection quantity depending

on RPM and boost pressure.
1 RPM
11B
2 Boost Pressure
• Calculate the mainly injection time depending on fuel-

injection quantity and RPM.
1 RPM
2 Fuel-injection Quantity
• Calculate the pre-injection time depending on fuel-

injection quantity and RPM
1 RPM
2 Fuel-injection Quantity
11B
4. HIGH PRESSURE COMMON RAIL.

(a) The high pressure oil pump transforms the low pressure diesel fuel into high pressure diesel fuel,
transfers it into high pressure rail for pressure accumulation in the rail. ECM controls the fuel pressure
in the high pressure rail through the pump actuator on the high pressure pump and the rail pressure
sensor on the high pressure rail feeds back the rail pressure information to ECM to form the close-loop
control. Based on inner calibration data, ECM calculates the injection of one cylinder and makes the
injector inject the fuel with calculated quantity at scheduled time by controlling the running of injector
magnetic valve. The spare fuel in the system returns to the fuel tank through the low pressure fuel
circuit.
5. IDLING-SPEED CONTROL PRINCIPLE.
(a) ECM calculates the target idling speed and takes close-loop control to meet the target idling speed.
(b) Factors influencing the target idling speed are:
• Coolant temperature
• Battery voltage
• A/C service condition
• Vehicle speed (the idling speeds increases by 50 RPM at vehicle starting; the idling speeds in gears
may be different)
(c) Factors influencing the idling speed close-loop parameters are:

• Coolant temperature
• Load
• Gear signal
• Braking signal (cadence braking)
6. PREHEATING CONTROL PRINCIPLE.
(a) The preheating process of BJ493ZQ3 diesel engine is controlled by ECM. The preheating actuator
executes the orders of ECM to power up the heating plug and only plays a role of relay.
(b) At the beginning of preheating, the coil first becomes red hot to complete the function of rapid
preheating. If the rapid preheating state continues and the temperature rises over the desired, the coil
can be shut off power automatically, but, for the braking coil with large temperature resistance
coefficient, the resistance value will increase with increasing temperature to reduce the power supply
current, so as to inhibit the temperature increasing and make the saturation temperature in given value.
Meanwhile the protective sleeve becomes red hot from the front end then to the rear, as reaching the
saturation temperature, the whole protective becomes red hot completely to achieve good preheating
performance.
(c) The post-heating after successful starting can promote to form a kind of unbroken and less smoke
speed up and idling running during warming up process. It can reduce the combustion noise and white
smoke during cold starting.
(d) Pre-heating system ensures the cold weather start-ability of diesel engine. The preheating system
enhances the engine start-ability through heating the pressed air by the heater plug before the engine
cold start. When the key is switched ON, the preheating process begins and meanwhile the preheating
lamp is lighted. When the preheating lamp is off, the heater plug has reached sufficiently high
temperature; this moment, switch the key quickly to START within 2 seconds and the engine is started.
NOTE
• If the key isn’t switched to START within 2 seconds as the preheating lamp is off, please turn the
ignition switch OFF for preheating again.
• If ECM reports an error as the ignition switch is ON, please turn the ignition switch OFF and
check the connection of each sensor connector.
7. EGR CONTROL PRINCIPLE.
(a) BJ493ZQ3 diesel engine is equipped with the electrically controlled Exhaust Gas Recirculation (EGR)
system. EGR system consists of the EGR valve, EGR cooler, EGR magnetic valve, pressure
maintaining valve and associated pipes.
(b) Based on the calibration data in different conditions, EGR calculates required quantity of exhaust gas
recirculation, controls the EGR valve opening by controlling the EGR magnetic valve, returns part of
exhaust gas in the exhaust pipe through recirculation to the intake manifold, makes it mixed with flesh
air and into the combustion chamber to reduce the combustion temperature, so as to reduce the
generation of oxynitride, thus to reduce the air pollution.
(c) The calibration inside ECM is to calibrate EGR rate by calibrating the air rate of Mass Air Flow (MAF)
sensor. The flow of gas inhaled into the engine in certain condition (speed, fuel quantity) is definite. The
exhaust gas required by ECM for recirculation is calculated by the inhaled gas minus the measured air
flow at EGR valve opening; through the control of EGR magnetic valve, it makes the EGR valve take
further action and measures the air flow by the air flow meter to meet the calibration value, thus to
obtain a required EGR rate; this is a control relationship moving forward in spiral, namely a close-loop
control.
8. TURBO-CHARGING PRINCIPLE.
BJ493ZQ3 diesel engine adopts the exhaust gas turbocharger unit. The air intake and exhaust and
supercharger system consists of the intake manifold, exhaust manifold, intake pipe, air filter and
supercharger. The turbo machine and compressor of the supercharger are installed on the same axis. 11B
The turbo is driven by the exhaust gas exhausted by the engine and drives the compressor to
compress the air inhaled by the air cleaner, so as to increase the air density in the cylinder and increase
the air input, which can accordingly increase the fuel delivery of fuel injection pump, thus to improve the
engine output.
11B
MAIN COMPNNENTS
• ECM optimization control

ECM Bosch the second generation 1 system depending on the
11B
sensor signal
Preheat controller Relay 1 • Apply battery to preheat

plug according to ECM
Preheat plug Coil type glow plug 4 • Make diesel engine starting
behavior is perfect
Water and oil separator Induction type 1 • Alarm
MAF sensor Hot wire type 1 • Check intake air
Injector 6-hole electromagnetic type 4 • Inject fuel depending on

the sensor form ECM
EGR valve Electromagnetic type 1 • Reduce the combustion

temperature
Electromagnetic induction
CKP sensor 1 • Check CKP and RPM
type
• Check No.1 cylinder

CMP sensor Hall effect type 1 BTDC depending on CKP
and CMP sensor
Accelerator pedal position 3-lines type carbon film resis- • Check accelerator pedal
1
sensor tor sliding indicator position
ECT sensor NTC thermal resistance type 1 • Check ECT
Common rail pressure sensor Piezoelectric type 1 • Check high rail pressure
Turbo type single-stage elec- • Supply the enough pres-

High pressure pump 1
tric pump sure fuel for system
11B
11B-16 ENGINE CONTROL SYSTEM - ENGINE CONTROL MODULE (ECM)
ENGINE CONTROL MODULE (ECM)

PRINCIPLE
1. PRINCIPLE OF ENGINE CONTROL MODULE (ECM).
(a) ECM is the electric control engine control center with the
micro processor as the core that having sensor signal
input interface and the executor drive circuit.
(b) The ECM receives and treats the engine status signal
that inputted from all sensors, sends control signal to the
executor to drive the engine running in accordance with
the preset procedures so as to make the engine run
under best status, ensure good power capability, fuel
economy and exhaust capability.
2. INFORMATION OF ECM.
(a) Normal operating voltage: 12 V.
(b) Continuity power：ecm terminal K1 and K3.
(c) Controlled by ignition key：ecm terminal K28.
(d) Ground wire：ECM terminal K02, K04, K06.
(e) STandard 5v power wire: ECM terminal A28, A11.
(f) ECM has self protection function, it may result the
ignition failure during repair and it will resume normal
after replacement of ECM, therefore we may deem as
the ecm trouble. In fact, the ECM doesn’t get damaged
but just enters into self protection mode. ECM will
resume normal after certain time period.
ENGINE CONTROL SYSTEM - ENGINE CONTROL MODULE (ECM) 11B-17
REPLACEMENT
2. DISCONNECT BATTERY NEGATIVE CABLE. 11B

NOTE
3. REMOVE DRIVER SEAT ASSY.

(a) Slide the driver seat assy foremost.
11B
(b) Using an allen wrench (key), remove 2 bolts.

(c) Slide the driver seat assy backmost.
(d) Remove 2 bolts.
(e) Remove the exting guisher bracket.
(f) Remove 2 bolts.

CAUTION
• Turn the driver seat assy over backward carefully
and slowly.
• Do not drag the electric buckle wire harness.
• Do not move the track to prevent malposition.
(g) Disconnect the electric buckle wire harness connector.
11B
(h) Using a screwdriver, pry the electric buckle wire harness

connector from the driver seat base welding assy.
NOTE
If the connector is broken, replace the electric buckle assy.
(Refer to “Chapter 63 seat belt - buckle assy, replacement”)
(i) Remove the driver seat assy. 11B

WARNING
Care must be taken because the driver seat assy is quite
heavy.
CAUTION
• Do not score surfaces of parts around.
• Do not move the track when storing to prevent mal-
position.
4. REMOVE ECM.
WARNING
Using the special diagnostic tool and soft-ware to operate.
If not, the ECM will be damaged.
NOTE
• After disconnecting ECM, pay attention to waterproof.
Not allow to contact water. Even more, not allow to
put into water.
• Pay attention to protect the terminals.
• Disconnect the battery negative cable for 1 minute

before removing ECM.
• Not allow to impact.
5. INSTALL ECM.
NOTE
Pay attention to electrostatic protection when
installing.
(a) Tighten ECM retaining bolts.
Torque: 45 ~ 55 N·m
6. INSTALL DRIVER SEAT ASSY.

(a) Position the driver seat assy behind the base welding assy, with the seat assy is turned over.
WARNING
Care must be taken because the driver seat assy is quite heavy.
CAUTION
• Do not move the track to prevent malposition.
(b) Install the clectric buckle wire harness connector to

mounting hole on the driver seat base welding assy.
CAUTION
NOTE
If the connector is broken, replace with a new electric
buckle assy. (Refer to “Chapter 63 seat belt - buckle assy,
replacement”)
(c) Connect the electric buckle wire harness connector.

CAUTION
Make sure there is no interference between electric buckle
wire harness and parts around. 11B
(d) Tighten 2 bolts.

CAUTION
• Make sure the driver seat assy is at the backmost
position.
• Help the seat assy carefully and slowly and position
it on the top of the base welding assy.
• Do not move the slding rails to prevent malposition.
(e) Position the exting guisher bracket properly.
11B

(g) Slide the driver seat assy foremost.
(h) Using an allen wrench (key), tighten 2 bolts.

ENGINE CONTROL SYSTEM - ENGINE COOLANT TEMPERATURE SENSOR 11B-23
ENGINE COOLANT TEMPERATURE SENSOR

PRINCIPLE
11B
1. PRINCIPLE OF ENGINE COOLANT TEMPERATURE
SENSOR.
(a) The Engine Coolant Temperature (ECT) sensor uses a
thermistor to control the signal voltage to the Engine
Control Module (ECM).
(b) This ECT sensor is the 2-line type. Normally the single-
line type is to provide coolant temperature signal to the
instrument.
11B
11B-24 ENGINE CONTROL SYSTEM - ENGINE COOLANT TEMPERATURE SENSOR
OVERHAUL

NOTE
When disconnecting or connecting the battery cables, please
first turn off the ignition switch and lighting switch and
completely loosen the cable nut. Do not pry up the cable when
peforming these operation.
4. DRAIN THE COOLANT. (Refer to “Chapter 17B cooling - precaution”)

6. REMOVE ECT SENSOR.

(a) Disconnect ECT sensor connector.
(b) Remove ECT sensor.
NOTE
• Clear the installation surface after removing.
• Clear the screw hollow after removing.
• Clear the thread of sensor after removing.
ENGINE CONTROL SYSTEM - ENGINE COOLANT TEMPERATURE SENSOR 11B-25
7. CHECK ECT SENSOR.

(a) Dip the sensing part of ECT sensor into hot water. Using
the multimeter, measure resistance of the sensor.
(b) If the check result is not OK, replace it. 11B
Check condition Specified Condition (KΩ)
- 40 ℃ 45.313
- 30 ℃ 26.114
- 20 ℃ 15.462
- 10 ℃ 9.397
0℃ 5.986
20 ℃ 2.500
40 ℃ 1.175
80 ℃ 0.323
100 ℃ 0.186
120 ℃ 0.113
140 ℃ 0.071
CAUTION
Don’t let the water into terminals. After checking, dry the
sensor.
8. INSTALL ECT SENSOR.

CAUTION
Apply sealant on thread. The specified sealant: 3M nut 11B
locking part, type: NO.4171 or the equivalent.
(a) Install ECT sensor. Tighten it to specified torque.
Torque: 29.4 N•m
(b) Connect ECT sensor connector.
9. FILL COOLANT. (Refer to “Chapter 17B cooling - precaution)

11B-26 ENGINE CONTROL SYSTEM - ENGINE COOLANT TEMPERATURE SENSOR

12. CHECK COOLANT LEAKAGE.

ENGINE CONTROL SYSTEM - CAMSHAFT POSITION SENSOR 11B-27
CAMSHAFT POSITION SENSOR

PRINCIPLE
11B
1. PRINCIPLE OF CAMSHAFT POSITION SENSOR.
(a) Camshaft Position (CMP) sensor consists of a hall
sensor and a signal impeller (semicircle ferromagnetic
body). When the signal impeller blade goes into the gap
of hall sensor permanent-magnet circuit, the hall effect
switch is in off state and the corresponding circuit outputs
a high level; When the signal impeller blade goes off the
gap of the sensor permanent-magnet circuit, the hall
effect switch is in on state and the corresponding circuit
outputs a low level. The position sensor gains the
camshaft position signal through monitoring the convex
plate position on the camshaft timing pulley so as to
determine the injection point and the injection sequence.
11B
11B-28 ENGINE CONTROL SYSTEM - CAMSHAFT POSITION SENSOR
temperature.
3. Connect hand-held tester to CMP sensor.
4. Start engine, push the shift lever to gear. using the hand-
held tester, check whether the output signal wave of ter-
minal 2 of the sensor is normal. If it’s not ok, check har-
ness and sensor.
ENGINE CONTROL SYSTEM - CAMSHAFT POSITION SENSOR 11B-29
OVERHAUL
2. OPEN ENGINE HOOD. 11B

NOTE

11B
5. REMOVE CMP SENSOR.

(a) Disconnect CMP sensor connector.
(c) Remove CKP retaining bolt.
NOTE
11B-30 ENGINE CONTROL SYSTEM - CAMSHAFT POSITION SENSOR
6. CHECK CMP SENSOR RESISTANCE.

(a) Turn the ignition switch OFF.
(b) Disconnect the E034 CMP connector.
(c) Check the resistance according to the value in the table
below.
Standard resistance
Tester Connection SpecifiedCondition

E034 (2) - E034 (3)
E034 (1) - E034 (2) Except 0 or ∞

E034 (1) - E034 (3)
(d) If it is OK, replace CMP sensor.
7. INSTALL CMP SENSOR.

(a) Connect CMP sensor and connector.
(b) Tighten CMP sensor retaining bolt.
Torque: 8 ± 0.5 N•m
NOTE
• CMP sensor is installed on the gear case. Install it by
applying pressure. Any impact tool is not allowed.
• Clearance: 0.2 ~1.8 mm.


ENGINE CONTROL SYSTEM - ACCELEARTOR PEDAL POSITION SENSOR 11B-31
ACCELEARTOR PEDAL POSITION SENSOR

PRINCIPLE
11B
1. PRINCIPLE OF ACCELEARTOR PEDAL POSITION
SENSOR.
(a) The electric Accelerator Pedal Position Sensor (APPS)
is mounted on the pedal bracket. It is 2 three-line types
of potentiometer sensor.
(b) The ECM applies a 5 V reference voltage to the sensor.
The sensor slide indicator connects with the accelerator
and rotates following the shaft. When the accelerator
pedal changes, the position of the slide indicator will also
change on the carbon film resistance, at such moment
the resistance output will also change, which reflects the
open extent of the accelerator indirectly.
11B
11B-32 ENGINE CONTROL SYSTEM - ACCELEARTOR PEDAL POSITION SENSOR
INSPECTION ON VEHICLE
temperature.
3. Connect the scan tool to the Data Link Connector (DLC)
- use the most current software available.
5. Select the item “AUTO DIAGNOSIS\ FOTON
(V03.20)\LIGHT BUS\MP-X MP\ ENGINE\DIESEL
ENGINE\ BOSCH DIESEL COMMON RAIL SYSTEM\
EDC16C39 OR EDC17C55\READ DATA STREAM”.
• Ignition switch ON (the throttle is closed): 0.899 V

APPS1
• Ignition switch: ON • Ignition switch ON (the throttle is fully open): 3.548 V
APPS
• Engine turn off • Ignition switch ON (the throttle is closed): 0.572 V
APPS2
• Ignition switch ON (the throttle is fully open): 1.608 V
6. If it is not OK, check APPS, harness or ECM.

REPLACEMENT
2. DISCONNECT BATTERY NEGATIVE CABLE. 11B

NOTE
3. REMOVE STEERING COLUMN LOWER COVER.

(a) Pull the engine hood lock handle.
(b) Remove 2 screws.
11B
(c) Pull out the engine hood control handle.

(d) Remove the engine hood control cable.
(e) Remove 3 retaining screws of the steering column lower

cover.
(f) Remove the steering column lower cover.
4. REMOVE APPS.
(a) Disconnect APPS connector.
NOTE
After removing, confirm the junction of the connector
without contacting the dirt, water and other foreign matter.
(b) Remove 3 APPS retaining bolts.

5. CHECK APPS RESISTANCE.

(a) Using the analogue multimeter, measure the continuity of
the APPS resistance.
(b) The pins of the multimeter connect to terminal 4 and 3 of 11B
APPS respectively. Turn the shaft of the APPS. The
value changes linearly varied with the opening of the
acceperator. When connecting to terminal 2 and 4, the
value is opposite.
(c) Check the resistance of the APPS.
Resistance
Tester Connection SpecifiedCondition

C050 (3) - C050 (4)
• Turn the shaft of the APPS.
C050 (2) - C050 (4)
• The value changes linearly
C050 (5) - C050 (6) varied with the opening of the
accelerator
C050 (1) - C050 (6)
(d) The resistance value is continuity.

(e) If the ckeck result is not OK, replace it.
6. INSTALL APPS.
(a) Tighten 3 APPS retaining bolts.
11B
(b) Connect APPS connector.
7. INSTALL STEERING COLUMN LOWER COVER.

(a) Connect the diagnosis wire harness connector.
(b) Position the steering column lower cover properly.
(c) Tighten 3 retaining screws of the steering column lower

cover.
(d) Tighten 3 retaining screws of the steering column lower

cover.
(e) Position the engine hood control handle properly.

11B
11B
11B-38 ENGINE CONTROL SYSTEM - MAF SENSOR
MAF SENSOR
PRINCIPLE
1. PRINCIPLE OF MAF SENSOR.
(a) MAF sensor is fixed in the intake air duct and which with-
out moving component. It operates more dependable.
(b) Maf test the air flow entering into engine with heating
method. The electric heating element is heated by elec-
tricity to a fixed value which higher than intake tempera-
ture.
ENGINE CONTROL SYSTEM - MAF SENSOR 11B-39
OVERHAUL
2. OPEN ENGINE HOOD. 11B

NOTE
4. REMOVE ENGINE COVER AND INTAKE AIR HOSE.

11B
5. LOOSEN INTAKE AIR HOSE CLIP.
6. REMOVE INTAKE AIR HOSE.

11B-40 ENGINE CONTROL SYSTEM - MAF SENSOR
7. REMOVE MAF SENSOR.
8. CHECK MAF SENSOR.

(a) Apply battery voltage between the E035 MAF sensor
terminal 3 and 4.
(b) Connect multimeter (+) to terminal 3, multimeter (-) to
terminal 2.
(c) Measure the voltage according to the value(s) in the
table below.
Standard voltage
Tester Connection Specified Condition

The signal output should even
E035 (2) - E035 (3) change when blowing air into MAF
sensor with mouth or fan
9. INSTALL MAF SENSOR TO INTAKE AIR DUCT.

10. INSTALL INTAKE AIR HOSE.
11. TIGHTEN INTAKE AIR HOSE CLIP.


ENGINE CONTROL SYSTEM - CKP SENSOR 11B-41
CKP SENSOR
PRINCIPLE
11B
1. PRINCIPLE OF CKP SENSOR.
(a) To provide revolution, angle, benchmark position signal
to the engine.
(b) The crankshaft position sensor can be divided as
magnetic pulse type, hall type, photoelectric type and so
on.
(c) The magnetic pulse type and hall type sensors are
widely used in available vehicle models and the
photoelectric type sensors are widely used in Japanese
and English vehicle models (the photoelectric type
sensors boast relatively high precision as well as the
weakness of high cost and difficult maintenance).
11B
11B-42 ENGINE CONTROL SYSTEM - CKP SENSOR
OVERHAUL

NOTE
4. RAISE VEHICLE.
5. REMOVE CKP SENSOR.

(a) Disconnect CKP sensor connector.
(c) Remove the CKP sensor retaining bolt.
NOTE
6. CHECK CKP SENSOR.

Standard resistance: 860 ± 86 Ω (20 ℃ )
ENGINE CONTROL SYSTEM - CKP SENSOR 11B-43
7. INSTALL CKP SENSOR.

CAUTION
Apply a layerof preventative oil on the O-ring of the CKP
sensor. 11B
8. TIGHTEN CKP SENSOR RETAINING BOLT.

NOTE
• Install it by applying pressure. Any impact tool is not
allowed.
• Clearance: 0.5 ~1.5 mm.
9. LOWER VEHICLE.
11B
11B-44 ENGINE CONTROL SYSTEM - ODOMETER SENSOR
ODOMETER SENSOR
PRINCIPLE
1. PRINCIPLE OF ODOMETER SENSOR
(a) ECM use the sensor to receive the digital pulse signal.
ECM can confirm the vehicle speed through the signal.
ENGINE CONTROL SYSTEM - ODOMETER SENSOR 11B-45
temperature. 11B
2. Turn the ignition switch off.
available.
5. Select the item “AUTO DIAGNOSIS\ FOTON (V03.20)\
LIGHT BUS\MP-X MP\ ENGINE\DIESEL ENGINE\
BOSCH DIESEL COMMON RAIL SYSTEM\ EDC16C39
OR EDC17C55\ READ DATA STREAM”.
6. Driving the vehicle, read the scan tool data stream:
vehicle speed.
7. Vehicle speed：Same value as the actual vehicle
speed.
8. If the displayed value is not equal to the actual value,
then check sensor, harness and ECM.
9. RAISE VEHICLE.
10. TURN THE IGNITION SWITCH ON AND ENGINE STOP. CHECK AS FOLLOWING:
(a) Set digital multimeter to voltage range. Check voltage between terminal 1 and 2 of the sensor. It should
be 12 V. If it is not OK, replace it.
(b) Start engine. push the shift lever to gear. Using the hand-held tester, check the wave output of terminal
of sensor. If it’s not OK, check harness and sensor.
11B
11B-46 ENGINE CONTROL SYSTEM - ODOMETER SENSOR
OVERHAUL

NOTE
4. RAISE VEHICLE.

ENGINE CONTROL SYSTEM - ODOMETER SENSOR 11B-47
6. REMOVE ODOMETER SENSOR.

(a) Disconnect odometer sensor connector.
(b) Remove odometer sensor retaining bolt.
11B
NOTE
Clear surface after installation.
7. INSTALL ODOMETER SENSOR.

(a) Tighten odometer sensor retaining bolt.
Torque: 7.8 N•m
NOTE
Install it by applying pressure. Any impact tool is not allowed.
(b) Connect odometer sensor connector.
9. LOWER VEHICLE.
11B
11B-48 ENGINE CONTROL SYSTEM - COMMON RAIL PRESSURE SENSOR
COMMON RAIL PRESSURE SENSOR

PRINCIPLE
1. PRINCIPLE OF COMMON RAIL PRESSURE SENSOR.
(a) The common rail pressure is converted to voltage signal
by the sensitive element on the film of the common rail
pewssur sensor. Then the signal is sent to ECM.
ENGINE CONTROL SYSTEM - COMMON RAIL PRESSURE SENSOR 11B-49
REPLACEMENT
1. RELEASE FUEL PRESSURE.
(a) Disconnect the high pressure pump wire harness connector.
11B
(b) Start engine and run at idle speed till engine stalls.
(c) Start engine again for about 5 seconds. Confirm the pressure of fuel supply manifold pipe is released.
(d) Connect the high pressure pump wire harness connector.

NOTE

4. DISCONNECT COMMON RAIL PRESSURE SENSOR

CONNECTOR.
11B
5. REMOVE HIGH PRESSURE DELIVERY PIPE.

NOTE
Remove common rail end first, then remove injectors and
high pressure pump end. When removing injector and
pump connecting nuts, fixing fuel pump injector bolt seat is
needed to avoid the looseness of the bolts seat.
11B-50 ENGINE CONTROL SYSTEM - COMMON RAIL PRESSURE SENSOR
6. REMOVE HIGH PRESSURE DELIVERY PIPE (CON-

NECTING HIGH PRESSURE PUMP).
7. REMOVE HIGH PRESSURE COMMON RAIL.

(a) Remove 2 bolts of high pressure common rail bracket.
(b) Take common rail and bracket away.
(c) Remove 2 bolts of high pressure common rail and
bracket.
(d) Seperate common rail from bracket.
8. INSTALL HIGH PRESSURE COMMON RAIL.

(a) Tighten 2 bolts of high pressure common rail and
bracket.
(b) Tighten 2 bolts of common rail bracket.
9. INSTALL HIGH PRESSURE COMMON RAIL DELIVEY

PIPE (CONNECT HIGH PRESSURE PUMP).
ENGINE CONTROL SYSTEM - COMMON RAIL PRESSURE SENSOR 11B-51
10. INSTALL EACH HIGH PRESSURE DELIVERY PIPE.

NOTE
11B
• Tighten the injector and pump first ,then install com-
mon rail.
• Each high pressure tube nut marked 1, 2, 3, 4 to
match relevant cylinder. Marked 5 tube match high
pressure pump.
WARNING
The most pressure in high pressure common rail can
achieve 145 MPa, do not loose high pressure pump,
common rail and injector nut when engine is running.

11B
MEMO
FUEL
12B
FUEL SYSTEM................................................................................. 12B-1
PRECAUTION............................................................................ 12B-1
DIESEL FUEL SYSTEM COMPONENTS AND PRINCIPLE ..... 12B-3
PROBLEM SYMPTOMS TABLE................................................ 12B-4 12B
COMPONENTS ......................................................................... 12B-6
FUEL TANK ASSY........................................................................... 12B-8
REPLACEMENT ........................................................................ 12B-8
DIESEL FUEL FILTER ASSY ........................................................ 12B-13 12B
REPLACEMENT ...................................................................... 12B-13
FUEL LEVEL SENSOR ASSY ....................................................... 12B-18
REPLACEMENT ...................................................................... 12B-18
HIGH-PRESSURE FUEL PUMP ASSY ......................................... 12B-20
REPLACEMENT ...................................................................... 12B-20
HIGH-PRESSURE COMMON RAIL...............................................12B-24
REPLACEMENT ...................................................................... 12B-24
FUEL INJECTOR ASSY................................................................. 12B-26
OVERHAUL ............................................................................. 12B-26
FUEL FILLING DOOR.................................................................... 12B-30
REPLACEMENT ...................................................................... 12B-30
11B
12B
FUEL - FUEL SYSTEM 12B-1
FUEL SYSTEM
FUEL
PRECAUTION
1. FUEL SYSTEM PRECAUTION. 12B
(a) Before working on fuel system, disconnect battery negative cable.
(b) When removing the fuel hose, use a suitable container to hold the diesel.
(c) Do not smoke, carry lighted tobacco or work near an open flame when working on fuel system.
Equipment with ventilator at woking area can avoid personal injury.
(d) Fuel in the fuel pump, railway and tubes remains under high pressure. In order to avoid personal injury,
do not loosen tube connector while engine is running.
(e) Keep diesel away from rubber and leather parts.
(f) Diesel injection equipment is manufatured to very precise tolerances and fine clearances. To prevent
fuel system damage, it is essential that absolute cleanliness is oberved when working with these
components. Always install fuel system caps to any open orifices or tubes.
(g) Before disconncting any of the fuel system tubes or fuel system components, relieve the fuel system
pressure to prevent accidental spraying of fuel, even when the engine is not running. Failure to follow
this instruction may result in serious personal injury.
(h) Check if there is any dirt like mud around the fuel tube connector before this work. Clean dirt away,
otherwise it can damage fuel system or engine.
(i) Keep cleaner away from the O-ring of tube connecter. Cleaner can harm seal of fuel system.
(j) Do not bend or twist the fuel system tube and pipe by force.
(k) Before connceting fuel system tube, be sure there is no damage to tube connector. If there is damage,
crack or dirt on surface, replace it with a new tube assy.
(l) Wearing eyeshield equipment is needed when working on fuel system compoments. Failure to follow
this instruction may result in personal injury.
(m) The metal parts like zn, cu, mn are easily dissolved in diesel. Coking may appears in fuel injector which
reduces the injected diesel to cylinder. So the matal parts above should not be used in high-pressure
common rail fuel system.
(n) It is essential to keep fuel system clean. Especially it can not consist any impurity, such as corrosion,
welding spatter. Otherwise, these impurity can block fuel tube, engine shut down suddenly. The
common rail parts are even damaged.
12B
12B-2 FUEL - FUEL SYSTEM
FUEL SYSTEM PRESSURE RELIEF PROCESS

(a) Disconnect the high-pressure pump connector.
(b) Start and idle the engine till it stops on its own. Turn the ignition switch to lock.
(c) Start the engine again for 5 seconds, ensure fuel manifold branch relief pressure is complete.
(d) Conncet the high-pressure pump conncetor.
DRAIN FUEL TANK PROCESS

(a) Disconnect battery negative terminal.
(b) Open the fuel filling door.
(c) Lift the vehicle in place.
(d) Remove the fuel tank drain bolt and drain the fuel to the
suitable container.
FUEL TUBE CLEAN

(a) Use fuel treatment that Foton recommends to clean fuel system.
(b) Use fuel additives that Foton recommends to clean fuel system.
DIESEL FUEL SYSTEM COMPONENTS AND PRINCIPLE

DIESEL ELECTRONICALLY CONTROLLED FUEL SYSTEM COMPONENTS
• BJ493ZQ3 disel apply BOSCH electrical control high pressure common rail system. High pressure 12B
common rail means four injectors share the same high pressure rail. The high pressure fuel pump build
high pressure in rail. Fuel store in rail and prepare injection. Stable fuel pressure inject and mixing
uniformity so that burn fully.
• Diesel electronically controlled fuel system consists of fuel tank,fuel filter, sensor, wire harness, ECU,
electronically controlled fuel pump, lower-pressure fuel tube,high-pressure fuel tube,fuel injectors.
DIESEL LOWER-PRESSURE FUEL CIRCUIT

• Lower pressure fuel circuit consists of fuel tank, lower-pressure tube, diesel filter, high-pressure pump
inlet hose, injector return tube.
DIESEL HIGH-PRESSURE FUEL CIRCUIT

• High pressure fuel circuit consists of high-pressure pump, high-pressure common rail, high-pressue
tube, injectors.
OPERATION PRINCIPLE
• The design principle of the fuel delivery of high pressure fuel pump is to ensure the demand of sum of
injected fuel quantity and controlled fuel quantity and the demand of fuel quantity change of the diesel
engine in any case. As the generation of nozzle pressure in common rail system is irrelevant to the fuel
injection course and the injection timing isn’t assured by the cam of high pressure fuel pump, the fuel
pumping cam of high pressure fuel pump can be designed on the design principles of minimum peak
torque, minimum contact stress and greatest wear resistance. Bosch corporation adopts a triplex radial
plunger pump driven by a diesel engine to generate a pressure up to 145 MPa. Equipped with many
fuel pumping cams in each fuel pumping unit. This high-pressure fuel pump, makes the loads even and
reduces the operating noise. In this system, the pressure in the high pressure common rail cavity is
controlled through the fuel drain in the common rail cavity. In order to reduce power loss, one fuel
pumping unit in the triplex radial plunger pump will be closed to reduce the fuel delivery in case of small
quantity of fuel injected.
• The orbit common rail distributes the high-pressure fuel supplied by the fuelfeed pump to each injector
and plays a role of pressure reservoir. It’s volume should be possible to reduce the fuel supply pressure
12B
fluctuation of high-pressure fuel pump and the pressure shock of each injector caused by the injection
process to control the pressure fluctuation in the high-pressure fuel pump within 5 MPa. But to ensure
enough pressure response speed to track the change of diesel engine conditions rapidly, the volume
should not be overcapacity.
• As the most critical and complicated part in the common rail fuel system, the electro-injector is used to
inject the fuel in the high-pressure fuel rail into the combustion chamber of diesel engine with optimal
injection timing, fuel delivery and fuel injection rate by controlling the on and off of magnetic valve
based on the control signals sent by ECM.

1. Main relay (Damage) -
2. No fuel or poor fuel quality -
3. Fuel system (Air inside) Chapter 12B fuel - fuel filter, replacement
4. Lower-pressure fuel circuit (Block or Chapter 12B fuel - precaution

leakage)
Engine does not start
Chapter 12B fuel - high-pressure fuel
5. High-pressure fuel pump (Damage) pump, overhaul
6. Heater plug (Damage) -
7. High pressure common rail pressure Chapter 12B fuel - high pressure com-
regulator (Damage) mon rail, overhaul
8. njector solenoid valve (Damage) Chapter 12B fuel - fuel injector, overhaul

low pressure)
2. Poor fuel quality -
4. Heater plug (Out of order) -
Engine start hard 5. High-pressure fuel circuit (Low pres- Chapter 12B fuel - high-ressure fuel
sure) pump, overhau
6. High-pressure common rail pressure Chapter 12B fuel - high pressure com-
regulator (Damage) mon rail, overhaul
Chapter 12B fuel - high-ressure fuel

7. High-ressure fuel pump (Out of order) pump, overhaul
8. Fuel injector (Out of order) Chapter 12B fuel - fuel injector, overhaul

low pressure)
Engine idles rough
5. Fuel injector control wiring (Out of Chapter 04 diagnostics - engine control
order) system
regulator (Out of order) mon rail, overhaul
Chapter 12B fuel - high-ressure fuel

7. High-ressure fuel pump (Out of order) pump, overhaul
Engine emit white or blue Chapter 12B fuel - precaution 12B
smoke 2. Lower-pressure fuel circuit (Block)
3. Heater plug (Out of order) -
Engine emit black smoke Chapter 04 diagnostics - engine control
2. Fuel injector control wiring (Out of
order) system

low pressure)
Engine loss of power mon rail, overhaul
regulator (Out of order)
4. Fuel injector (Work badness) Chapter 12B fuel - fuel injector, overhaul
5. High-pressure fuel pump (Out of Chapter 12B fuel - high-pressure fuel

order) pump, overhaul
12B
COMPONENTS
1 Diesel Fuel Filter Assy 6 Fuel Tank Retaining Belt
2 Fuel Tube 7 Fuel Tank Front Fender
3 Fuel Level Sensor 8 Fuel Tank Filler Cap
4 Fuel Tank 9 Fuel Filling Guid Assy
5 Rear Fuel Tank Bracket

12B
1 Fuel Tank 5 Fuel Injector
2 Diesel Fuel Filter 6 Fuel Injector Return Hose
3 High-pressure Fuel Pump 7 Fuel Tee Joint Return Tube
4 High-pressure Common Rail 8 High-pressure Fuel Tube
12B
12B-8 FUEL - FUEL TANK ASSY
FUEL TANK ASSY

REPLACEMENT
1. RELIEVE FUEL PRESSURE. (Refer to “Chapter 12B fuel - precaution”).
2. DRAIN FUEL TANK. (Refer to “Chapter 12B fuel - precaution”)
5. SUPPORT FUEL TANK BY A JACK.
6. LOOSEN FUEL OUTLET HOSE CLIP AND DISCONNECT

HOSE.
7. LOOSEN FUEL RETURN HOSE CLIP AND DISCONNECT

HOSE.
8. LOOSEN FUEL FILLING HOSE CLIP AND DISCONNECT

IT FROM FUEL TANK.
9. LOOSEN FUEL TANK BREATHER HOSE CLIP AND

DISCONNECT HOSE FROM FUEL TANK.
FUEL - FUEL TANK ASSY 12B-9
10. DISCONNECT FUEL LEVEL SENSOR CONNECTOR.
12B
11. REMOVE REAR FUEL TANK BRACKET.

(a) Remove 2 rear fuel tank bracket retaining bolts.
(b) Take off the rear fuel tank bracket.
12. REMOVE FUEL TANK ASSY.

(a) Remove 2 fuel tank belt retaining bolts.
(b) Take off the fuel tank retaining belt.
(c) Take off the fuel tank assy.
NOTE
• Check if there is any dirt like mud and tube, harness
around the fuel tank, clean them if necessary.
• When removing fuel tank, as fuel tank is large and
heavy, it is necessary to use sutiable tool or have
others help.

12B
screws.
(b) Separate fuel lever sensor from sealing cover.
NOTE
fuel level sensor before this work and clean the dirty
away.
14. REMOVE FUEL TANK FRONT FENDER.

(a) Remove 3 front fender retaining bolts.
(b) Take off the front fender.

(a) Tighten 5 fuel level sensor sealing cover retaining
screws.
16. INSTALL FUEL TANK FRONT FENDER.

(a) Tighten 3 front fender retaining bolts.
17. INSTALL FUEL TANK.

(a) Lift the fuel tank assy to satiable position by jack.
(b) Tighten 2 rear fuel tank bracket retaining bolts.
(c) Install the 2 fuel tank retaining belt and tighten the bolts.
NOTE
• The fuel tank should be fastened and there shouldn’t
be abnormal viberation.
• The fuel tank retaining belt should be uniform and
flat.
FUEL - FUEL TANK ASSY 12B-11
18. CONNECT OUTLET HOSE AND TIGHTEN HOSE CLIP.
12B
19. CONNECT INLET HOSE AND TIGHTEN HOSE CLIP.
20. CONNECT FUEL TANK BREATHER HOSE AND FUEL

TANK, THEN TIGHTEN CLIP.
21. CONNECT FUEL FILLING HOSE AND FUEL TANK,

THEN TIGHTEN CLIP.
12B
22. CONNECT FUEL LEVEL SENSOR CONNECTOR.

23. LOWER VEHICLE.

25. CHECK FUEL TUBE.
Turn ignition switch ON and inspect the fuel gauge conditions. Start engine and inspect if there is fuel
leaks from pipe.
26. CHECK FUEL TANK.
(a) After installing fuel tank, inspect if fuel tank is damaged. It shoud be repaired on time.
27. CHECK FUEL TANK FILLER CAP.
(a) Check fuel filler cap in good conditions. If cap spring damaged or corroded, repair or replace it with a
new one.
FUEL - DIESEL FUEL FILTER ASSY 12B-13
DIESEL FUEL FILTER ASSY

REPLACEMENT
1. RELIEVE FUEL PRESSURE. (Refer to “Chapter 12B fuel - precaution”) 12B

3. LOOSEN DIESEL FILTER INLET HOSE CLIP AND

DISCONNECT IT FROM FUEL FILTER.
4. LOOSEN DIESEL FILTER OUTLET HOSE CLIP AND

DISCONNECT IT FROM FUEL FILTER.
12B
12B-14 FUEL - DIESEL FUEL FILTER ASSY
5. REMOVE DIESEL FILTER HAND PUMP RETAINING

BOLTS.
6. REMOVE DIESEL FILTER ASSY.

7. REPLACE DIESEL FILTER ASSY.
(a) Clean diesel filter suface completly and clamp diesel inlet hose.
(b) Remove the diesel filter assy by wrench or special tool.
(c) Clean filter bottom base, be sure to tighten the screw

connector of filter.
(d) Apply clean diesel to the new filter seal surface and fill
clean diesel to new filter.
(e) Lightly screw the diesel filter into bottom base, and
tighten it until feeling resistance.
(f) Using wrench or special tool, tighten diesel filter. Inspect
fuel leakage. 12B
(g) Bleed the air from diesel filter.
8. TIGHTEN DIESEL FILTER HAND PUMP RETAINING

BOLTS.
9. BLEED DIESEL FILTER.

(a) Open the fuel tank switch.
(b) Loosen the injector pump return hose.
12B
12B-16 FUEL - DIESEL FUEL FILTER ASSY
(c) Push hand pump knob at 40 times/min till outlet fuel with-
out air bubble. Discharge air from low pressure tube
(from fuel tank to fuel pump tube) and tighten the return
tube.
(d) Drag engine by starter to bleed air in high fuel pressure

tube (from fuel pump to injector tube). Do not loosen fuel
pump nut and rail end nut, injector end nut.
10. BLEED WATER FROM WATER/FUEL SEPARATOR .

NOTE
During engine running, water/fuel separator indicator keeps light, it means that water in water/fuel sep-
arator needs to be bleeded.
(a) Stop the vehicle at flat and safe place.
(b) Open the engine hood, put the suitable container (0.2L)
under the fuel/water seperator.
(c) Loosen drain plug (about five circles). Push and pull
knob ten times to drain water until fuel/water seperator is
full of diesel.
12B
(d) Tighten drain plug after bleeding the water. Pull and push
konb serval times.
(e) Start the engine to make sure that no fuel leaks from
drain plug. Check water/fuel indictor off.
NOTE
• If draining water from water/fuel sperator is frequent, it means that fuel is not qualified or there
is water in fuel tank. Please drive the vehicle to service station for repair.
• In order to ensure fuel clean, in strict accordance with maintenance requirement to operate fuel
filter sechudle maintenance. Replacement cycle: 15000 km.
11. CHECK.
Turn ignition switch ON and inspect the fuel gauge conditions. Start engine and inspect if there is fuel 12B
leakage from pipe.
12B-18 FUEL - FUEL LEVEL SENSOR ASSY
FUEL LEVEL SENSOR ASSY

REPLACEMENT
1. RELIEVE FUEL PRESSURE. (Refer to “Chapter 12B fuel - precaution”)
3. RAISE VEHICLE IN PLACE.
4. REMOVE FUEL TANK. (Refer to “Chapter 12B fuel - fuel tank, replacment”)

screws.
(b) Separate fuel level sensor from sealing cover.
NOTE
fuel level sensor before this work and clean the dirty
away.
6. REPLACE FUEL LEVEL SENSOR ASSY.

(a) Install fuel level sensor to sealing cover.
(b) Tighten 5 fuel level sensor sealing cover retaining
screws.
8. INSTALL FUEL TANK. (Refer to “Chapter 12B fuel - fuel tank, replacement”)
FUEL - FUEL LEVEL SENSOR ASSY 12B-19

CONNECTOR.
12B
10. CHECK.
(a) After disconnecting fuel pump connector, connect fuel level sensor connector and turn ignition switch
ON. Slide fuel level sensor position manually. Ensure that fuel gauge is in good condition from
instrument cluster.
(b) After connecting, check if the fuel tube connector and pipe are securely connected by pulling them.
Turn ignition switch On and inspect the fuel gauge conditions. Start engine and inspect if if there is fuel
leaks from pipe.
12B
12B-20 FUEL - HIGH-PRESSURE FUEL PUMP ASSY
HIGH-PRESSURE FUEL PUMP ASSY

REPLACEMENT
2. DISCONNECT BATTERY NEGATIVE CABLE .

4. LOOSEN HIGH-PRESSURE INLET FUEL HOSE CLIP

AND DISCONNECT INLET HOSE.
5. LOOSEN HIGH-PRESSURE RETURN FUEL HOSE

CLIP AND DISCONNECT RETURN HOSE.
6. DISCONNECT HIGH-PRESSURE PUMP CONNEC-

TOR.
FUEL - HIGH-PRESSURE FUEL PUMP ASSY 12B-21
7. DISCONNECT HIGH-PRESSURE FUEL TUBE.
12B
8. REMOVE 3 BOLTS ATTACHING HIGH-PRESSURE

PUMP TO FUEL PUMP FLANGE.
9. REMOVE ENGINE TIMING BELT. (Refer to “Chapter 15B engine mechanical - timing belt,
overhaul”)
10. REMOVE HIGH-PRESSURE PUMP TIMING PULLY

RETAINING BOLT.
12B
11. SEPERATE HIGH-PRESSURE PUMP AND PULLY.
12. REMOVE HIGH-PRESSURE PUMP.
NOTE
• Diesel apply BOSCH high-pressure pump. It can not be replaced freely.
• Every bolt of high-pressure pump has already been tighten before leaving factory. Do not
remove or adjust when using. If high-pressure pump has malfunction, it need authroized
engineer to inspect and test if necessary.
• Do not knock pump shaft when installing.
• The new fuel pump must be lubricated with special equipment and correct process at the first
time. Pump fuel from inlet till no bubble appear at fuel return flow. Noraml lubrication is needed
for friction pieces and sealing area.
12B-22 FUEL - HIGH-PRESSURE FUEL PUMP ASSY
13. TIGHTEN 3 BOLTS ATTACHING HIGH-PRESSURE

PUMP TO PUMP FLANGE.
NOTE
• Before installing fuel pump, clean dirt from drive
shaft by gasoline and alcohol.
• Ensure that the correct installing position is followed
when installing the high-pressure pump.
14. TIGHTEN HIGH-PRESSURE PUMP TIMING PULLEY

RETAINING BOLT.
15. INSTALL ENGINE TIMING BELT. (Refer to “Chapter 15b engine mechanical - timing belt,
overhaul”)
16. CONNECT HIGH-PRESSURE TUBE (CONNECTING

HIGH-PRESSURE COMMON RAIL).
17. CONNECT FUEL INLET HOSE (CONNECTING DIE-

SEL FILTER AND HIGH-PRESSURE PUMP ) AND
TIGHTEN CLIP.
FUEL - HIGH-PRESSURE FUEL PUMP ASSY 12B-23
18. CONNECT FUEL RETURN HOSE (CONNECTING

INJECTOR FUEL RETURN PARTS AND FUEL TANK )
AND HIGH-PRESSURE PUMP, THEN TIGHTEN CLIP.
12B
19. CONNECT HIGH-PRESSURE PUMP CONNECTOR.

12B
12B-24 FUEL - HIGH-PRESSURE COMMON RAIL
HIGH-PRESSURE COMMON RAIL

REPLACEMENT

4. DISCONNECT HIGH-PRESSURE COMMON RAIL

PRESSURE SENSOR.
5. REMOVE HIGH-PRESSURE DELIVERY PIPE.

NOTE
Remove common rail end first , then remove injectors and
high-pressure pump end. When removing injector and
pump connecting nuts, it is need to fix fuel pump injector
bolt seat to avoid the looseness of the bolts seat.
6. REMOVE HIGH-PRESSURE DELIVERY PIPE (CON-

NECTING HIGH-PRESSURE PUMP).
FUEL - HIGH-PRESSURE COMMON RAIL 12B-25
7. REMOVE HIGH-PRESSURE COMMON RAIL.

(a) Remove 2 bolts of high-pressure common rail bracket.
(b) Take common rail and bracket away.
(c) Remove 2 bolts of high-pressure common rail and bracket. 12B
(d) Seperate common rail from bracket.
8. INSTALL HIGH PRESSURE COMMON RAIL.

(a) Tighten 2 bolts of high-pressure common rail and bracket.
(b) Tighten 2 bolts of common rail bracket.
9. INSTALL HIGH-PRESSURE COMMON RAIL DELIVEY

PIPE (CONNECT HIGH-PRESSURE PUMP).
10. INSTALL EACH HIGH-PRESSURE DELIVERY PIPE.

NOTE 12B
• Tighten the injector and pump first, then install com-
mon rail.
• Each high-pressure tube nut marked 1, 2, 3, 4 to
match relevant cylinder. Marked 5 tube match high
pressure pump.
WARNING
The most pressure in high-pressure common rail can achieve
145 MPa, do not loosen high-pressure pump, common rail and
injector nuts when engine is running.
12B-26 FUEL - FUEL INJECTOR ASSY
FUEL INJECTOR ASSY

OVERHAUL

4. REMOVE INTAKE AIR HOSE. (Refer to “Chapter 14B intake air - intake air hose, replacement”)
5. REMOVE NUT FROM HIGH-PRESSURE TUBE (CON-

NECT COMMON RAIL).
NOTE
To avoid injector bolt seat looseness, it is need to fix
related bolt seat by other tool when removing injector nut.
6. DISCONNECT INJECT CONNECTOR.

NOTE
Connect or disconncet connetor only at switch off.
7. REMOVE INJECTOR PRESSING PLATE NUT.

FUEL - FUEL INJECTOR ASSY 12B-27
8. DISCONNECT INJECT FUEL RETURN TUBE CLIP.
12B
9. REMOVE FUEL INJECTOR ASSY.

NOTE
• Inspect the injector solenoid pin and surface.
• Inspect the injector with carbon deposition blocked. Clean carbon deposition by ultrasonic-
cleaning.
• Replace it with a new copper gasket after removing the injector.
10. REMOVE INJECTOR PRESSING PLATE PAD.
11. INSTALL INJECTOR PRESSING PLATE PAD.

NOTE
• Pressing plate pad installation direction: slope higher
side face injector. Do not install in opposite.
• BJ493 diesel has two different depth shim. (1.5mm 12B
and 3.5mm). BJ493ZLQ3 adopt 1.5mm depth shim.
BJ493ZQ3 turbo diesel adopt 3.5mm depth shim.
12. INSTALL FUEL INJECTOR ASSY.

NOTE
• Position injector gasket on atomizer element seal surface. Slightly push injector into cylinder
injector hole.
• Apply clean oil to lubricate all seal (O type ) when installing.
12B-28 FUEL - FUEL INJECTOR ASSY
13. TIGHTEN INJECTOR PLATE RETAINING BOLTS.

Torque:
First step: 7.5 ~ 9 N•m
Second step: turn 40 ~ 45°
14. CONNECT INJECTOR FUEL RETURN TUBE ASSEMBLY

CLIP.
NOTE
Fixing bracket of injector fuel return tube assembly must be
relaced if bended. Don’t install injector fuel return tube
assembly without fixing bracket.
15. CONNECT FUEL INJECTOR CONNECTOR.

NOTE
Clip must be installed correctly when connecting.
16. TIGHTEN HIGH-PRESSURE TUBE RETAINING BOLT

(CONNECTING HIGH-PRESSURE COMMON RAIL).
Torque: 25~29 N•m
17. INSTALL INTAKE AIR HOSE. (Refer to“Chapter 14B intake air - intake air hose, replacement”)

FUEL - FUEL INJECTOR ASSY 12B-29
19. CHECK.
(a) After connecting all connectors, check if the fuel tube connector and pipe are securely connected by
pulling them. Turn the ignition switch ON and inspect the fuel gauge conditions. Start engine and 12B
inspect if there is fuel leaks from fuel filter pipe.
12B
12B-30 FUEL - FUEL FILLING DOOR
FUEL FILLING DOOR

REPLACEMENT
1. PULL FUEL FILLING DOOR OPENING CABLE UNDER
DRIVER SEAT.
2. REMOVE FUEL FILLING DOOR RETAINING BOLT.
3. ADJUST FUEL FILLING DOOR POSITION IF FUEL

FILLING DOOR CAN NOT BE CLOSED COMPLETELY.
4. TIGHTEN FUEL FILLING DOOR RETAINING BOLTS.

EMISSION CONTROL
13B
FUEL TANK CAP .............................................................................13B-1
INSPECTION ............................................................................. 13B-1
EXHAUST GAS RECIRCULATION VALVE (EGR VALVE) ............ 13B-2
COMPONENTS ......................................................................... 13B-2 13B
REPLACEMENT ........................................................................ 13B-3
VACUUM REGULATOR .................................................................. 13B-5
OVERHAUL ............................................................................... 13B-5
13B
11B
12B
13B
EMISSION CONTROL - FUEL TANK CAP 13B-1
FUEL TANK CAP

EMISSION CONTROL
INSPECTION
13B
1. OPEN FUEL TANK FILLER CAP.
2. INSPECT FUEL TANK FILLER CAP ASSY.

(a) Visually inspect fuel tank cap and gasket if deformed or
damaged. Replace it with a new one if necessary.
(b) Termly lubricate the rotating part.
13B
13B-2 EMISSION CONTROL - EXHAUST GAS RECIRCULATION VALVE (EGR VALVE)
EXHAUST GAS RECIRCULATION VALVE (EGR VALVE)

COMPONENTS
1 EGR Valve 5 EGR Cooling Pipe Bracket
2 Gasket 6 EGR Connect Pipe
3 EGR Connect Pipe 7 Vacuum Regulator
4 EGR Cooling Pipe

EMISSION CONTROL - EXHAUST GAS RECIRCULATION VALVE (EGR VALVE) 13B-3
REPLACEMENT
(a) Remove 4 engine cover retaining bolts. 13B
2. REMOVE INTAKE AIR HOSE. (Refer to “Chapter 14B intake air system - intake air hose, replace-
ment”)
3. DISCONNECT EGR VACUUM TUBE (CONNECT VAC-

UUM REGULATOR).
4. REMOVE BOLTS ATTACHING EGR VALVE TO

EXHAUST MANIFOLD.
13B
5. REMOVE BOLTS ATTACHING EGR VALVE TO EGR
CONNECT PIPE.
13B-4 EMISSION CONTROL - EXHAUST GAS RECIRCULATION VALVE (EGR VALVE)
6. REPLACE EGR VALVE.

NOTE
Inspect whether EGR valve open/close smoothly or not. Replace it with a new one if blocked .
7. TIGHTEN BOLTS ATTACHING EGR VALVE TO EGR

CONNECT PIPE.
8. TIGHTEN BOLTS ATTACHING EGR VALVE TO

EXHAUST MANIFOLD.
9. CONNECT EGR VACUUM TUBE (CONNECT VACUUM

REGULATOR).
10. INSTALL INTAKE AIR HOSE. (Refer to “Chapter 14B intake air system - intake air hose, replace-
ment”)

EMISSION CONTROL - VACUUM REGULATOR 13B-5
VACUUM REGULATOR
OVERHAUL
1. DISCONNECT CONNECTOR OF VACUUM REGULATOR. 13B
2. DISCONNECT VACUUM REGULATOR TUBE (CON-

NECT EGR VALVE).
3. DISCONNECT VACUUM REGULATOR TUBE (CON-

NECT EXHAUST MANIFOLD).
13B
4. REMOVE VACUUM REGULATOR RETAINING BOLTS.
13B-6 EMISSION CONTROL - VACUUM REGULATOR
5. TAKE OFF VACUUM REGULATOR.

NOTE
• Visully inspect vacuum regulator without deformed or damage. Replace it with a new one if
abnormal.
• Turn the ignition switch OFF. Remove vacuum regulator connector and measure the resistance
between two terminal. The resistance should be around 41 ohm. If not, replce it with a new one.
Vacuum regulator working volts is 12 volt. Start time is less than 1s, shut down time is less than
0.2s.
• When EGR valve opens difficult or vacuum degree absence, please check whether air leaks
from the connected tube first.
• It can cause engine exhaust heavy black smoke with failed vacuum regulator.
6. POSITION VACUUM REGULATOR.
7. TIGHTEN VACUUM REGULATOR RETAINING BOLTS.

8. CONNECT VACUUM REGULATOR TUBE (CONNECT

EXHAUST MANIFOLD).
EMISSION CONTROL - VACUUM REGULATOR 13B-7
9. CONNECT VACUUM REGULATOR TUBE (CONNECT

EGR VALVE).
NOTE
When installing vacuum regulator, please connect the port 13B
with white point to vaccum port of EGR valve.
10. CONNECT CONNECTOR OF VACUUM REGULATOR.
13B
MEMO
INTAKE AIR
14B
INTAKE AIR SYSTEM...................................................................... 14B-1
PRECAUTION............................................................................ 14B-1
COMPONENTS ......................................................................... 14B-2
INTAKE AIR HOSE .......................................................................... 14B-3 14B
REPLACEMENT ........................................................................ 14B-3
AIR FILTER ASSY ........................................................................... 14B-5
REPLACEMENT ........................................................................ 14B-5
TURBOCHARGER ASSY ................................................................ 14B-9 14B
COMPONENTS ......................................................................... 14B-9
MAINTENANCE OF TURBOCHARGER ................................. 14B-10
OVERHAUL ............................................................................. 14B-11
INTAKE CONNECTION PIPE ........................................................ 14B-16
REPLACEMENT ...................................................................... 14B-16
INTAKE MANIFOLD....................................................................... 14B-19
REPLACEMENT ...................................................................... 14B-19
11B
12B
14B
14B
INTAKE AIR - INTAKE AIR SYSTEM 14B-1
INTAKE AIR SYSTEM

INTAKE AIR
PRECAUTION
1. INTAKE AIR SYSTEM PRECAUTION. 14B
(a) To avoid impuriy entry, the intake air must be filtered before entrying the engine. If the intake manifold
hose is broken or loosened, the unfilter air will enter and abrade.
(b) The intake manifold hose connection must be reliable enough to avoid gaps and looseness, etc.
(c) Each cushion and bracket connection with intake manifold hose must be reliable. There are no cracks
on the apperance or gaps in the connection portion.
(d) When using the solvent, acid or alkaline material washing, please follow the manufacturers’ advice.
wear protective clothing and goggles to avoid personal injury.
(e) When dealing with corrosive work, use skin and eye protection device to reduce the possibility of
personal injury.
(f) When using compressed air, wear appropriate goggles and protective mask. both dust particles and dirt
will cause injury.
14B
14B-2 INTAKE AIR - INTAKE AIR SYSTEM
COMPONENTS
1 Intake Resonator Assy (With Cushion) 5 Crankcase Breather Hose
2 Air Filter Assy 6 Air Intake Duct
3 Intake Air Hose 7 Intake Three-way Pipe
4 Turbocharger Intake Hose

INTAKE AIR - INTAKE AIR HOSE 14B-3
INTAKE AIR HOSE

REPLACEMENT
14B
1. LOOSEN INTAKE AIR HOSE CLIP.
2. REMOVE INTAKE AIR HOSE.
3. LOOSEN TURBOCHARGER INTAKE AIR HOSE CLIP.
4. DISCONNECT CRANKCASE BREATHER HOSE CLIP.
5. REMOVE TURBOCHARGER INTAKE AIR HOSE.

14B
6. CHECK INTAKE AIR HOSE. IF FIND SOMETHING DAMAGE LIKE BROKEN, PLEASE REPLACE
WITH A NEW ONE.
14B-4 INTAKE AIR - INTAKE AIR HOSE
7. POSITION TURBOCHARGER INTAKE AIR HOSE.
8. TIGHTEN TURBOCHARGER INTAKE AIR HOSE

CLIPS.
9. CONNECT CRANKCASE BREATHER HOSE CLIP.
10. POSITION INTAKE AIR HOSE.
11. TIGHTEN INTAKE AIR HOSE CLIPS.

INTAKE AIR - AIR FILTER ASSY 14B-5
AIR FILTER ASSY

REPLACEMENT
14B
1. REMOVE 2 AIR FILTER INTAKE DUCT RETAINING
BOLTS AND TAKE AWAY AIR FILTER INTAKE DUCT.
2. LOOSEN INTAKE AIR HOSE CLIPS.
3. LOOSEN INTAKE THREE-WAY PIPE CONNECTING

CLIPS.
14B
4. REMOVE 3 AIR FILTER ASSY RETAINING BOLTS.

14B-6 INTAKE AIR - AIR FILTER ASSY
5. LOSSEN AIR FILTER UPPER COVER CLIPS.
6. OPEN AIR FILTER UPPER COVER AND TAKE OUT

AIR FILTER.
NOTE
Air filter is made from paper. If necessary, clean the air filter
with the high pressure air gun. Do not clean the air filter
with water.
7. CLEAN OR REPLACE THE AIR FILTER.
8. INSTALL AIR FILTER UPPER COVER AND TIGHTEN

CLIPS.
NOTE
Before installing the air filter upper cover clip, adjust the
position attaching the air filter upper cover to the pressur-
izer tank intake hose.
INTAKE AIR - AIR FILTER ASSY 14B-7
9. POSITION AIR FILTER ASSY.
10. TIGHTEN 3 AIR FILTER ASSY RETAINING BOLTS.

14B
11. TIGHTEN INTAKE AIR HOSE CLIP.
12. INSTALL INTAKE THREE-WAY PIPES AND TIGHTEN

CLIPS.
14B
13. TIGHTEN 2 AIR FILTER INTAKE DUCT RETAINING
BOLTS.
NOTE
• The clean intake air has a great effect on diesel engine
using, do not operate the engine without installing the air
filter.
• Air filter blocking will cause oil leakage from
turbocharger. Therefore, the maintenance or
replacement of air filter must be performed periodically.
14B-8 INTAKE AIR - TURBOCHARGER ASSY
TURBOCHARGER ASSY
COMPONENTS
1 Adjustable Nut 10 Compressor Machine
2 Exhaust Valve 11 Intake Hose
3 Rocker Arm 12 Fresh Air
4 Pin 13 Vacuum Hose
5 Exhaust Pipe 14 Compressing Room
6 Turbo Machine 15 Mebrane
7 Turbine Blade 16 Spring
8 Middle Body 17 Push Rod
9 Compressor Blade 18 Exhaust Gas Intake

INTAKE AIR - TURBOCHARGER ASSY 14B-9
MAINTENANCE OF TURBOCHARGER
To ensure work efficiency and reliability of turbo-charged diesel, the turbocharger must be given a
regular maintenance besides the proper operation of the diesel. Turbocharger is a kind of precise
machine with high rotating speed, its maximum speed can reach 180000 r/min and even normal speed 14B
can reach from tens of thousands per minute to hundreds of thousands per minute, therefore, pay
attention not to disassemble its assembly. If the rotor is hard to rotate or the diesel engine has poor
performance due to excessive dirt or carbon deposits, replace turbocharger parts.
NOTE
Don’t have the impeller collided when replacing the turbocharger. In case there is a collision on the
blade, the deformed blades should not be used after correction. Kerosene, gasoline or diesel oil with
high quality can be used as cleaning agent.
14B
OVERHAUL
3. REMOVE TURBOCHARGER OIL INLET PIPE

RETAINING BOLT.
4. REMOVE 2 TURBOCHARGER OIL OUTLET PIPE

RETAINING BOLTS.
5. LOOSEN TURBOCHARGER AIR OUTLET HOSE

CLIPS.
6. REMOVE EGR EXHAUST PIPE RETAINING BOLTS.
14B
7. REMOVE EXHAUST MANIFOLD WITH TURBOCHARGER ASSY. (Refer to “Chapter 16B exhaust -
exhaust manifold, replacement”)
8. REMOVE 4 BOLTS ATTACHING TURBOCHARGER

TO EXHAUST PIPE.
9. REMOVE GASKET AND REPLACE WITH A NEW ONE.
10. REMOVE 4 BOLTS ATTACHING TURBOCHARGER

TO EXHAUST MANIFOLD.
11. REMOVE GASKET AND REPLACE WITH A NEW ONE.

12. REMOVE TURBOCHARGER ASSY. 14B
NOTE
• The valve of open pressure is set by the manufacturer. Forbidden user to make any
adjustments for the nut on the push rod. Otherwise, it will seriously damage the engine
performance, economy and reliability.
• During the engine operation, if find leakage from lead tracheal or push rod not flexible enough,
please stop the engine and resolve the malfunction at once.
• Neither exhaust valve nor compressoring room can be serviced. If damaged, replace the
turbocharger assy.
• Please do not replace the turbocharger unless you find out the malfunction.
13. INSPECT TURBOCHARGER.

(a) Check of rotor’s radial clearance: Press the compressor blades with a hand in radial direction and
measure the minimum clearance between the compressor blade and compressor casing with thickness
gauge. The measured value should not be less than 0.10mm, if not, replace the turbocharger assy.
(b) Check of rotor’s axial clearance: Fix a magnetic base on outlet flange facing of turbocharger, let the dial
indicator touch the rotor spindle, and then push or pull the turbocharger rotor in axial direction to get a
clearance value, the measured value is the clearance value. The rotor’s axial clearance value of new
turbocharger should not be more than 0.1mm and operating limit value should not be more than
0.25mm. If the axial clearance value of turbocharger rotor exceeds the operating limit value, replace the
turbocharger.
(c) Check whether the impeller blades of compressor of turbocharger are damaged. If there is a damage,
replace the turbocharger. If the impeller of compressor is damaged, check whether the inlet pipe and
core of filter are damaged. Repair all damaged parts before running the engine.
(d) Check whether the turbine blades are damaged. If there is a damage, replace the turbocharger.
(e) Check whether there is an abnormal status in linked push rod. If the push rod is bent or has excessive
abrasion, replace the turbocharger.
(f) Check whether there is any oil in compressor inlet and outlet of the turbocharger. If there is oil in
compressor inlet and outlet, check the upper parts of turbocharger to find out the source of oil leakage.
NOTE
A little oil and/or mist on the engine of closed crankcase ventilation system is permitted. The oil and/or
mist is discharged into the intake pipe through the crankcase.
14. INSTALL TURBOCHARGER ASSY.
15. TIGHTEN BOLTS ATTACHING TURBOCHARGER TO

EXHAUST MANIFOLD AFTER INSTALLING A NEW
GASKET.
16. TIGHTEN 4 BOLTS ATTACHING TURBOCHARGER

TO EXHAUST PIPE AFTER INSTALLING A NEW GAS-
KET.
17. INSTALL EXHAUST MANIFOLD WITH TURBOCHARGER ASSY. (Refer to “Chapter 16B exhaust -
exhaust manifold, replacement”)
18. TIGHTEN EGR EXHAUST PIPE RETAINING BOLTS.

14B
19. TIGHTEN TURBOCHARGER AIR OUTLET HOSE

CLIP.
20. TIGHTEN 2 TURBOCHARGER OIL OUTLET PIPE

RETAINING BOLTS.
Torque: 7.5 ~ 8.5 N•m
21. TIGHTEN TURBOCHARGER OIL INLET PIPE

RETAINING BOLT.
14B
22. INSTALL INTAKE AIR HOSE. (Refer to “Chapter 14B intake air - intake air hose, replacement”)

INTAKE AIR - INTAKE CONNECTION PIPE 14B-15
INTAKE CONNECTION PIPE

REPLACEMENT
1. DRAIN COOLANT. (Refer to “Chapter 17B cooling - precaution”) 14B
2. REMOVE 2 EGR EXHAUST PIPE RETAINING BOLTS.

CLIPS.
4. REMOVE 2 BOLTS ATTACHING INTAKE CONNECTING

PIPE TO INTAKE MANIFOLD.
5. REMOVE 2 BOLTS ATTACHING EGR EXHAUST PIPE

TO EGR EXHAUST COOLING PIPE. 14B
14B-16 INTAKE AIR - INTAKE CONNECTION PIPE
6. REMOVE 4 BOLTS ATTACHING EGR EXHAUST PIPE TO

INTAKE CONNECTING PIPE.
7. LOOSEN EGR EXHAUST COOLING PIPE COOLANT

INLET\OUTLET HOSE CLIPS.
8. REMOVE INTAKE CONNECTING PIPE ASSY.
9. INSTALL INTAKE CONNECTING PIPE ASSY.
10. INSTALL EGR EXHAUST COOLING PIPE CLIPS.

INTAKE AIR - INTAKE CONNECTION PIPE 14B-17
11. TIGHTEN 4 BOLTS ATTACHING EGR EXHAUST PIPE TO

INTAKE CONNECTING PIPE.
14B
12. TIGHTEN 2 BOLTS ATTACHING EGR EXHAUST PIPE

TO EGR EXHAUST COOLING PIPE.
13. TIGHTEN 2 BOLTS ATTACHING INTAKE CONNECTING

PIPE TO INTAKE MANIFOLD.

CLIPS.
14B
15. TIGHTEN 2 EGR EXHAUST PIPE RETAINING BOLTS

AND FILL COOLANT.
14B-18 INTAKE AIR - INTAKE MANIFOLD
INTAKE MANIFOLD
REPLACEMENT
2. DRAIN COOLANT. (Refer to “Chapter 17B cooling - precaution”)

3. REMOVE INTAKE CONNECTING PIPE. (Refer to “Chapter 14B intake air - intake connecting
pipe, replacement”)
4. REMOVE 8 INTAKE MANIFOLD RETAINING BOLTS.
5. REMOVE INTAKE MANIFOLD.

NOTE
Check the intake manifold carefully. If there is groove,
scratch, craze or crank on it, please replace it with a new
one.
6. REMOVE INTAKE MANIFOLD GASKET.

NOTE
Any debris on seal surface will lead to leakage. Use scraper to clean intake manifold gaskete. Be
careful, do not scratch the connection protion of metal surface.
INTAKE AIR - INTAKE MANIFOLD 14B-19
7. INSTALL INTAKE MANIFOLD WITH A NEW GASKET.
14B
8. INSTALL 8 RETAINING BOLTS BY HAND FIRST,

THEN TIGHTEN BOLTS FROM MIDDLE TO SIDE
REGULARLY.
9. INSTALL INTAKE CONNECTING PIPE. (Refer to “Chapter 14B intake air - intake connecting pipe,
replacement”)
10. FILL COOLANT. (Refer to “Chapter 17B cooling - precaution”)

14B
MEMO
ENGINE MECHANICAL
15B
ENGINE MECHANICAL PART ........................................................ 15B-1
PRECAUTION............................................................................ 15B-1
PROBLEM SYMPTOMS TABLE................................................ 15B-2
ENGINE ASSY ................................................................................. 15B-5 15B
REPLACEMENT ........................................................................ 15B-5
ENGINE ACCESSORY BELT ........................................................ 15B-21
POWER STEERING PUMP AND A/C COMPRESSOR BELT
OVERHAUL ............................................................................. 15B-21 15B
GENERATOR OVERHAUL...................................................... 15B-25
ENGINE TIMING BELT COVER .................................................... 15B-29
REPLACEMENT ...................................................................... 15B-29
ENGINE TIMING BELT .................................................................. 15B-32
COMPONENTS ....................................................................... 15B-32
OVERHAUL ............................................................................. 15B-33
CYLINDER HEAD AND VALVE..................................................... 15B-42
COMPONENTS ....................................................................... 15B-42
OVERHAUL ............................................................................. 15B-43
CAMSHAFT.................................................................................... 15B-56
OVERHAUL ............................................................................. 15B-56
ENGINE BLOCK ............................................................................ 15B-59
COMPONENTS ....................................................................... 15B-59
OVERHAUL ............................................................................. 15B-61
PISTON AND CONNECTING ROD ASSY..................................... 15B-68
COMPONENTS ....................................................................... 15B-68
OVERHAUL ............................................................................. 15B-70
11B
12B
14B
14B
15B
ENGINE MECHANICAL - ENGINE MECHANICAL PART 15B-1
ENGINE MECHANICAL PART

ENGINE MECHANICAL
PRECAUTION
1. ENGINE MECHANICAL PART PRECAUTION. 15B
(a) When using, follow the instructions of maintenance methods and regulations to adjust or maintain.
(b) Before starting the engine, check the coolant level, fill or drain the coolant if necessary. check the
engine oil level, fill the engine oil if necessary.
(c) The clearance between ckp sensor and flywheel is 0.5 ~ 1.5 mm. do not try to adjust it.
(d) Use the oil as requirement. otherwise exacerbate engine wear.
(e) Use the original fittings, otherwise it will damage the engine or affect the engine working condition.
(f) Do not use the high pressure water cannons wash the ecm shell though it is waterproof.
(g) The engine starting time should be less than 5 s. two starting interval 2 ~ 3 minutes, if can not start the
engine in five times, troubleshooting, then restarting.
(h) Keep the normal coolant temperature 85 ～ 105 ℃ .
(i) When the engine in high speed or high load, do not turn the ignition switch off.
(j) Before opening the radiator cap, ensure the engine is cool.
(k) Use the sealant scraper to clear the sundrise in seal surface. confirm seal surface flat and smooth, no
pollution and foreign bodies.
(l) Disassembly sequence should be generally from inner to outer, assembly to parts. In order to improve
the efficiency and ensure the assembly and disassembly correct, pay attention to checking and making
mark. Removed parts should be cleaned and inspected. the parts can be reused according to the
classification. Precision parts should be separated with general parts. put them in clean containers.
(m) Assembly sequence should be from inside to outside, parts to components, components to assembly.
Pay attention to the size, location, clearance, torque, etc. When assembling, avoid the missing,
mistaking, scratching and foreign parts into machine. Assemble bolts, nuts with suitable wrench,
uniform properly. Use anti-losseness device correctly. According to regulations, appropriately use split
cotters, spring washer, thrust washers, etc. In addition, in the assembly process, must pay attention to
the marks to ensure the good position.
(n) Ensure the diesel engine always in the state of complete cleaness. Before removing or assembling,
parts should be cleaned to ensure clean and high quality assembly. More complicated adjustment and
maintenance should be done indoor to prevent diesel engine internal parts from environmental
pollution.
(o) The machine adopts bosch high pressure common rail system. the efi parts are sensitive components,
avoid wet. before maintaining and repairing diesel engine, disconnect the battery connector to prevent
damaging the ecm.
(p) Pay attention to the security when repairing or dismantling. improper tool or engine starting suddenly
will result in injury.
15B
15B-2 ENGINE MECHANICAL - ENGINE MECHANICAL PART

DESCRIPTIONS
1. Due to part abrasion, deformation, improper use and technical maintenance and other reasons,
technical conditions of each part get worse. If some technical indexes exceed permissible limit,
it indicates that the diesel engine has a fault. If the fault of diesel engine isn’t eliminated timely
and correctly, the diesel engine would not be able to work normally. It will not only cause the
decline in power performance and fuel economy of the engine and deterioration of operation,
but may cause earlier abrasion to parts, and even may cause accidental damage.
2. Some faults of diesel engine such as air existing in fuel system, block of filter, loose drive belt
etc, can be eliminated after necessary technical maintenances and adjustments. However, some
faults of diesel such as serious damage of cylinder head gasket, serious abrasion of piston ring,
abrasion of valve cone surface etc. can not be eliminated after general maintenances and
adjustments because the part itself is damaged. Those faults can be eliminated only through
disassembling and repairing the diesel engine or replacing some parts.
3. BJ493ZQ type of diesel engine adopts Electronic Controlled Common Rail System. Fault of
electronic control system refers to illuming of SVS malfunction indicator lamp. If the SVS mal-
function indicator lamp lights up, it indicates that the electronic control system has a fault
which needs an immediate elimination. Both types of fault need to be checked with the diagnos-
tic scanner or special equipment which can achieve equivalent function.
NOTE
• Faults of diesel engine are often caused by improper operation or absence of maintenance. When a
fault appears, first check whether you strictly followed the rules and regulations of operation and
maintenance.
• Fault of the diesel engine should be immediately eliminated. For troubleshooting, at first, carefully
check and analyze the cause of fault rather than disassemble fault part blindly. Diagnosis and
troubleshooting for more complex fault can be carried out with the help of some instruments and special
equipments.
• Only the diesel engine in good technical condition can be permitted to work, diesel engine in “sick”
condition is not allowed to work. If the diesel engine works in “sick” condition, it will not only increase
parts damage and shorten service life, but even cause a fatal accident.
ENGINE MECHANICAL - ENGINE MECHANICAL PART 15B-3
cause of the problem. Check each part in the order shown. If necessary, repair or replace these parts

15B
1. Battery (Low voltage or loose Chapter 20B starting and charging - battery,
connect) precaution
2. Fuel pump (Damaged) Chapter 12B fuel - fuel pump, overhaul
Chapter 20B starting and charging - starter,

3. Starting (Damaged) overhaul
4. Fuel system (Block) Chapter 12B fuel - precaution
5. Main relay (Damaged) -
Engine does not start 7. High-pressure fuel pump Chapter 12B fuel - high-pressure fuel pump,
(Damaged) overhaul
8. Injector solenoid valve (Damaged) Chapter 12B fuel - fuel injector, overhaul
Chapter 15B engine mechanical - piston and

9. Piston ring (Wear) connecting rod, overhaul
Chapter 15B engine mechanical - cylinder

10.Valve (Air leakage) head, overhaul
Chapter 15B engine mechanical - timing belt,

11. Engine timing (Incorrect) overhaul
12.Cylinder compressure (Lower) -
1. Fuel system (Block) Chapter 12B fuel - precaution
Chapter 15B engine mechanical - timing belt,

2. Engine timing (Incorrect) overhaul
3. Cylinder head gasket (Air leak- Chapter 15B engine mechanical - cylinder
age) head, overhaul
Engine loss of power -
4. Cylinder compressure (Lower)
5. Valve (Burned, warped, excessive Chapter 15B engine mechanical - cylinder

clearance) head, overhaul
6. Exhaust system (Block) Chapter 16B exhaust - precaution

15B
15B-4 ENGINE MECHANICAL - ENGINE MECHANICAL PART
1. Piston pin and small head bushing Chapter 15B engine mechanical - piston and
hole clearance (Excessive connecting rod, overhaul
bearing clearance)
2. Piston and cylinder sleeve clear- Chapter 15B engine mechanical - piston and
ance (Excessive bearing connecting rod, overhaul
clearance)
Engine noise 3. Connecting rod bearing, main Chapter 15B engine mechanical - piston and
bearing (Excessive bearing connecting rod, overhaul
clearance)
4. Valve and piston (Valve touch the Chapter 15B engine mechanical - cylinder
piston) head and valve, overhaul
5. Intake and exhaust valve Chapter 15B engine mechanical - cylinder

(Excessive clearance) head and valve, overhaul
1. Piston ring (Lock, excessive Chapter 15B engine mechanical - piston and
wear, wrong position) connecting rod, overhaul
Engine exhaust blue 2. Piston and cylinder sleeve clear- Chapter 15B engine mechanical - piston and
vapor ance (Excessive bearing connecting rod, overhaul
clearance)
3. Engine oil (Too much) -
1. Diesel (Water inside) -Chapter 12B fuel - fuel filter, replacement

Engine exhaust white
vapor
2. Individual cylinder is not burning -
1. Diesel engine overload Chapter 15B engine mechanical - precaution
Chapter 15B engine mechanical - cylinder

2. Valve (Excessive clearance) head and valve, overhaul
Engine exhaust black Chapter 14B intake air - intake air filter,
vapor 3. Intake air filter (Block) replacement
Chapter 13B emission control - EGR valve,

4. EGR valve (Damaged) replacement
5. Injector solenoid valve (Damaged) Chapter 12B fuel - fuel injector, overhaul
ENGINE MECHANICAL - ENGINE ASSY 15B-5
ENGINE ASSY
REPLACEMENT
NOTE 15B
• Before raising the vehicle, ensure the support position on the vehicle correctly.
• Turn the ignition switch off and lock the steering column assy.
• Use the fender protect cover to avoid damaging paint surface.
• Avoid damage, hold the head of the connector and connect wire carefully.
• Mark in all wires and hoses, and confirm not touch with the other wires or hoses, or interfere
with other parts.
• Drain coolant. (Refer to “Chapter 17B cooling - coolant, replacement”)
1. REMOVE ENGINE HOOD. (Refer to “Chapter 87 engine hood and doors - engine hood,
replacement”)

3. DISCONNECT BATTERY NEGATIVE CABLE, THEN BATTERY POSITIVE CABLE.
4. REMOVE BATTERY HOLD DOWN RETAINING BOLTS

AND TAKE IT AWAY.
5. REMOVE BATTERY.
6. REMOVE INTAKE AIR HOSE. (Refer to “Chapter 14B intake air - intake air hose, replacement”) 15B
7. DISCONNECT ENGINE ROOM JUNCTION BOX WIRE CONNECTOR.
8. DISCONNECT ENGINE ROOM JUNCTION BOX LOAD OF ELECTRICAL EQUIPMENT
CONNECTORS (IF AFFECT ENGINE MOUNT REMOVAL).
9. REMOVE ENGINE CONTROL WIRE HARNESS CLIP.
10. TAKE ENGINE ROOM JUNCTION BOX AWAY.
15B-6 ENGINE MECHANICAL - ENGINE ASSY
11. DISCONNECT HIGH-PRESSURE FUEL PUMP INLET

HOSE CLIP AND SEPARATE HOSE (CONNECT FUEL
FILTER).

HOSE CLIP AND SEPARATE HOSE (CONNECT FUEL
TANK AND FUEL INJECTOR RETURN HOSE).
13. DISCONNECT HIGH-PRESSURE FUEL PUMP CON-

NECTOR.
NOTE
After disconnecting the fuel hose, using the plastic bag,
seal up the fuel hose connector, prevent the dust entering
the fuel hose.
14. REMOVE VACUUM BOOSTER ASSY HOSE.

15. DRAIN CLUTCH/BRAKE FLUID.
16. DISCONNECT CLUTCH CYLINDER AND CLUTCH

HYDRAULIC PIPELINE CONNECTOR.
15B
18. REMOVE GEAR SELECTOR RETURN SPRING.

WARNING
When removing the return spring, take the necessary
protection method to prevent injuries.
19. REMOVE NUT ATTACHING TRANSMISSION CONTROL

15B
20. DISCONNECT TRANSMISSION CONTROL UNIT WITH

GEAR SELECTOR ROD ASSY AND CHANGE SHIFTER
ASSY.
(a) Remove the nut attaching gear selector rod arm to gear
selector rod assy.
(b) Remove the nut attaching gearshift arm to gearshift assy.
21. DRAIN STEERING FLUID, DISCONNECT STEERING

FLUID RESERVOIR INLET HOSE AND OUTLET PIPE.
NOTE
Do not splash the steering fluid on the engine parts, erase
the fluid immediately.
22. REMOVE 2 VACUUM CONTAINER RETAINING BOLTS

AND DISCONNECT VACUUM HOSE.
23. DISCONNECT HEATER INLET/OUTLET HOSES ON

THE VEHICLE.
15B
24. DISCONNECT RADIATOR UPPER COOLANT HOSE.
25. DISCONNECT RADIATOR LOWER COOLANT HOSE.
26. RECOVER REFRIGERANT. (Refer to “Chapter 61 heater and air conditioning - refrigerant,
replacement”)
27. REMOVE 2 BOLTS ATTACHING A/C PIPE TO A/C

COMPRESSOR.
NOTE
Using clean cloth, block the A/C pipe and A/C compressor
hole to avoid dust entering.
15B
28. INSTALL ENGINE LIFT CHAIN HANGERS.

29. RAISE VEHICLE TO TOP PLACE.
30. REMOVE THE FRONT WHEEL. (Refer to “ Chapter 33 tire and wheel - front tire and wheel,
replacement”)
32. REMOVE 2 BOLTS ATTACHING CATALYTIC CONVERTER

TO EXHAUST PIPE.
33. REMOVE LOWER CONTROL ARM. (Refer to “Chapter 31 front suspension - lower control arm,
replacement”)
34. REMOVE STEERING GEAR ASSY. (Refer to “Chapter 52 steering - steering gear assy,
replacement”)
35. SEPARATE TRANSMISSION TO PROPELLER SHAFT ASSY. (Refer to “Chapter 34 axle and
36. DISCONNECT FOLLOWING ELECTRICAL CONNECTORS.
• MAF Sensor
• Generator
• Generator Positive Terminal
• Fuel Injector
• Glow Plug
• Common Rail Pressure Sensor
• High-pressure Fuel Pump
• Fuel/Water Seperator
• ECT Sensor
• ECM
• CMP Sensor
• CKP Sensor
• A/C Compressor
• Starter Positive Terminal
• Cooling Fan
37. USING A JACK, SUPPORT VEHICLE.
38. REMOVE BOLT ATTACHING ENGINE MOUNT TO

SUB-FRAME.
15B
39. REMOVE NUTS ATTACHING TRANSMISSION MOUNT TO

VEHICLE BODY.
40. REMOVE 4 BOLTS ATTACHING SUB-FRAME TO

VEHICLE BODY AND TAKE AWAY SUB-FRAME.
NOTE
Before removing sub-frame, mark the sub- frame and sub-
frame retaining bolts.
41. LOWER ENGINE SUPPORT JACK AND RELEASE ENGINE LIFT CHAIN HANGERS SLOWLY.
42. VERIFY ALL VACUUM HOSES, FUEL AND COOLANT HOSES, ELECTRICAL CONNECTORS
BETWEEN ENGINE/TRANSMISSION AND VEHICLE ARE DISCONNECTED.
43. LOWER ENGINE ABOUT 150 MM SLOWLY. VERIFY ALL COMPONENTS BETWEEN THE
ENGINE/TRANSMISSION AND VEHICLE ARE DISCONNECTED AGAIN.
44. REMOVE ENGINE WITH TRANSMISSION ABOVE VEHICLE.
15B
45. REMOVE BOLTS ATTACHING ENGINE TO SUB-

FRAME AND SEPARATE THEM.
46. REMOVE STARTER RETAINING BOLTS AND SEPARATE

STARTER FROM TRANSMISSION.
47. REMOVE BOLTS ATTACHING ENGINE TO TRANSMISSION

AND SEPARATE TRANSMISSION FROM ENGINE.
48. REMOVE CLUTCH PRESSURE PLATE RETAINING BOLTS. (Refer to “Chapter 42 clutch - clutch
49. REMOVE ENGINE ACCESSORY BELT. (Refer to “Chapter 15B engine mechanical - engine
50. REMOVE GENERATOR RETAINING BOLTS AND

SEPARATE GENERATOR FROM BRACKET.
15B
51. REMOVE BOLTS ATTACHING A/C COMPRESSOR TO ENGINE AND TAKE AWAY A/C
COMPRESSOR. (Refer to “Chapter 61 heater and air conditioning - compressor, overhaul”)
52. TIGHTEN GENERATOR RETAINING BOLTS.

53. TIGHTEN A/C COMPRESSOR RETAINING BOLTS. (Refer to “Chapter 61 heater and air
conditioning - compressor, overhaul”)
54. TIGHTEN CLUTCH PRESSURE PLATE RETAINING BOLTS. (Refer to “Chapter 42 clutch - clutch
55. INSTALL ENGINE ACCESSORY BELT. (Refer to “Chapter 15B engine mechanical - engine
56. TIGHTEN BOLTS ATTACHING ENGINE TO TRANSMISSION.

15B
57. TIGHTEN STARTER RETAINING BOLTS.

58. TIGHTEN BOLTS ATTACHING ENGINE TO SUB-

FRAME.
59. INSTALL ENGINE WITH TRANSMISSION FROM BOTTOM OF VEHICLE, INSTALL ENGINE LIFT
CHAIN HANGERS.
60. TIGHTEN 4 BOLTS ATTACHING SUB-FRAME TO

VEHICLE BODY.
Torque: 205 ~ 215 N•m
NOTE
According to the mark on the sub-frame retaining bolt,
position the sub-frame.
61. TIGHTEN BOLT ATTACHING ENGINE MOUNT TO

SUB-FRAME.
62. TIGHTEN NUTS ATTACHING TRANSMISSION MOUNT

TO VEHICLE BODY.
Torque: 110 ~ 130 N•m
15B
63. TIGHTEN 2 BOLTS ATTACHING CATALYTIC CONVERTER

TO EXHAUST PIPE.
64. INSTALL EXHAUST PIPE RETAINING BELT BOLT.

65. INSTALL LOWER CONTROL ARM. (Refer to “Chapter 31 front suspension - lower control arm,
replacement”)
66. INSTALL STEERING GEAR ASSY. (Refer to “Chapter 52 steering - steering gear assy,
replacement”)
67. CONNECT TRANSMISSION TO PROPELLER SHAFT ASSY. (Refer to “Chapter 34 axle and
68. INSTALL THE FRONT WHEEL. (Refer to“Chapter 33 tire and wheel - front tire and wheel,
replacement”) 15B
69. LOWER VEHICLE AND LOSSEN ENGINE LIFT CHAIN HANGERS.
70. TIGHTEN 2 BOLTS ATTACHING A/C PIPE TO A/C

COMPRESSOR.
NOTE
Install a new O-ring.
71. CONNECT THE HEATER INLET/OUTLET HOSES ON

THE VEHICLE.
72. TIGHTEN 2 VACUUM CONTAINER RETAINING BOLTS

AND CONNECT VACUUM HOSE.
73. CONNECT RADIATOR UPPER COOLANT HOSE AND

TIGHTEN CLAMP.
74. CONNECT RADIATOR LOWER COOLANT HOSE AND

TIGHTEN CLAMP.
75. CONNECT STEERING FLUID RESERVOIR INLET HOSE

AND OUTLET PIPE.
77. CONNECT CLUTCH CYLINDER AND CLUTCH HYDRAULIC

PIPELINE CONNECTOR.
15B
78. INSTALLE GEAR SELECTOR RETURN SPRING.

WARNING
When installing the return spring, take the necessary
protection method to prevent injuries.
79. TIGHTEN NUT ATTACHING GEAR SELECTOR ROD

ARM TO GEAR SELECTOR ROD ASSY.
15B
80. TIGHTEN NUT ATTACHING GEARSHIFT ARM TO

GEARSHIFT ASSY.
81. TIGHTEN NUT ATTACHING TRANSMISSION CONTROL

82. LOWER VEHICLE.
83. CONNECT VACUUM BOOSTER ASSY HOSE AND

TIGHTEN CLAMP.

HOSE CLAMP AND SEPARATE HOSE (CONNECTING
FUEL FILTER).
15B

HOSE CLAMP AND SEPARATE HOSE (CONNECTING
FUEL TANK AND FUEL INJECTOR RETURN HOSE).
86. DISCONNECT HIGH-PRESSURE FUEL PUMP

CONNECTOR.
87. INSTALL ENGINE ROOM JUNCTION BOX.

88. CONNECT FOLLOWING ELECTRICAL CONNECTORS:
• MAF Sensor
• Generator
• Generator Positive Terminal
• Fuel Injectors
• Glow Plug
• Common Rail Pressure Sensor 15B
• High-pressure Fuel Pump
• Fuel/Water Seperator
• ECT Sensor
• ECM
• CMP Sensor
• CKP Sensor
• A/C Compressor
• Starter Positive Terminal
• Cooling Fan
89. INSTALL LOWER GUARD PLATE RETAINING BOLT.


91. FILL STEERING FLUID. (Refer to “Chapter 52 power steering - steering fluid, replacement”)
92. FILL BRAKE FLUID. (Refer to “Chapter 35 brake - brake fluid, bleeding6”)

94. INSTALL ENGINE HOOD. (Refer to “Chapter 87 engine hood and doors - engine hood,
replacement”)
ENGINE MECHANICAL - ENGINE ACCESSORY BELT 15B-21
ENGINE ACCESSORY BELT

POWER STEERING PUMP AND A/C COMPRESSOR BELT OVER-
HAUL 15B

2. REFRIGERATE ENGINE, LET BELT SURFACE TEMPERATURE AS CLOSE AS POSSIBLE TO THE

NORMAL TEMPERATURE.
3. LOOSEN 2 POWER STEERING PUMP BRACKET

RETAINING BOLTS.
NOTE
Loosen, not remove.
4. LOOSEN ADJUSTMENT BOLT.
5. TAKE POWER STEERING PUMP BELT AND A/C

15B
COMPRESSOR BELT AWAY.
15B-22 ENGINE MECHANICAL - ENGINE ACCESSORY BELT
6. INSPECT POWER STEERING PUMP BELT AND A/C

COMPRESSOR BELT.
glistening.

of the belt.

7. INSPECT EACH PART OF POWER STEERING PUMP BELT AND A/C COMPRESSOR BELT
CAREFULLY, IF FIND ANY DAMAGE, REPLACE WITH A NEW ONE.
8. POSITION POWER STEERING PUMP BELT AND A/C

COMPRESSOR BELT.
15B
9. ROTATE ADJUSTMENT BOLT, TENSION POWER

STEERING PUMP BELT AND A/C COMPRESSOR
BELT.
10. TIGHTEN 2 POWER STEERING PUMP BRACKET

RETAINING BOLTS.
11. CHECK TENSITY OF POWER STEERING PUMP BELT AND A/C COMPRESSOR BELT, ADJUST IT
IF NECESSARY.

MOVE SPACE.
Item Deflection
15B

GENERATOR OVERHAUL
(a) Remove 4 engine cover retaining bolts. 15B
2. REFRIGERATE ENGINE, LET BELT SURFACE TEMPERATURE AS CLOSE AS POSSIBLE TO

NORMAL TEMPERATURE.
3. REMOVE POWER STEERING PUMP BELT AND A/C COMPRESSOR BELT. (Refer to “Chapter
15B engine mechanical, power steering pump and A/C compressor belt, overhaul”)
4. LOOSEN BOLT ATTACHING GENERATOR TO

GENERATOR BRACKET.
NOTE
Loosen, not to remove.
5. LOOSEN GENERATOR TENSIONER LOCK NUT.

NOTE
Loosen, not to remove.
6. TAKE GENERATOR BELT AWAY AND CHECK IT.

(a) Inspect the timing belt back rubber for signs of aging and 15B
glistening.

of the belt.

7. INSPECT EACH PART OF GENERATOR BELT CAREFULLY, IF FIND ANY DAMAGE, REPLACE
WITH A NEW ONE.
8. POSITION GENERATOR BELT.

9. TIGHTEN GENERATOR LOCK UNT.

15B
10. TIGHTEN BOLT ATTACHING GENERATOR TO

GENERATOR BRACKET.
11. CHECK TENSITY OF GENERATOR BELT, ADJUST IT IF NECESSARY.

DEFLECTION.
Item Deflection
New belt 6 ~ 7 mm
Used belt 7 ~ 8 mm

15B
15B-28 ENGINE MECHANICAL - ENGINE TIMING BELT COVER
ENGINE TIMING BELT COVER

REPLACEMENT
3. DISCONNECT CMP SENSOR CONNECTOR.
4. REMOVE GENERATOR BELT. (Refer to “Chapter 15B engine mechanical， generator belt,
overhaul”)

BOLTS.
6. REMOVE CRANKSHAFT PULLEY RETAINING BOLT.

ENGINE MECHANICAL - ENGINE TIMING BELT COVER 15B-29
7. REMOVE ENGINE TIMING BELT COVER RETAINING

BOLTS.
15B
8. TAKE ENGINE TIMING BELT COVER AWAY.

9. CHECK WHETHER TIMING BELT COVER IS CRACKED. CLEAN DIRT IN TIMING BELT COVER.
10. TIGHTEN TIMING BELT COVER RETAINING BOLTS.

11. TIGHTEN 4 COOLANT PUMP PULLEY RETAINING

BOLTS.
15B
15B-30 ENGINE MECHANICAL - ENGINE TIMING BELT COVER
12. TIGHTEN CRANKSHAFT PULLEY RETAINING BOLTS.

Torque: 260 ~ 300 N•m
13. REMOVE GENERATOR BELT. (Refer to “Chapter 15B engine mechanical, generator belt,
overhaul”)
14. CONNECT CMP SENSOR CONNECTOR.

ENGINE MECHANICAL - ENGINE TIMING BELT 15B-31
ENGINE TIMING BELT

COMPONENTS
15B
1 High-pressure Fuel Pump Timing Pulley 4 Crankshaft Timing Pulley
2 Tension Pull Rod 5 Camshaft Timing Pulley
3 Timing Belt Tensioner 6 Idle Pulley
15B
15B-32 ENGINE MECHANICAL - ENGINE TIMING BELT
OVERHAUL


4. SET ENGINE WIRE HARNESS ASIDE.
6. REMOVE ENGINE TIMING BELT COVER. (Refer to “Chapter 15B engine mechanical - engine tim-
ing belt cover, replacement”)
7. REMEMBER ROTATE DIRECTION OF TIMING BELT

IN ORDER TO AVOID ANY ERROR WHEN
ASSEMBLING.
8. REMOVE 4 STOP COLLAR RETAINING BOLTS ON

HIGH-PRESSURE FUEL PUMP TIMING PULLEY.
9. REMOVE 3 STOP COLLAR RETAINING BOLTS ON

CAMSHAFT TIMING PULLEY.
10. ROTATE CRANKSHAFT TIMING PULLEY AND ALIGN

TIMING MARKS AS SHOWN.
15B
11. ENSURE TIMING LOCATION HOLE ON CAMSHAFT

TIMING PULLEY ALIGN WITH LOCATION OF
INSTALLATION BOLT HOLE.
12. ALIGN TIMING MARKS WITH HIGH-PRESSURE FUEL

PUMP TIMING PULLEY.
13. REMOVE TIMING BELT TENSION PULL ROD

RETAINING BOLT.
15B
14. LOOSEN TIMING BELT TENSIONER RETAINING

BOLT.
15. REMOVE ENGINE TIMING BELT.

NOTE
• Water or oil on the belt will shorten its life drastically, so the removed timing belt, sprocket, and
• If there is oil or water on the part, check the front case oil seals, camshaft oil seal and water
pump for leakage.
NOTE
glistening.

of the belt.

15B
17. REMOVE IDLE PULLEY AND TIMING BELT

TENSIONER RETAINING BOLTS.
18. TAKE CRANKSHAFT TIMING PULLEY AWAY DIRECTLY.

NOTE
If the crankshaft timing pulley is locked, pry it lightly.
19. USING SUITABLE TOOL, PRY FRONT CRANKSHAFT

OIL SEAL OUT.
20. REMOVE BOLT ATTACHING HIGH-PRESSURE FUEL

PUMP TO HIGH-PRESSURE FUEL PUMP TIMING
PULLEY.
15B
21. REMOVE 3 CAMSHAFT TIMING PULLEY RETAINING

BOLTS.
22. TAKE CAMSHAFT TIMING PULLEY AWAY.
23. REMOVE CAMSHAFT PULLEY RETAINING BOLT.
24. TAKE CAMSHAFT PULLEY AWAY.
25. REMOVE CAMSHAFT OIL SEAL HOUSING RETAINING

BOLTS.

27. USING SUITABLE TOOL, INSTALL CAMSHAFT OIL

SEAL AND TIGHTEN CAMSHAFT OIL SEAL
HOUSING RETAINING BOLTS.
Torque: 7 ~ 13 N•m 15B
28. TIGHTEN CAMSHAFT PULLEY RETAINING BOLT.

29. TIGHTEN 3 CAMSHAFT TIMING PULLEY RETAINING

BOLTS.
30. USING SPECIAL TOOL, INSTALL FRONT CRANKSHAFT

OIL SEAL.
NOTE
Lightly coated with engine oil on crankshaft oil seal lip area.
Position the oil seal and avoid leakage. Oil seal end face
should keep space with the pulley room about 0.7 ~ 1.3 mm
distance.
31.INSTALL CRANKSHAFT TIMING PULLEY.
15B
32. ROTATE CRANKSHAFT TIMING PULLEY AND ALIGN

TIMING MARKS AS SHOWN.
33. ENSURE TIMING LOCATION HOLE ON CAMSHAFT

TIMING PULLEY IS ALIGN WITH LOCATION OF
INSTALLATION BOLT HOLE.
34. INSTALL LOCATION BOLT, MAKE SURE IT CAN BE

INSTALLED VERTICALLY.
35. ENSURE TIMING MARKS ALIGNS WITH HIGH-

PRESSURE FUEL PUMP TIMING PULLEY.
36. TIGHTEN IDLE PULLEY RETAINING BOLT.

Torque: 110 ~ 130 N•m
37. ACCORDING TO MARKS, INSTALL ENGINE TIMING BELT.

38. INSTALL TIMING BELT TENSIONER.
NOTE
• The engine timing belt should be installed after installing camshaft timing pulley, crankshaft
timing pulley, high-pressure fuel pump timing pulley, idle pulley and tensioner location bolt and
before installing the tensioner retaining bolt.
• When installing the timing pulley, align the timing marks to avoid any mistakes. Otherwise, it will
cause that engine can not start or power loss, increase fuel consumption. Even makes the valve
actuating mechanism parts damaged, when the mark is not clear or pulleys worn. It should be
replaced. 15B
• The timing belt must be replaced each 80000 Km.
• The timing belt should be checked each 15000 Km.
39. USING 98 N PUSH TENSION PULL ROD AT

VERTICAL DIRECTION AND TENSIONING TIMING
BELT TENSIONER, THEN TIGHTEN TENSION PULL
ROD MIDDLE BOLT.
40. INSTALL TENSION PULL ROD RETAINING BOLT.
41. TIGHTEN TIMING BELT TENSIONER RETAINING

BOLT.
Torque: 110 ~ 130 N•m
42. CLOCKWISE ROTATE TIMING BELT TWO TURNS UNTIL THE TIMING MARKS ARE ALIGNED
PROPERLY AGAIN. 15B
43. TIGHTEN 4 STOP COLLAR RETAINING BOLTS ON
HIGH-PRESSURE FUEL PUMP TIMING PULLEY.
44. TIGHTEN 3 STOP COLLAR RETAINING BOLTS ON

CAMSHAFT TIMING PULLEY.
45. INSTALL ENGINE TIMING BELT COVER. (Refer to “Chapter 15B engine mechanical - engine

ENGINE MECHANICAL - CYLINDER HEAD AND VALVE 15B-41
CYLINDER HEAD AND VALVE

COMPONENTS
15B
1 Valve Spring Lock 11 Cylinder Head Cover Gasket
2 Upper Valve Spring Retainer 12 Oil Filling Cap
3 Valve Spring 13 Cylinder Head Cover
4 Valve Oil Seal 14 Rocker Arm And Rocker Shaft Assy
5 Lower Valve Spring Retainer 15 Cylinder Head Bolt
6 Exhaust Valve 16 Cylinder Head Bolt (With Groove)
7 Intake Valve 17 Fuel Injector Pressure Plate Bolt

15B
8 Rear Engine Lifting Hook 18 Fuel Injector Pressure Plate
9 Front Engine Lifting Hook 19 Fuel Injector Pressure Plate Block
10 Cylinder Head Cover Bolt

15B-42 ENGINE MECHANICAL - CYLINDER HEAD AND VALVE
OVERHAUL
3. DRAIN COOLANT. (Refer to “Chapter 17B cooling - coolant, replacement”)

7. DISCONNECT COOLANT HOSE CLAMP ON INTAKE

CONNECT PIPE.
8. REMOVE INTAKE CONNECT PIPE. (Refer to “Chapter

14B intake air - intake connect pipe, replacement”)
9. REMOVE 3 CYLINDER HEAD COVER RETAINING

BOLTS.
10. DISCONNECT CRANKCASE BREATHER HOSE.
15B
11. REMOVE INTAKE MANIFOLD. (Refer to “Chapter 14B intake air - intake manifold, replacement”)
12. REMOVE EXHAUST MANIFOLD. (Refer to “Chapter 16B exhaust - exhaust manifold,
replacement”)
13. REMOVE FUEL INJECTORS. (Refer to “Chapter 12B fuel - fuel injector, overhaul”)
14. REMOVE A/C COMPRESSOR. (Refer to “Chapter 61 heater and air conditioning - compressor,
replacement”)
15. REMOVE ROCKER ARM AND ROCKER SHAFT ASSY

RETAINING BOLTS.
16. TAKE ROCKER ARM AND ROCKER SHAFT ASSY

AWAY.
17. TAKE 8 VALVE PUSH RODS AWAY.

15B
18. REMOVE GLOW PLUG.
19. REMOVE CYLINDER HEAD BOLTS IN SEQUENCE AS

SHOWN.
NOTE
The 4 cylinder head retaining bolts at intake manifold side
are with groove.
20. TAKE CYLINDER HEAD ASSY AWAY.
21. TAKE CYLINDER HEAD GASKET AWAY.
22. CHECK CYLINDER HEAD GASKET.

(a) There should be no damage, oil leakage, water leakage and indication.
23. CHECK CYLINDER HEAD GASKET SURFACE FOR

FLATNESS BY USING A RULER AND THICKNESS
GAUGE.
Standard: 0.05 mm 15B
Limit: 0.2 mm
NOTE
• If the service limit is exceeded, grind to meet
specification.
Grind limit: 0.2 mm (0.2 mm includes combination
with cylinder block grinding)
• Cylinder head height (new specification): 91.95 ~ 92.05
mm
• Check the cylinder head whether corroded underside，
replace with a new cylinder head if find.
24. USING SUITABLE TOOL, COMPRESS VALVE SPRING

AND TAKE VALVE SPRING LOCK AWAY.
25. REMOVE UPPER VALVE SPRING RETAINER AND VALVE SPRING.

NOTE
Store removed valves, springs and other parts, tagged to indicate their cylinder number and location
for reassembly.
26. INSPECT VALVE SPRING.

(a) Check the valve spring free length/height， discard the
springs that do not meet specifications.
Standard: 48.0 mm
(b) Check the valve spring center line, discard the springs
that do not meet specifications.
Standard: ≤ 2°
15B
27. REMOVE VALVE OIL SEAL.

NOTE
Do not reuse valve oil seal.
28. REMOVE LOWER VALVE SPRING RETAINER.

29. TAKE VALVE AWAY AND CHECK IT.
(a) Check valve work surface, such as carbon deposition existence, clear it if find.
(b) Check valve work surface, such as burn or wear, replace with a new one if necessary.
• When the valves and valve seat wear lighting, can use manual polishing method of recovery.
The method is as follows: first, remove valve, the valve seat catheter and coke, then in the valve
cone are coated with a thin layer of valve sand. Use the eraser bowl with wooden valve flap to
absorb, combined with the method of rotating and grinding. Each rotation is not more than 90°,
until the valve cone appears a well-balanced without burnish band width for 1.5 ~ 2 mm. Too
wide band is harm for seal. Too narrow, against heat dissipation, the valve will burned for high
temperature. Sand has the different in thick and thin. According to the wear and ablation of
choice.
(c) Chenck the valve tightness.

• Using pencil, draw 8 ~ 12 marks on the valve work
surface, tap the valve with the valve seat (do not
rotate the valve), if the mark is broken in middle part
of the mark, the valve tightness is OK.
(d) Measure the valve diameter.
Item Standard
Intake Valve 7.946 ~ 7.961 mm
Exhaust Valve 7.921 ~ 7.936 mm
(e) Measure valve stem diameter and valve guide inner

diameter. Check that clearance is within specification. If it
exceeds the limit, replace valve or valve guide.
Clearance Standard Limit

Intake Valve 0.039~0.071 mm 0.20 mm
Exhaust Valve 0.064~0.096 mm 0.25 mm
30. HEAT CYLINDER HEAD AND TAKE VALVE SEAT AWAY.

31. USING A PRESSOR, PUSH VALVE GUIDE OUT TOWARD THE CYLINDER BLOCK SIDE.
32. REBORE THE VALVE GUIDE HOLE IN THE CYLINDER HEAD TO MATCH THE OVERSIZE VALVE
GUIDE THAT IS TO BE FITTED.
Valve Guide Hole Diameter

15B
0.05 oversize 11.05~11.068 mm
0.25 oversize 11.25~11.268 mm
0.50 oversize 11.50~11.518 mm
NOTE
Do not install a valve guide of the same size again.
33. THE VALVE GUIDE MUST BE INSTALLED FROM UPPER SIDE OF CYLINDER HEAD.
34. AFTER INSTALLING VALVE GUIDE, CHECK VALVE SEAT INNER DIAMETER.
Standard: 8.000 ~ 8.017 mm
35. AFTER INSTALLING VALVE GUIDE, INSERT A NEW VALVE AND CHECK IT SLIDES SMOOTHLY.
36. FOLLOW THE MARK BEFORE REMOVAL TO INSTALL VALVE.
37. INSTALL LOWER VALVE SPRING RETAINER.
38. USING A SUITABLE TOOL, INSTALL NEW VALVE OIL

SEAL. IMPROPER INSTALLATION WILL CAUSE OIL
LEAKAGE.
39. INSTALL VALVE SPRING.

NOTE
Position the valve spring end with color toward the upper valve spring retainer.
40. INSTALL UPPER VALVE SPRING RETAINER.
41. USING A SUITABLE TOOL, COMPRESS VALVE SPRING

AND TAKE VALVE SPRING LOCK AWAY.
15B
42. CHOOSE A SUITABLE CYLINDER HEAD GASKET.

(a) Carefully clear the carbon deposition and residue on the top of piston and surface of cylinder head.
(b) Position a micrometer caliper on the top of piston.
(c) Measure the piston protruding length. Measure it on

point (1) (3) on piston top and point (2) (4) on engine
block. Each piston need be measured.
(d) Record the highest measured values. This value will determine the thickness of the cylinder head
gasket. The piston protruding length is 0.700 ~ 1.000 mm, divided into three groups of the four piston
protruding length of the engine in one group. If the length is out of specification, replace the piston
connecting rod according to the chart below.
Cylinder Head Gasket Mark Piston Protruding Length Cylinder Head Gasket Thinkness
One Gap 0.700 ~ 0.800 mm 1.60 mm
Two Gaps 0.801 ~ 0.900 mm 1.65 mm
Three Gaps 0.901 ~ 1.000 mm 1.70 mm
43. INSTALL A NEW CYLINDER HEAD GASKET.

CAUTION
Please position the cylinder head gasket according to the
mark on the gasket, align the water and oil way. Otherwise it
will damage the engine.
44. POSITION CYLINDER HEAD GASKET TO LOCATE PIN.

45. POSITION CYLINDER HEAD ASSY.
15B
46. CYLINDER HEAD BOLTS SHOULD BE INSTALLED AND

TIGHTENED IN SEQUENCE AS SHOWN.
NOTE
The 4 cylinder head retaining bolts at intake manifold side
are with groove.
Tighten steps:
(a) Tighten the bolts to 35 N·m.
(b) Completely loosen the bolts.
(c) Retighten the bolts to 30 ~ 35 N·m.
(d) Tighten the bolts an additional 60° ~ 180°.
47. INSTALL 8 VALVE PUSH RODS.
48. INSTALL GLOW PLUG.
15B
49. INSTALL ROCKER ARM AND ROCKER SHAFT ASSY.
NOTE
When installing the rocker arm and rocker shaft assy,
position the oil hole forward.
50. TIGHTEN ROCKER ARM AND ROCKER SHAFT ASSY

RETAINING BOLTS.
Torqure: 46 ~ 63 N•m
NOTE
Rocker arm and rocker shaft assy retaining bolts should be
installed and tightened in sequence as shown. Before
tightening the bolts, loosen the valve adjustment bolt to
avoid damaging the valve, push rod, camshaft and rocker
arm.
51. ADJUST VALVE CLEARANCE.

NOTE
When the engine is cool, the intake valve clearance and the exhaust valve clearance is 0.35 ~ 0.45 mm.
If excessive clearance, it will close lax. If the clearance is less than standard, it will damage the valve. 15B
(a) Rotate the crankshaft to NO.1 cylinder in compression

stroke BTDC. The crankshaft pulley first mark align to the
mark on engine timing cover, and the NO.1 cylinder
intake and exhuast valve are closed.
(b) Adjust the valve clearance as shown.
(c) Set the valve clearance feeler gauge into rocker arm and
valve top which need adjusting. Loosen the rocker arm
retaining bolt and rotate the adjustment screw until the
feeler guage moves out of nimbleness, then tighten the
rocker arm retaining bolt.
(d) After adjusting the valve clearance above, rotate the

crankshaft 360°. NO.4 cylinder is in compression stroke
BTDC. Adjust the valve clearance as shown in the same
way. 15B
52. INSTALL INTAKE MANIFOLD. (Refer to “Chapter 14B intake air - intake manifold, replacement”)
53. INSTALL EXHAUST MANIFOLD. (Refer to “Chapter 16B exhaust - exhaust manifold,
replacement”)
54. INSTALL A/C COMPRESSOR. (Refer to “Chapter 61 heater and air conditioning - compressor,
replacement”)
55. INSTALL FUEL INJECTORS. (Refer to “Chapter 12B fuel - fuel injector, overhaul”)
56. TIGHTEN 3 CYLINDER HEAD COVER RETAINING

BOLTS.
57. CONNECT CRANKCASE BREATHER HOSE.
58. INSTALL INTAKE CONNECT PIPE. (Refer to “Chapter

14B intake air - intake connect pipe, replacement”)
59. INSTALL COOLANT HOSE CLAMP ON INTAKE

CONNECT PIPE.
63. FILL COOLANT. (Refer to “Chapter 17B cooling - coolant, replacement”)

15B
15B
15B-54 ENGINE MECHANICAL - CAMSHAFT
CAMSHAFT
OVERHAUL
NOTE
MPX diesel engine is adopted camshaft in the middle block.
1. REMOVE ENGINE TIMING BELT. (Refer to “Chapter 15B engine mechanical - engine timing belt,
overhaul”)
2. REMOVE CAMSHAFT TIMING PULLEY RETAINING

BOLTS.
3. TAKE CAMSHAFT TIMING PULLEY AWAY.
4. INSPECT CAMSHAFT AXIAL CLEARANCE.

Standard: 0.050 ~ 0.190 mm
5. REMOVE CAMSHAFT PULLEY RETAINING BOLT.
6. TAKE CAMSHAFT PULLEY AWAY.

ENGINE MECHANICAL - CAMSHAFT 15B-55
7. REMOVE CAMSHAFT OIL SEAL HOUSING RETAINING

BOLTS.
15B
9. KEEP 0.4 ~ 0.6 mm DISTANCE BETWEEN CRANKSHAFT OIL SEAL OUTER SIDE AND
CRANKSHAFT OIL SEAL HOUSING OUTER SIDE.
10. PULL OUT CAMSHAFT.
11. INSPECT CAMSHAFT.

(a) Measure the camshaft base diameter.
Base diameter: 35.5 mm
(b) Measure the camshaft cam lobe height.
Cam lobe height: 6.511 mm
(c) If there is any wear or flaw on the journal, replace the
camshaft.
12. USING A BUSHING PULLER, REMOVE CAMSHAFT JOURNAL BUSHING.

(a) If there any wear or flaw on the camshaft journal bushing, replace the camshaft bushing.
13. USING A SUITABLE TOOL, INSTALL NEW BUSHING.
NOTE 15B
• When installing the bushing, align the oil hole on camshafe journal bushing with the oil hole on
engine block.
• The diameter after installing the bushing is 50.010 ~ 50.035 mm.
• Check the clearance between camshaft journal bushing and camshaft journal.
Standard: 0.025 ~ 0.085 mm
Limit: 0.12 mm
• If excessive limit clearance, relpace the camshaft.
14. INSTALL CAMSHAFT.
15B-56 ENGINE MECHANICAL - CAMSHAFT
15. USING A SUITABLE TOOL, INSTALL CAMSHAFT OIL

SEAL AND TIGHTEN CAMSHAFT OIL SEAL
HOUSING RETAINING BOLTS.
16. TIGHTEN CAMSHAFT PULLEY RETAINING BOLT.

17. TIGHTEN CAMSHAFT TIMING PULLEY RETAINING

BOLTS.
18. INSTALL ENGINE TIMING BELT. (Refer to “Chapter 15B engine mechanical - engine timing belt,
overhaul”)
ENGINE MECHANICAL - ENGINE BLOCK 15B-57
ENGINE BLOCK
COMPONENTS
15B
15B
15B-58 ENGINE MECHANICAL - ENGINE BLOCK
1 Engine Block Vacuum Pump Fuel Supply Line

14
Connector
2 Round Pin
15 Coolant Drain Plug
3 Upper Crankshaft Bearing
16 Oil Return Pipe
4 Lower Crankshaft Bearing
17 Location Pin
5 Fifth Main Bearing Cap
18 Cylinder Head Gasket
6 Third Main Bearing Cap
19 Cylinder Sleeve
7 First ,Second, Fourth Main Bearing Cap
20 Rear Engine Block Cover
8 Main Bearing Cap Bolt
21 Rear Crankshaft Oil Seal
9 Crankshaft Thrust Bearing
22 Plug
10 Front Camshaft Journal Bushing
23 Left Bracket
11 Middle Camshaft Journal Bushing
24 Engine Oil Pressure Switch Seat
12 Oil Plug
25 Engine Oil Pressure Switch
13 Right Bracket
OVERHAUL
1. REMOVE ENGINE ASSY. (Refer to “Chapter 15B engine mechanical - engine assy, replace-
ment”)
15B
2. REMOVE CYLINDER HEAD ASSY. (Refer to “Chapter 15B engine mechanical - cylinder head,
overhaul”)
overhaul”)
4. REMOVE OIL PAN. (Refer to “Chapter 18B lubrication - oil pan, replacement”)
5. REMOVE OIL STRAINER. (Refer to “Chapter 18 B lubrication - oil pump, overhaul”)
6. REMOVE OIL PUMP. (Refer to “Chapter 18B lubrication - oil pump, replacement”)
7. FIX ENGINE BLOCK ASSY TO FLIP FRAME AND DISASSEMBLE IT.
8. REMOVE CLUTCH PRESSURE PLATE.

(a) Make a mark on clutch pressure plate and flywheel.
(b) Loosen 6 bolts diagonally until the clutch pressure plate
relieve completely.
9. LOOSEN 8 FLYWHEEL RETAINING BOLTS DIAGONALLY.
10. REMOVE REAR ENGINE BLOCK COVER RETAINING 15B

BOLTS.
11. USING A SUITABLE TOOL, REMOVE REAR CRANKSHAFT

OIL SEAL.
12. ROTATE ENGINE BLOCK AND MAKE OIL PAN PART UP.
13. REMOVE MAIN BEARING CAP BOLTS IN SEQUENCE

AS SHOWN.
NOTE
The crankshaft main bearing caps is precision-machined
with the engine block, do not exchange with each other.
Avoid installing error, there are mark number such as
"1","2" on the connecting rod cap. The arrow on the
crankshaft main bearing cap forward crankshaft pulley.
14. REMOVE MAIN BEARING CAP AND DISASSEMBLE THE LOWER CRANKSHAFT BEARING.
15. DISASSEMBLE UPPER CRANKSHAFT BEARING

AND THRUST BEARING ON THIRD CRANKSHAFT
JOURNAL.
16. INSPECT THRUST BEARING, THERE SHOULD BE

NO SERIOUS WEAR, GALLING, PITTING.
15B
17. TAKE ENGINE BLOCK FROM FLIP FRAME AND

INSPECT IT.
(a) Visually check for scratches, rust, and corrosion. Use a
flaw detecting agent for the check as well. If defects are
found, correct or replace it.
(b) Use a straightedge and feeler gauge, check the block top
surface for warpage. Make sure that the surface is free
from gasket chips and other foreign matters.
(c) If the warpage is excessive, correct it within the allowable

limit or replace.
Grinding limit: 0.2 mm
(d) The cylinder walls should be checked for out-of-round
and taper with cylinder indicator or equivalent. If the
cylinder walls are badly scuffed or scored, the cylinder
block should be replaced and install new pistons and
rings.
18. MARK CYLINDER NUMBER AT SIDE OF

ASSEMBLING.
NOTE
15B
SEQUENCE AS SHOWN.
20. USING A HAMMER HANDLE OR SIMILAR TOOL,

PUSH PISTON AND CONNECTING ROD ASSY OUT
THROUGH CYLINDER HEAD SIDE OF ENGINE
BLOCK.
21. REMOVE CRANKSHAFT.
22. PRESS CYLINDER SLEEVE TOWARD CYLINDER

HEAD DIRECTION.
23. MEASURE CYLINDER BORE AT THREE LEVELS IN

DIRECTIONS A AND B. TOP MEASUREMENT
SHOULD BE 12 MM DOWN AND BOTTOM
MEASUREMENT SHOULD BE 12 MM UP FROM
BOTTOM OF BORE.
Standard:
Cylinder size: 95.001 ~ 95.030 mm
Cylinder cylindrically: ≤ 0.01 mm
24. CHOOSE CYLINDER SLEEVE ACCORDING TO CYLINDER SIZE.
Item Group 0 Group 1 Group 2 Group 3 Group 4

94.991~ 95.001~ 95.011~ 95.021~ 95.031~
Cylinder Size
95.000 mm 95.010 mm 95.020 mm 95.030 mm 95.040 mm
Cylinder Sleeve 95.001~ 95.011~ 95.021~ 95.031~ 95.041~

Outer Diameter 95.010 mm 95.020 mm 95.030 mm 95.040 mm 95.050 mm
25. mesure main bearing inner diameter, choose suitable bearing bushing.
Group Number Bearing Inner Diameter Suitable Bearing Thickness

1 73.991~74.000 mm 2.002~2.006 mm 15B
2 73.983~73.990 mm 2.006~2.010 mm
3 73.975~73.982 mm 2.010~2.014 mm
26. USING A SUITABLE TOOL, PRESS CORRECT CYLINDER SLEEVE TO ENGINE BLOCK.
27. INSTALL PISTON AND CONNECTING ROD ASSY. (Refer to “Chapter 15B engine mechanical -
piston and connecting rod, overhaul”)
28. INSTALL MAIN BEARING AND THRUST BEARING.

• Install the main bearings with oil grooves on the
cylinder block side.
• Install the main bearings without oil grooves on the
bearing cap.
• Install the 2 thrust bearings on crankshaft journal
No.3. Apply clean oil to the surface of thrust bearing.
29. INSTALL MAIN BEARING CAPS.

• Install the main bearing caps with the arrow on the
main caps facing the front of the engine.
30. INSTALL THE MAIN BEARING CAP BOLTS.

(a) Apply clean engine oil to the threaded portion bearing surface of the bolt.
(b) Tighten the bearing cap bolts in sequence as shown.

Torque:
First tighten the bolts: 40 ~ 50 N•m
Second tighten the bolts: 90 ~ 100 N•m 15B
Third tighten the bolts: 160 ~ 180 N•m
31. USING A SUITABLE TOOL, INSTALL REAR CRANK-

SHAFT OIL SEAL.
32. TIGHTEN REAR ENGINE BLOCK COVER RETAINING

BOLTS.
33. TIGHTEN 8 FLYWHEEL RETAINING BOLTS

DIAGONALLY.
Torque: 113 ~ 133 N•m
34. INSTALL CLUTCH PRESSURE PLATE AND TIGHTEN

BOLTS.
Torque: 35 N•m
NOTE
According to the mark made before removal, install the
clutch pressure plate retaining bolts diagonally.
35. INSTALL OIL STRAINER. (Refer to “Chapter 18B lubrication - oil pump, overhaul”)
36. INSTALL OIL PUMP. (Refer to “Chapter 18B lubrication - oil pump, replacement”)
37. INSTALL OIL PAN. (Refer to “Chapter 18B lubrication - oil pan, replacement”)
overhaul”)
39. INSTALL CYLINDER HEAD ASSY. (Refer to “Chapter 15B engine mechanical - cylinder head,
overhaul”) 15B
40. INSTALL ENGINE ASSY. (Refer to “Chapter 15B engine mechanical - engine assy, replacement”)
15B
15B-66 ENGINE MECHANICAL - PISTON AND CONNECTING ROD ASSY
PISTON AND CONNECTING ROD ASSY

COMPONENTS
1 Crankshaft Pulley Bolt 5 Crankshaft
2 Crankshaft Pulley 6 Piston And Connecting Rod Assy
3 Crankshaft Timing Pulley 7 Flywheel
4 Crankshaft Flat Key 8 Flywheel Bolt

ENGINE MECHANICAL - PISTON AND CONNECTING ROD ASSY 15B-67
15B
1 No.1 Compression Ring 6 Connecting Rod
2 No.2 Compression Ring 7 Piston Pin
3 Oil Control Ring 8 Piston Pin Snap Spring
4 Piston 9 Connecting Rod Nut
5 Connecting Rod Bolt 10 Connecting Rod Bearing

15B
OVERHAUL
1. REMOVE ENGINE ASSY. (Refer to “Chapter 15B engine mechanical - engine assy, replace-
ment”)
2. REMOVE CYLINDER HEAD ASSY. (Refer to “Chapter 15B engine mechanical - cylinder head,
overhaul”)
overhaul”)
4. REMOVE OIL PAN. (Refer to “Chapter 18B lubrication - oil pan, replacement”)
5. REMOVE OIL STRAINER AND OIL PUMP. (Refer to “Chapter 18B lubrication - oil pump, over-
haul”)
6. FIXING ENGINE BLOCK ASSY TO FLIP FRAME AND DISASSEMBLE IT.
7. REMOVE CLUTCH PRESSURE PLATE.

(a) Make a mark on clutch pressure plate and flywheel.
(b) Loosen 6 bolts diagonally until the clutch pressure plate
relieve completely.
8. LOOSEN 8 FLYWHEEL RETAINING BOLTS DIAGONALLY.
9. REMOVE REAR ENGINE BLOCK COVER RETAINING

BOLTS.
10. USING A SUITABLE TOOL, REMOVE REAR CRANKSHAFT

OIL SEAL.
15B
11. ROTATE ENGINE BLOCK AND MAKE OIL PAN PART UP.
12. REMOVE CRANKSHAFT MAIN BEARING CAP BOLTS IN

SEQUENCE AS SHOWN.

ASSEMBLING.
NOTE

SEQUENCE AS SHOWN. 15B
15. USING A HAMMER HANDLE OR SIMILAR TOOL, PUSH

PISTON AND CONNECTING ROD ASSY OUT THROUGH
THE CYLINDER HEAD SIDE OF ENGINE BLOCK.

ASSEMBLING.
NOTE
17. TAKE CRANKSHAFT AWAY AND INSPECT CRANKSHAFT

MAIN JOURNALS.
Crankshaft main journals: 69.932 ~ 69.917 mm
(a) Check for excessive wear, roundness and scoring. If
found, check the oil hole pluged or not.
(b) Limits of out of round on any crankshaft journals should
be held to less than 30 g•cm.
18. REMOVE NO.1 COMPRESSION RING, NO.2 COMPRESSION RING AND OIL CONTROL RING BY
HAND.
NOTE
Keep the disassembled pistons, piston pins and connecting rods in order according to the cylinder
number.
(a) If the piston needs to be reused, clean the carbon deposition on piston, compression ring and the
greasy dirt on oil ring with clean diesel.
NOTE
Do not damage the piston surface.
(b) Check the piston ring for damage, excessive wear, and breakage. Replace it if defects are found. If the
piston has been replaced with a new one, the piston rings must also be replaced with a new one.
(c) Check piston ring to groove side clearance.If the limit is

exceeded, replace the ring or piston, even both.

15B
Standard 0.078 ~ 0.137 0.045 ~ 0.090 0.030 ~ 0.070
mm mm mm
Limit 0.20 mm 0.15 mm 0.15 mm
20. INSERT PISTON RING INTO CYLINDER BLOCK.

FORCE IT DOWN WITH A PISTON TO CORRECTLY
POSITION IT. THEN MEASURE END GAP WITH A
FEELER GAUGE. IF RING GAP IS EXCESSIVE,
REPLACE PISTON RING.

0.20 ~ 0.40 0.60 ~ 0.85 0.35 ~ 0.65
Standard
mm mm mm
Limit 0.8 mm 1.5 mm 1.2 mm

3.70 ~ 4.00 3.75 ~ 4.05 3.25 ~ 3.50
Standard
mm mm mm
22. USING SNAP RING PLIERS, REMOVE PISTON PIN

SNAP RING.
15B
23. CHECK SNAP RING, THERE SHOULD BE NO CRACK, WOUND. WHEN INSTALLING, SNAP RING
OPENING SHOULD STAGGER WITH NOTCH ON PISTON TOP.
24. USING A PRESSURE MACHINE, PUSH PISTON PIN

OUT.
25. CHECK DIAMETER OF PISTON PIN BORE, AND

CHECK OUTER DIAMETER OF PISTON PIN.
Item Specification
Piston Pin Bore Diameter 34.002 ~ 34.010 mm
Piston Pin Outer Diameter 33.994 ~ 34.000 mm
Piston Pin Bore And Piston Pin

0.002 ~ 0.015 mm
Clearance
Wear Limit 0.03 mm
26. CHECK THE INNER DIAMETER OF CONNECTING

ROD (SMALL END).
Item Specification
Connecting Rod And Piston
0.008 ~ 0.020 mm
Pin Clearance
Wear Limit 0.05 mm
27. MEASURE PISTON OUTER DIAMETER.

28. ACCORDING TO CYLINDER SLEEVE INNER DIAMETER (AFTER INSTALLING INTO CYLINDER
BLOCK) CHOOSE SUITABLE PISTON SIZE.
Size
Item 15B
Piston Cylinder Sleeve
S 92.960 ~ 92.931 mm 93.011 ~ 93.020 mm
A 92.970 ~ 92.979 mm 93.021 ~ 93.030 mm
B 92.980 ~ 92.989 mm 93.031 ~ 93.040 mm
C 92.990 ~ 92.999 mm 93.041 ~ 93.050 mm
D 93.000 ~ 93.009 mm 93.051 ~ 93.060 mm
E 93.010 ~ 93.019 mm 93.061 ~ 93.070 mm
• The clearance between piston and cylinder sleeve is 0.042 ~ 0.060 mm， wear limit is 0.20 mm. Mea-
sure the clearance, if the clearance exceed the wear limit, replace the piston and cylinder sleeve.
NOTE
If replace the piston, replace the piston ring also.
29. INSTALL PISTON PIN.

(a) Heater the piston to 70 ℃ ~ 80 ℃ and press the piston
pin into piston pin bore.
(b) The piston pin center should outline with the piston cen-
ter, reduce the noise.
(c) When installing the connecting rod, the mark on piston

top, bulge at connect rod center should toward engine
front end.
15B
30. INSTALL PISTON PIN SNAP RING.

31. INSTALL SPIRAL SPRING BY HAND, THEN INSTALL

OIL CONTROL RING.
NOTE
• Do not use a piston ring expander when installing oil
control ring. Use of ring expander to expand the oil
control ring end gap can break the oil control ring,
unlike other piston rings.
• Ensure the ring can turn from the left to the right
freely after installation.
32. INSTALL NO.1 COMPRESSION RING, NO.2 COMPRESSION RING.
(a) Using a piston ring expander, install the NO.2

compression ring, then install the NO.1 compression
ring.
NOTE
• The NO.1 compression ring is the keystone ring.
• The NO.2 compression ring is the cone distortion

ring.
• The compression rings have an identification mark

on the top of the ring.
15B
(b) Oil the piston rings and piston side.
(c) Position the piston rings in the proper alignment with the
piston pin as shown:
1 No.2 Compression Ring Opening
2 Piston Pin Position
3 No.1 Compression Ring Opening
4 Spiral Oil Control Ring Opening
5 Oil Control Ring Opening
6 Crankshaft Pulley Side
33. USING A SUITABLE PISTON RING COMPRESSOR,

INSERT PISTON AND CONNECTING ROD
ASSEMBLY INTO CYLINDER ACCORDING TO MARK
BEFORE REMOVAL.
34. INSTALL CRANKSHAFT.
35. VERIFY MARK MADE DURING DISASSEMBLY,

INSTALL BEARING CAP TO THE CONNECTING ROD.
IF CONNECTING ROD IS NEW WITH NO MARK, 15B
MAKE SURE THAT BEARING LOCK NOTCHES
COME ON THE SAME SIDE AS SHOWN.
36. INTSALL CONNECTING ROD CAP.

NOTE
The pulge mark on the connecting rod cap is toward the
engine timing belt side.
37. APPLY ENGINE OIL TO EACH CONNECTING ROD BOLT.
38. TIGHTEN CONNECTING ROD CAP NUTS IN

SEQUENCE AS SHOWN.
Torque:
First step: 40 ~ 50 N•m
Second step: 80 ~ 90 N•m
39. CHECK AXIAL CLEARANCE OF CONNECTING

RODS.
Limit: 0.4 mm
40. ROTATE CRANKSHAFT, AVOID CRANKSHAFT BALANCE BLOCK CRASHING WITH CONNECT-
ING ROD BIG END.
Item Specification
Crankshaft Connecting Rod Journal Standard 52.015 ~ 52.030 mm
Radial Chance Between Connecting Rod Standard 0.029 ~ 0.075 mm

Bearing And Journal
Wear Limit 0.10 mm
Clearance Between Connecting Rod And Standard 0.175 ~ 0.29 mm

Crankshaft Journal
Wear Limit 0.35 mm
41. INSTALL CRANKSHAFT MAIN BEARING CAP BOLTS

IN SEQUENCE AS SHOWN.
Torque:
First step: 40 ~ 50 N•m 15B
Second step: 90 ~ 100 N•m
Third step: 160 ~ 180 N•m
42. USING A SUITABLE TOOL, INSTALL REAR CRANK-

SHAFT OIL SEAL.
43. TIGHTEN REAR ENGINE BLOCK COVER RETAINING

BOLTS.
44. TIGHTEN 8 FLYWHEEL RETAINING BOLTS DIAGONALLY.

Torque: 113 ~ 133 N•m
15B
45. INSTALL CLUTCH PRESSURE PLATE AND TIGHTEN

BOLTS.
Torque: 35 N•m
NOTE
According to the mark made before removal, install the
clutch pressure plate retaining bolts diagonally.
46. INSTALL OIL STRAINER. (Refer to “Chapter 18B lubrication - oil pump, overhaul”)
47. INSTALL OIL PUMP. (Refer to “Chapter 18B lubrication - oil pump, replacement”)
48. INSTALL OIL PAN. (Refer to “Chapter 18B lubrication - oil pan, replacement”)
overhaul”)
50. INSTALL CYLINDER HEAD ASSY. (Refer to “Chapter 15B engine mechanical - cylinder head,
overhaul”)
51. INSTALL ENGINE ASSY. (Refer to “Chapter 15B engine mechanical - engine assy, replacement”)
EXHAUST
16B
EXHAUST PIPE ............................................................................... 16B-1
COMPONENTS ......................................................................... 16B-1
REPLACEMENT ........................................................................ 16B-2
EXHAUST MANIFOLD..................................................................... 16B-6 16B
REPLACEMENT ........................................................................ 16B-6
16B
11B
12B
14B
16B
EXHAUST - EXHAUST PIPE 16B-1
EXHAUST PIPE
EXHAUST
COMPONENTS
16B
1 Exhaust Gasket 4 Middle Exhaust Pipe With Muffler Assy
2 Front Exhaust Pipe 5 Joint Rubber
3 Heat Shield 6 Rear Exhaust Pipe With 2-stage Muffler
16B
16B-2 EXHAUST - EXHAUST PIPE
REPLACEMENT

WARNING
4. REMOVE LOWER GUARD PLATE RETAINING

BOLTS.

PIPE TO EXHAUST MANIFOLD.

PIPE TO MIDDLE EXHAUST PIPE WITH MUFFLER
ASSY.
7. REMOVE FRONT EXHAUST PIPE.

8. REMOVE BOLTS ATTACHING MIDDLE EXHAUST

16B
9. DISCONNECT MIDDLE EXHAUST PIPE WITH



NOTE
After a long-time used, the exhaust pipe gasket will be adhered to exhaust pipe. After removing the
muffler, use the scraper to clean the surface of exhaust pipe and replace a new gasket to avoid exhaust
leakage.

16B

16B-4 EXHAUST - EXHAUST PIPE
14. INSTALL MIDDLE EXHAUST PIPE WITH MUFFLER

ASSY JOINT RUBBER.
15. INSTALL REAR EXHAUST PIPE WITH 2-STAGE


17. POSITION FRONT EXHAUST PIPE.

PIPE TO EXHAUST MANIFOLD.

PIPE AND CATALYTIC CONVERTER ASSY TO
EXHAUST MANIFOLD.
21. CONNECT REAR EXHAUST PIPE WITH 2-STAGE

MUFFLER ASSY SUPPORT ISOLATORS.
16B
22. TIGHTEN BOLTS ATTACHING MIDDLE EXHAUST

23. TIGHTEN LOWER GUARD PLATE RETAINING

BOLTS.
24. LOWER VEHICLE.

16B
16B-6 EXHAUST - EXHAUST MANIFOLD
EXHAUST MANIFOLD
REPLACEMENT

WARNING
4. REMOVE EXHAUST MANIFOLD HEAT SHIELD

RETAINING BOLTS.
5. REMOVE TURBOCHARGER OIL INLET PIPE

RETAINING BOLTS.
EXHAUST - EXHAUST MANIFOLD 16B-7
6. REMOVE 2 TURBOCHARGER OIL RETURN PIPE

RETAINING BOLTS.
16B

CLIPS.
8. REMOVE EXHAUST MANIFOLD RETAINING NUTS.

NOTE
The exhaust manifold retaining nuts will be rusted after a
long-time running. Use derusting spray when loosen the
nuts.
9. REMOVE EXHAUST MANIFOLD AND TURBOCHARGER ASSY.

10. SEPARATE TURBOCHARGER. (Refer to “Chapter 14B intake air - tubo charger, overhaul”）
11. REMOVE EXHAUST MANIFOLD GASKET.
NOTE
• Check whether parts have any damage or crack.
• Using a ruler and thickness gauge, check exhaust manifold and cylinder head surface for
flatness.
Standard: 0.15 mm or less
Limit: 0.20 mm
• Clean the dirt on exhaust manifold and cylinder head surface. 16B
12. INSTALL A NEW EXHAUST MANIFOLD GASKET.
NOTE
If do not replace a new gasket, use exhaust sealant to avoid exhaust leakage.
13. POSITION EXHAUST MANIFOLD AND TURBOCHARGER ASSY.
16B-8 EXHAUST - EXHAUST MANIFOLD
14. TIGHTEN EXHAUST MANIFOLD RETAINING NUTS.

NOTE
• Apply rust-inhibiting lubricant on nuts for next
remove conveniently.
• Install the exhaust manifold retaining bolts
diagonally.
15. TIGHTEN TURBOCHARGER OIL INLET PIPE

RETAINING BOLTS.
16. TIGHTEN 2 TURBOCHARGER OIL RETURN PIPE

RETAINING BOLTS.

CLAMPS.
EXHAUST - EXHAUST MANIFOLD 16B-9
18. TIGHTEN EXHAUST MANIFOLD HEAT SHIELD

RETAINING BOLTS.
16B

16B
MEMO
COOLING
17B
COOLING SYSTEM ......................................................................... 17B-1
PRECAUTION............................................................................ 17B-1
ON-VEHICLE INSPECT............................................................. 17B-3 17B
COOLANT ........................................................................................ 17B-4
REPLACEMENT ........................................................................ 17B-4
RADIATOR ....................................................................................... 17B-7
COMPONENTS ......................................................................... 17B-7 17B
REPLACEMENT ........................................................................ 17B-8
COOLING FAN............................................................................... 17B-13
REPLACEMENT ...................................................................... 17B-13
THERMOSTAT ............................................................................... 17B-15
OVERHAUL ............................................................................. 17B-15
COOLANT PUMP...........................................................................17B-18
OVERHAUL ............................................................................. 17B-18
11B
12B
14B
14B
17B
COOLING - COOLING SYSTEM 17B-1
COOLING SYSTEM
COOLING
PRECAUTION
1. COOLING SYSTEM PRECAUTION. 17B
(a) When removing the cooling hose, use a suitable container to recycle the retains of coolant. If not
(b) When disconnecting the pipes of cooling system, do not let debris into the pipes of cooling system. It
may damage the cooling system and engine.
(c) When disconnecting the cooling system pipes connectors, a special plug must be used to cover the
nozzle to prevent dirt or impurities.
(d) Coolant is poisonous, always keep it away from children and pets. If not continue to use, according to
regulations for disposal.
(e) Do not open the radiator cap when the engine is hot. Such as coolant temperature should be reduced
to 50 ° c (120 ° f) below, remove the radiator cap. Otherwise, the cooling liquid or vapor emitting heat
(f) Use FOTON specified coolant, do not only use water as coolant. Water will damage the engine
because of corrosion.
(g) Regular clean radiator outside, and prevent mud or dust deposition to affect radiator.
17B
17B-2 COOLING - COOLING SYSTEM

1. Coolant (Lack or leakage) Chapter 17B cooling - coolant, replacement
2. Coolant (Non-standard) Chapter 17B cooling - coolant, replacement
3. Thermostat (Damaged) Chapter 17B cooling - thermostat, overhaul
Engine overheats 4. Engine (Rough work) -
Chapter 17B cooling - cooling system,

5. Radiator (Poor cooling) precaution
6. Cooling fan (Damaged) Chapter 17B cooling - cooling fan, overhaul
7. Cooling system (Block) -
1. Radiator Chapter 17B cooling - radiator, replacement
2. Cooling system hose (Broken) -
Coolant leakage Chapter 17B cooling - coolant pump,

Chapter 17B cooling - coolant reservoir,

4. Coolant reservoir replacement
1. Cooling fan Chapter 17B cooling - cooling fan, overhaul

Engine room noise
Chapter 17B cooling - coolant pump,
COOLING - COOLING SYSTEM 17B-3
ON-VEHICLE INSPECT
1. CHECK WHETHER COOLANT LEVEL IS NORMAL. IF NOT, CHECK COOLING SYSTEM
LEAKAGE.
17B
WARNING
To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are
still hot, as fluid and steam can be blown out under pressure.
(a) Fill the radiator with coolant and attach a radiator cap
tester.
(b) Warm up the engine.
(c) Pump it to 110 kPa, and check that the pressure does not
drop.
NOTE
If the pressure drops, check the hoses, radiator or water
pump for leaks. If no external leaks are found, check the
heater core, cylinder block and head.
2. CHECK ENGINE COOLANT LEVEL IN COOLANT RESERVOIR.

(a) When the engine is cool, the engine coolant level should be between the “LOW” and “FULL” line.
(b) If low, check for leaks and add “FOTON long-effective coolant” or equivalent up to the “FULL” line.
NOTE
Do not use water as coolant.
3. CHECK ENGINE COOLANT QUALITY.
WARNING
To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are
still hot, as fluid and steam can be blown out under pressure.
(a) Remove the radiator cap.
(b) Place a container under the radiator to bloom the coolant from the coolant drain hole.
(c) Loosen the coolant drain plug to drain the coolant and check if there is any excessive deposits of rust or
scale around the radiator cap and radiator filler hole, the coolant should be free from oil. If excessively
dirty, replace the coolant.
(d) Tighten the drain plug, check the coolant level in the coolant reservoir. Fill the coolant, if necessary.
4. INSPECT FINS BLOCKAGE.
(a) If fins are clogged, wash them with water or a steam cleaner and dry them with compressed air.
NOTE
If the distance between the steam cleaner and core is too close, there is a possibility of damaging the
fins, so keep the following injection distance. 17B
(b) Be careful not spary water directly onto electronic components.
(a) Disconnect the cooling fan connector.
(b) Connect battery and ammeter to the connector.
(c) Check that the cooling fan rotates smoothly, and check the reading on the ammeter.
Standard amperage：
Approx. 8.0 ~ 12.0 A at 20°C (68°F)
(d) Connect the cooling fan connector.
(e) No abnormal noise except fan itself when the fan is running at a high speed.
17B-4 COOLING - COOLANT
COOLANT
REPLACEMENT
WARNING
to 50 °C (120 °F) below, remove the radiator cap. Otherwise, the cooling liquid or vapor emitting heat

3. REMOVE RADIATOR CAP.

NOTE
Press the radiator cap and counterclockwise rotate to open radiator cap.
6. LOOSEN COOLANT DRAIN PLUG AT RADIATOR

BOTTOM.
COOLING - COOLANT 17B-5
7. INSTALL CONDUIT BETWEEN RADIATOR DRAIN

PLUG AND CONTAINER.
NOTE
Using a suitable container, hold the coolant. If do not 17B
8. DICONNECT CLIP ATTACHING COOLANT RESERVOIR

HOSE TO RADIATOR.
9. REMOVE COOLANT RESERVOIR RETAINING BOLT.
10. DISCONNECT COOLANT LEVEL SENSOR CONNECTOR.

11. REMOVE COOLANT RESERVOIR AND DRAIN THE COOLANT.
12. TIGHTEN COOLANT DRAIN PLUG AT RADIATOR

BOTTOM.
17B
17B-6 COOLING - COOLANT
14. INSTALL COOLANT RESERVOIR AND TIGHTEN

BOLT.
15. CONNECT COOLANT LEVEL SENSOR CONNECTOR.
16. CONNECT CLAMP ATTACHING COOLANT RESERVOIR

HOSE TO RADIATOR.
17. FILL COOLANT FROM RADIATOR FILLER HOLE.

18. FILL COOLANT TO STANDARD LEVEL.
19. START ENGINE AND ACCELERATE TO 2500 RPM. FILL RADIATOR WITH COOLANT.
20. INSTALL RADIATOR CAP, RUN ENGINE UNTIL COOLING FAN RUNNING AT HIGH SPEED.
CHECK COOLANT LEVEL IN COOLANT RESERVOIR.
NOTE
The air in cooling system can be bled automatic.

COOLING - RADIATOR 17B-7
RADIATOR
COMPONENTS
17B
1 Rubber Cushion 6 Engine Outlet Coolant Hose
2 Radiator 7 Coolant Reservoir Hose
3 Radiator Support 8 Coolant Reservoir
4 Cooling Fan 9 Coolant Level Sensor
5 Engine Inlet Coolant Hose 10 Radiator Cap
17B
17B-8 COOLING - RADIATOR
REPLACEMENT
WARNING


4. DRAIN COOLANT. (Refer to “ Chapter 17B cooling - coolant, replacement”)
5. DISCONNECT UPPER RADIATOR COOLANT HOSE CLAMP.


17B
10. DISCONNECT LOWER RADIATOR COOLANT HOSE

CLAMP.
11. LOOSEN 2 RADIATOR LOWER SUPPORT RETAINING

BOLTS.
12. LOWER VEHICLE.
13. REMOVE 2 RADIATOR UPPER SUPPORT RETAINING

BOLTS.
17B
14. REMOVE RADIATOR AND COOLING FAN ASSY.

16. REMOVE RADIATOR, CLEAN IT IF NECESSARY.
17. POSITION COOLING FAN AND TIGHTEN 4 COOLING

FAN RETAINING BOLTS.
18. INSTALL RADIATOR AND COOLING FAN ASSY TO RADIATOR FRAME.

NOTE
Before installing radiator, position the rubber cushion.
19. RAISE VEHICLE.
20. TIGHTEN 2 LOWER RADIATOR SUPPORT RETAINING

BOLTS.
21. CONNECT LOWER RADIATOR COOLANT HOSE AND

TIGHTEN CLAMP.
17B
23. LOWER VEHICLE.
24. TIGHTEN 2 UPPER RADIATOR SUPPORT RETAINING

BOLTS.
25. CONNECT UPPER RADIATOR COOLANT HOSE AND

TIGHTEN CLAMP.
17B

30. FILLING COOLANT. (Refer to “Chapter 17B cooling - coolant， replacement”)

31. AFTER INSTALLING RADIATOR, START ENGINE UNTIL COOLING FAN RUNNING AT HIGH
SPEED, CHECK COOLANT FOR LEAKAGE.
COOLING - COOLING FAN 17B-13
COOLING FAN
REPLACEMENT
17B
17B
6. CHOOSE A SUITABLE POSITION TO REMOVE COOLING FAN.

17B-14 COOLING - COOLING FAN

(a) Using an ohmmeter, measure the resistance between the terminals
Resistance: 1.17 - 1.43 Ω at 20 ℃
(b) Rotate cooling fan by hand, the fan blades should be rotated smoothly.
8. POSITION COOLING FAN.
9. TIGHTEN 4 COOLING FAN RETAINING BOLTS.


COOLING - THERMOSTAT 17B-15
THERMOSTAT
OVERHAUL
WARNING 17B

(b) Remove 2 intake air duct retaining bolts

5. REMOVE THERMOSTAT HOUSING RETAINING

BOLTS.
6. REMOVE THERMOSTAT.
17B
17B-16 COOLING - THERMOSTAT
7. INSPECT THERMOSTAT.
(a) The thermostat is numbered with the valve opening
temperature.
(b) Immerse the thermostat in water and gradually heat the

water.
(c) Check the valve opening temperature.
Valve opening temperature: 80 ~ 84 ℃
NOTE
If the valve opening temperature is not as specified, replace
with a new thermostat.
(d) Check the valve lift.

Valve lift: 8 mm or more, at 95 ℃ .
NOTE
If the valve lift is not as specified, replace with a new thermostat.
• Check that the valve is fully closed when the thermostat is at low temperature (below 77 ℃ ).
• If not close, replace with a new thermostat.
8. INSTALL THERMOSTAT.
COOLING - THERMOSTAT 17B-17
9. TIGHTEN THERMOSTAT HOUSING RETAINING

BOLTS.
17B

11. FILL COOLANT. (Refer to “Chapter 17B cooling - coolant, replacement”)

13. AFTER INSTALLING THERMOSTAT, RUN ENGINE UNTIL COOLING FAN RUNNING AT HIGH
SPEED, CHECK COOLANT FOR LEAKAGE.
17B
17B-18 COOLING - COOLANT PUMP
COOLANT PUMP
OVERHAUL
WARNING


6. DISCONNECT CAMSHAFT POSITION SENSER

CONNECTOR, AND REMOVE CAMSHAFT POSITION
SENSOR.

BOLTS.
COOLING - COOLANT PUMP 17B-19
8. REMOVE COOLANT PUMP RETAINING BOLTS.
17B
9. REMOVE ENGINE TIMING BELT COVER. (Refer to “Chapter 15B engine mechanical - engine
10. USING A PULLER, REMOVE COOLANT PUMP.
11. REMOVE COOLANT PUMP GASKET.

12. USING A SCRAPER, CLEAN DIRT ON COOLANT PUMP AND ENGINE BLOCK CONNECT
SURFACE.
NOTE
Clean the dirt, do not damage coolant pump and engine block connect surface.
13. INSPECT COOLANT PUMP.
(a) Rotate coolant pump and it should turn smoothly.
(b) There should be no clearance between coolant pump shaft and coolant punp bearing and no abnormal
noise when it turns.
(c) No coolant leaks around water pump.
14. INSTALL COOLANT PUMP GASKET. TO AVOID COOLANT LEAKAGE, USE COOLANT PUMP
SEALANT IF NECESSARY.
NOTE
After using the coolant pump sealant, wait for 15 minutes then fill the coolant.
17B
15. INSTALL ENGINE TIMING BELT COVER. (Refer to “Chapter 15B engine mechanical - engine
16. INSTALL COOLANT PUMP.

17B-20 COOLING - COOLANT PUMP
17. TIGHTEN COOLANT PUMP RETAINING BOLTS.

18. TIGHTEN COOLANT PUMP PULLEY RETAINING

BOLTS.
21. FILLING COOLANT. (Refer to “Chapter 17B cooling - coolant, replacement”)

23. AFTER REPLACING COOLANT PUMP, START ENGINE UNTIL COOLING FAN RUNNING AT HIGH
LUBRICATION
18B
LUBRICATION SYSTEM ................................................................. 18B-1
PRECAUTION............................................................................ 18B-1
COMPONENTS ......................................................................... 18B-2
ENGINE OIL ..................................................................................... 18B-3 18B
REPLACEMENT ........................................................................ 18B-3
OIL FILTER ...................................................................................... 18B-6
REPLACEMENT ........................................................................ 18B-6
OIL PAN ...........................................................................................18B-9 18B
REPLACEMENT ........................................................................ 18B-9
OIL PUMP ...................................................................................... 18B-13
OVERHAUL ............................................................................. 18B-13
OIL FILTER BRACKET.................................................................. 18B-16
REPLACEMENT ...................................................................... 18B-16
11B
12B
14B
18B
15B
LUBRICATION - LUBRICATION SYSTEM 18B-1
LUBRICATION SYSTEM
LUBRICATION
PRECAUTION
1. LUBRICATION SYSTEM PRECAUTION. 18B
(a) Diesel Engine has two ways of pressure and splash lubrication. The gear type oil pump is fixed on the
cylinder block. The pump inner rotor is driven by the camshaft. Oil pump strainer tube is in the sump of
the oil pan.
WARNING
Prolonged and repeated contact with engine oil will cause the skin fat to be removed, resulting in dry
skin, allergies and dermatitis. In addition, used engine oil contains potentially harmful pollutants may
cause skin cancer. Therefore, the skin must be protected in appropriate methods and with cleaning
equipment.
(b) Avoid contacting with oil for a long time, especially the used engine oil.
(c) Wear protective clothing, including waterproof work gloves.
(d) Avoid contaminated clothing, especially underwear containing the oil.
(e) Never put rags contaminated with oil in pockets.
(f) Avoid eyes contact with oil, must wear goggles, In addition, equipment must be prepared to clean the
eyes and wrapping the wound must be dealt with immediately.
(g) Frequent use of soap and water can clean, especially before meals, and make sure all the oil have
been removed (skin cleansers can also be used to assist with the nail brush). After cleaning, it is
recommended to replace the natural skin oils cotton suet.
(h) Do not use gasoline, kerosene, diesel, thinner or solvent to clean skin.
(i) Before each work, apply cream to help skin cleaning after work.
(j) If your skin is abnormal, consult a doctor immediately.
18B
18B-2 LUBRICATION - LUBRICATION SYSTEM
COMPONENTS
1 Oil Pan 6 Camshaft
2 Oil Strainer 7 Crankshaft
3 Oli Filter 8 Piston
4 Oli Filter Bracket 9 Valve Push Rod
5 Oil Cooler 10 Valve Rocker Arm

LUBRICATION - ENGINE OIL 18B-3
ENGINE OIL
REPLACEMENT
1. PARK VEHICLE IN LEVEL ROAD, SLOWLY PULL OUT OIL DIPSTICK, AND CHECK OIL LEVEL, 18B
OIL LEVEL MUST BE LOCATED WITHIN THE OIL DIPSTICK MARK.
2. CHECK OIL WITHOUT EXCESSIVE POLLUTION, NO PETROL AND LIQUID MIXED. THERE
MUST HAVE ENOUGH CONCENTRATIONS AND LUBRICATION DEGREE.

WARNING
18B

18B-4 LUBRICATION - ENGINE OIL
9. REPLACE NEW DRAIN PLUG GASKET AND TIGHTEN

PLUG.
Torque: 35 ~ 45 N.m
10. TIGHTEN LOWER GUARD PLATE RETAINING

BOLTS.
11. LOWER VEHICLE.

12. FILL ENGINE OIL.
Engine oil: 4.5 ~ 5 L
Oil filter oil: 0.3 L
NOTE
Engine oil with specifications of CF- 4, 15W-40 and 15W-30.

LUBRICATION - OIL FILTER 18B-5
OIL FILTER
REPLACEMENT
NOTE 18B
Without special circumstances, the oil filter should be replaced with engine oil replacement, avoid oil
pollution and keep engine operation.

WARNING
6. USING A SPECIAL CONTAINER, COLLECT USED OIL, DISPOSAL AS REQUIRED. 18B

7. USING SPECIAL TOOL MD-991396 OR TOOLS SOLD
ON MARKET, REMOVE OIL FILTER.
8. CLEAN INTERFACE OF OIL FILTER AND OIL FILTER BRACKET.

18B-6 LUBRICATION - OIL FILTER
9. APPLY OIL TO NEW OIL FILTER O-RING.
10. FILL CLEAN OIL INTO OIL FILTER.
11. TIGHTEN OIL FILTER BY HAND UNTIL O-RING

TOUCHES OIL FILTER BRACKET. USING SUITABLE
TOOL, TIGHTEN OIL FILTER.
Torqure: 25 ~ 30 N•m

Torque: 35 ~ 45 N.m
LUBRICATION - OIL FILTER 18B-7
18B
14. LOWER VEHICLE.


18B
18B-8 LUBRICATION - OIL PAN
OIL PAN
REPLACEMENT

WARNING

LUBRICATION - OIL PAN 18B-9
6. REMOVE OIL PAN RETAINING BOLTS.
18B
7. DRIVE IN A SCREWDRIVER BETWEEN CYLINDER BLOCK AND OIL PAN, THEN SEPARATE
THEM BY HAMMER.
8. TAKE OIL PAN GASKET.
9. CLEAN THE INTERFACE OF OIL PAN AND ENGINE BLOCK.
10. REPLACE CRANKSHAFT FRONT SIDE (CRANKSHAFT

PULLEY SIDE) OIL PAN ARC GASKET.
11. REPLACE CRANKSHAFT REAR SIDE (FLYWHEEL

SIDE) OIL PAN ARC GASKET.
18B
18B-10 LUBRICATION - OIL PAN
12. INSTALL OIL PAN GASKET, APPLY SEALANT ON

ROOTS OF BOTH SIDES OF CRANKSHAFT BEARING
CAP.
NOTE
Be sure to install the oil pan quickly while the sealant is wet
(within 15 minutes).
13. TIGHTEN OIL PAN RETAINING BOLTS DIAGONALLY.

NOTE
After installation, keep the sealant area away from the oil for about one hour.

Torque: 35 ~ 45 N.m
LUBRICATION - OIL PAN 18B-11
18B
18B
18B-12 LUBRICATION - OIL PUMP
OIL PUMP
OVERHAUL

WARNING

6. REMOVE OIL PAN. (Refer to “Chapter 15B， lubrication - oil pan, replacement”)
LUBRICATION - OIL PUMP 18B-13
7. REMOVE OIL PUMP RETAINING BOLTS.
18B
8. TAKE OIL PUMP AWAY.
9. INSPECT OIL PUMP.

(a) Oil pump gear and camshaft gear tooth surface should not have erosion, wear, or missing teeth. If
found, replace the oil pump assembly.
(b) Ensure the oil pump can be rotated smoothly.
10. TIGHTEN OIL PUMP RETAINING BOLTS.

11. INSTALL OIL PAN. (Refer to “Chapter 18B， lubrication - oil pan, replacement”）
18B
18B-14 LUBRICATION - OIL PUMP
12. TIGHTEN OIL DRAIN PLUG.


LUBRICATION - OIL FILTER BRACKET 18B-15
OIL FILTER BRACKET

REPLACEMENT
1. REMOVE OIL FILTER. (Refer to “Chapter 18B 18B
lubrication - oil filter, replacement”)
2. DISCONNECT OIL COOLER WATER INLET AND

OUTLET HOSE CLAMP.
3. REMOVE 4 OIL FILTER RETAINING BOLTS.
18B
18B-16 LUBRICATION - OIL FILTER BRACKET
4. REMOVE OIL COOLER RETAINING BOLT.
5. SEPARATE OIL COOLER, TAKE OIL FILTER BRACKET AWAY.
6. POSITION OIL COOLER TO OIL FILTER BRACKET

AND TIGHTEN RETAINING BOLT.
7. TIGHTEN OIL FILTER BRACKET RETAINING BOLTS.

LUBRICATION - OIL FILTER BRACKET 18B-17
8. CONNECT OIL COOLER WATER INLET AND OUTLET

HOSE AND TIGHTEN CLAMP.
18B
9. INSTALL OIL FILTER. (Refer to “Chapter 18B lubrication - oil filter, replacement”)
18B
MEMO
20B
STARTING AND CHARGING SYSTEM .......................................... 20B-1
PRECAUTION............................................................................ 20B-1
GENERATOR ................................................................................... 20B-3 20B
OVERHAUL ............................................................................... 20B-3
Generator and Regulator Maintainance ................................... 20B-11
STARTER ....................................................................................... 20B-12
COMPONENTS ....................................................................... 20B-12 20B
OVERHAUL ............................................................................. 20B-13
BATTERY ....................................................................................... 20B-22
COMPONENTS ....................................................................... 20B-22
USE AND MAINTENANCE ...................................................... 20B-23
INSPECTION ........................................................................... 20B-25
BATTERY COMMON PROBLEMS, THE CAUSES
ANALYSES AND TROUBLESHOOTING ............................... 20B-26
REPLACEMENT ...................................................................... 20B-27
11B
12B
20B
14B
15B
STARTING AND CHARGING - STARTING AND CHARGING SYSTEM 20B-1
STARTING AND CHARGING SYSTEM

PRECAUTION
1. STARTING AND CHARGING SYSTEM PRECAUTION.
(a) Battery may have escaping explosive gas. In order to avoid personal injury, before maintaining battery,
keep ventilated in engine room. To avoid electric arc, disconnect battery negative cable first and
connect the negative cable last.
(b) Battery electrolyte is very dangerous, it can damage the machine and cause serious burns. When
maintaining battery, prepare neutralizers concentration soda water, wear safety eyepiece and wear
protective clothing, which can avoid personal injury.
(c) When using compressed air, wear appropriate goggles and protective mask. Dust particles and dirt can
cause injury.
(d) Don't tighten the electrical connectors excessive, which may damage the starter.
(e) Never short two cables of the battery, it will cause a rapid battery fever even a explosion occur. The
escaping gas from battery is easily be burned by the spark, so do not use fire near battery.
(f) After the generator operation, do not try to use spark check whether the generator works. use bulb or
multimeter to perform the test. Otherwise it will damage the generator diode.
(g) Check the generator silicon rectifier devices, multimeter and 220v check is strictly forbidden to check
generator insulation, otherwise it will make diode breakdown and damaged.
20B
20B-2 STARTING AND CHARGING - STARTING AND CHARGING SYSTEM

1. Starter switch control circuit (Open) -
Starter out-of - Chapter 20B starting and charging - starter,

2. Brush and rectifier (Poor connection) overhaul
operation
3. Starter inside circuit (Open or short) overhaul
Chapter 20B starting and charging - battery, use

1. Battery (Low voltage) and maintenance
2. Starter wire (Poor connection) -
3. Rectifier (Surface damage or stains) -

Starter loss
power, can not 4. Brush (Wear) or Brush spring (Loss Chapter 20B starting and charging - starter,
srart engine elastic force) overhaul

5. Solenoid switch (Contacts ablation) overhaul
6. Bearing (Wear)， commutator (Wipe Chapter 20B starting and charging - starter,
shell) overhaul

1. Starter relay (Copper contacts bond) overhaul
Starter keep Chapter 20B starting and charging - starter,
working after 2. Starter commutator (Bend or break) overhaul
engine start.
3. Starter gear tooth surface contact Chapter 20B starting and charging - starter,
(Roughening or stuck) overhaul
1. Generator connect wire -
Chapter 20B starting and charging - generator,

2. Rotor winding (Open) overhaul
Generator out-of Chapter 20B starting and charging - generator,

3. Rectifier diode (Damaged) overhaul
-operation
4. Brush (Poor connection) overhaul

5. Regulator (Damaged) overhaul
Chapter 15B engine mechanical - engine acces-

1. Belt losing tensity sory belt, overhaul
2. Brush (Poor connection) or Collector Chapter 20B starting and charging - generator,
Generator loss ring (Smery) overhaul
enough electricity
3. Regulator (Damaged) overhaul
Chapter 20B starting and charging - battery, use

4. Battery lose electrolyte and maintenance
STARTING AND CHARGING - GENERATOR 20B-3
GENERATOR
OVERHAUL
2. COOL ENGINE, MAKE BELT TEMPERATURE CLOSE TO NORMAL TEMPERATURE.

3. ROTATE GENERATOR BELT AND CHECK FOR CRACK.
4. LOOSEN BOLT ATTACHING GENERATOR TO

GENERATOR BRACKET.
5. LOOSEN GENERATOR TENSIONER LOCK NUT.
20B
6. REMOVE GENERATOR BELT.

7. LOOSEN GENERATOR POSITIVE CABLE CONNECT NUT.
8. DISCONNECT GENERATOR CONNECTOR.
9. REMOVE VACUUM PUMP INLET OIL PIPE.

20B-4 STARTING AND CHARGING - GENERATOR
10. REMOVE VACUUM PUMP OUTLET OIL HOSE CLIP.
11. DISCONNECT VACUUM OUTLET HOSE CLIP.
12. REMOVE 3 VACUUM PUMP RETAINING BOLTS.
13. REMOVE VACUUM PUMP.
14. REMOVE GENERATOR RETAINING BOLTS.
15. REMOVE GENERATOR.

16. USING PNEUMATIC TOOLS, REMOVE GENERATOR

BELT PULLEY RETAINING NUT.
17. REMOVE GENERATOR FAN.
18. REMOVE RETAINING BOLTS ATTACHING GENERATOR

19. INSERT SCREWDRIVER TO INTERVAL BETWEEN FRONT COVER AND STATOR THEN SEPARATE
THEM.
NOTE
• If they are difficult to be separated, slap the front cover slightly with rubber hammer and pry it
with screwdriver.
• Do not insert screwdriver too deep to prevent stator component damaged.
20. USING A ELECTRIC IRON (180 ~ 250 W), REMOVE

STATOR. THIS OPERATION SHOULD BE WITHIN 4
SECONDS TO PREVENT TRANSMITTING HEAT TO
DIODE.
20B
21. REMOVE 4 RETAINING BOLTS FROM RECTIFIER.

22. USING A ELECTRIC IRON, REMOVE RECTIFIER

FROM REGULATOR.
NOTE
• Ensure that heat is not transmitted from electric iron to diode for long time.
• Do not let diode pin bear too much force.
23. REMOVE AND INSPECT ROTOR.

(a) Check the rotor coil is conductive, and confirm that the
collector rings are conductive. Measure the resistance of
rotor. If the resistance is less than Specified value, it
means the rotor is short circuit. If it is not conductive or it
is short circuit, replace the rotor assy.
Specified value: 3 ~ 5 Ω
(b) Check that rotor coil ground. Confirm that it is insulative

between collector ring and core. If not insulative, replace
the rotor assy.
(c) Using a vernier calipers, measure the slip ring diameter.

24. REMOVE AND INSPECT STATOR.

(a) Check the stator for continuity. Confirm that the coil lead
is conductive. If there is a continuty, replace the stator
assy.
Standard: 5 ~ 6 Ω
(b) Check the coil ground. Confirm that it is conductive

between coil and stator core. Replace the stator assy if
not conductive.
25. INSPECT STATOR RECTIFIER.

(a) Diode group (three diodes) check: Using an ammeter to
connect two ends of each diode, check if three diodes
are conductive. If it is not conductive in both directions, it
means the diodes are broken, and it is required to
replace the rectifier assy.
26. GET RID OF WELDING POINT OF BRUSH LEAD,

THEN TAKE OUT THE BRUSH.
20B
27. IF BRUSH IS SO WORN TO REACH WEAR LIMIT MARK

LINE, REPLACE BRUSH.
28. WHEN INSTALLING NEW BRUSH, WELD BRUSH

LEAD IN THE CONDITION WHEN BRUSH IS
PRESSING DOWN BRUSH BRACKET AS SHOWN.
29. INSTALL 4 RETAINING BOLTS FROM RECTIFIER.

Torque: 6 ~ 8 N•m
30. WELD RECTIFIERS AND STATOR CONNECTION.
31. POSITION ROTOR.
32. INSTALL RETAINING BOLTS ATTACHING GENERATOR

33. POSITION GENERATOR FAN.

34. POSITION GENERATOR BELT PULLY AND USING PNEUMATIC TOOLS, INSTALL GENERATOR BELT
PULLEY RETAINING NUT.
35. INSTALL GENERATOR RETAINING BOLTS.
36. INSTALL GENERATOR BELT.
37. TIGHTEN BOLT ATTACHING GENERATOR TO

GENERATOR BRACKET.
38. USING CROWBAR, PRY THE GENERATOR AND

TIGHTEN THE LOCK NUT.

(b) Tighten 2 intake air duct retaining bolts. 20B
Generator and Regulator Maintainance

• After disassemble the generator, blow dust inside by compressed air. Clean greasy dirt inside by
gasline. Grind slip ring of rotor by NO.00 sandpaper.
• Clean bearing and check loosen. Replace with new one and fill grease if loosen.
• Check rotor field coil and slip ring welding is firm or not (the field coil resistance is about 5 ~ 6 Ω).
Check stator lead line and diode lead line welding is firm or not.
STARTING AND CHARGING - STARTER 20B-11
STARTER
COMPONENTS
1 Front Bracket 11 Overdrive Clutch 20B

2 Spring 12 Locating Snap Ring
3 Starter Drive Lever 13 Magnet Yoke Assy
4 Rubber Washer 14 Commutator
5 Planetary Gear Bracket 15 Brush
6 Solenoid Component 16 Brush Bracket
7 Rubber Washer 17 Starter Shell Bolt
8 Steel Ball 18 Rear Bearing
9 Planetary Gear 19 Rear Bracket
10 Internal Gear
20B-12 STARTING AND CHARGING - STARTER
OVERHAUL

4. REMOVE 2 STARTER RETAINING BOLTS.
5. DISCONNECT STARTER ELECTRICAL WIRE

CONNECTING NUT.
6. DISCONNECT STARTER CONTROL WIRE CONNEC-

TOR.
7. REMOVE STARTER AND INSPECT IT.

(a) Pinion gap adjustment.
magnetic switch.
terminal.
NOTE
• When the 12-volt battery is connected between the S-

terminal and M-terminal. the pinion will move out.
• Check the pinion-to-stopper clearance (pinion gap) with

a feeler gauge.
(b) Magnetic switch pull-in test.

magnetic switch.
terminal.
NOTE
• If the pinion moves out, the pull-in coil is good. If it
doesn't, replace the magnetic switch.
(c) Magnetic switch hold-in test.
20B
magnetic switch.
• Connect a 12-volt battery between the S-terminal and
body.
NOTE
• Manually pull out the pinion as far as the pinion stopper

position.
• If the pinion remains out, everything is in order. If the
pinion moves in, the hold-in circuit is open. Replace the
magnetic switch.
(d) Magnetic switch return test.

magnetic switch.
• Connect a 12-volt battery between the M-terminal and
body.
NOTE
• Pull the pinion out and release. If the pinion quickly

returns to its original position, everything is operating
properly. If it doesn't, replace the magnetic switch.
WARNING
Be careful not to get your fingers caught when pulling out
the pinion.
8. DISCONNECT MAGNETIC COIL LEAD NUT FROM

MAGNETIC SWITCH.
9. REMOVE MAGNETIC SWITCH RETAINING BOLTS.
10. REMOVE STARTER SHELL RETAINING BOLTS.
11. DISASSEMBLY STARTER AS COMPONENTS ART SHOWN.

NOTE
When removing commutator, do not lose the steel ball mounted in the bearing ends.
(a) Using a proper control sleeve, push and press the

locating snap ring to the overdrive clutch side, and make
it brake away from the clip spring.
(b) Remove the snap spring with snap ring pliers, then
remove the locating snap ring and overdrive clutch.
12. CLEAN STARTER PARTS.

NOTE
• Do not put the parts in the detergent for cleaning. If the magnet yoke, excitation winding lead or
rotor is immerged in detergent, their insulating ability is damaged.
• Clean starter parts with cloth.
• Drive parts cannot be immerged in detergent for cleaning. Before delivering out of factory, the
overdrive clutch is greased. If clean it by detergent, its grease might be removed.
• Using a brush and dip with detergent, clean drive parts then dry them with a cloth.
13. INSPECT COMMUTATOR.

(a) Support the commutator with a pair of V block and turn it
to measure the runout of the surface using a dial gauge.
Limit: 0.1 mm 20B
(b) Measure the diameter of the commutator.

Standard: 29.4 mm
Limit: 28.4 mm
(c) Measure the depth of the undercut between segments.

Standard: 0.5 mm
Limit: 0.2 mm
14. INSPECT BRUSH AND BRUSH BRACKET.

(a) Check that it is conductive between brush plate and brush bracket; if not conductive, it is normal.
(b) Check the commutator contact surface of each brush for abnormal roughness. Also check the height of
the brush. Replace the brush holder if the height is lower than the limit.
Limit: 7.0 mm
(c) When the contact surface of the brush is rectified or the brush holder is replaced, recondition the
contact surface with sandpaper wrapping around the commutator.
15. INSPECT OVERDRIVE CLUTCH.

(a) Make sure that the pinion cannot be turned
counterclockwise and can be turned clockwise freely.
(b) Check the pinion for abnormal ware and damage.
16. INSPECT ARMATURE COIL.

(a) Set the armature in a growler.
(b) While holding a thin strip of iron against the armature in
parallel with its axis, turn the armature slowly. The
armature is normal if the iron strip is not attracted to the
armature or it does not vibrate.
NOTE
Clean the surface of the armature thoroughly before
performing the test.
(c) Check the insulation between commutator segments and

armature coils. The armature coils are properly insulated
if no continuity is present.
(d) Check continuity between a segment and another. It is

normal if there is continuity.
17. INSPECT MAGNETIC SWITCH.

(a) Coil open circuit test.
• Check that there is continuity between the M terminal
and body A.
(b) Contact fusion check.

• Check that there is no continuity between the B terminal
and M terminal.
• If there is continuity, replace the magnetic switch.
(c) Switch contact check.

• Push the indicated end of the magnetic switch with a
strong force to close the internal contacts. Without
releasing the switch end, check that there is continuity
20B
between the B terminal and M terminal.
18. USING A SUITABLE PULLER, PULL STOP RING UNTIL

IT GETS OVER SNAP RING.
19. INSTALL LOCATING SNAP RING AND OVERDRIVE

CLUTCH.
20. ASSEMBLY STARTER AS COMPONENTS ART SHOWN.
21. TIGHTEN STARTER SHELL RETAINING BOLTS.

22. TIGHTEN MAGNETIC SWITCH RETAINING BOLTS.

23. CONNECT MAGNETIC COIL LEAD NUT FROM

MAGNETIC SWITCH.
24. CONNECT STARTER ELECTRICAL WIRE CONNECTING

NUT.
25. CONNECT STARTER CONTROL WIRE CONNECTOR.
26. TIGHTEN 2 STARTER RETAINING BOLTS.

27. LOWER VEHICLE.


(a) Tighten 4 engine cover retaining bolts. 20B
20B-20 STARTING AND CHARGING - BATTERY
BATTERY
COMPONENTS
Lead-acid battery consists of plus and minus plate, partition, sulfuric acid electrolyte, battery shell.
1 Negative Terminal 5 Overall Groove
2 Battery Cover 6 Negative Plate
3 Cross Wall Connect 7 Partition
4 Bus Bars 8 Positive Plate
、
STARTING AND CHARGING - BATTERY 20B-21
USE AND MAINTENANCE

1. CHARGING DEVICE.
NOTE
DC power supply must be used for battery charging, howerever, what is supplied by power plant is AC
that it must be transformed into DC, After transform, the charging can be performed.
(a) Rectifier.
(b) Controllable silicone voltage regulation charger.
2. CHARGE PRECAUTIONS
(a) Charging should choose in ventilated dry room, indoor temperature in 5 ℃ ~ 40 ℃ is advisable.
(b) Battery can not be overlap shelved, also do not put them on the ground directly. It should be put on the
wooden support, and cannot be set with alkaline battery or other chemicals.
(c) Charging in field should be far away from fire and heat.
(d) Liquid temperature should not exceed 45 ℃ and otherwise cooling measures shouldl be taken(by
reducing filling current or stopping sharge or being cooled down in water tank)
3. CHARGE CONNECTION.
(a) The positive pole of charger is to be connected with the positive pole of battery, while the negative pole
of charger should be connected with the negative pole of battery. Never connect them reversely.
(b) Charge of most batteries may be determined based on the size of moter power. Connection for charge
must be firm.
4. CHARGING MODES.
(a) Constant current charge.
(b) Constant voltage charge.
(c) Quick charge.
5. AFTER CHARGING, USING THE BELOW METHODS, CHECK THE BATTERY CAPACITY IS
RESTORED TO STANDARD.
(a) Voltage method

11.5 ～ 12.5 v Undercharge Additional charge
Below 11.5 V Over-discharge or internal failure To be further checked after charging

20B
(b) Capacity method
Capacity Tester Display Determination Treatment


6. USING AND MAINTENANCE OF BATTERY IN WINTER

(a) Keep the battery is to be maintained under full charge status, avoid the electrolyte from being frozen
arising from drop in density, which may give rise to breakage of container, curve of pole plats, as well as
smash and dropout of active substances, and other failures.
(b) Because the battery capacity reduced in winter, when start the engine in cold status, preheated the
engine and each time start the engine should not more than 15 seconds, two starting interval 2 ~ 3
minutes, if can not start the engine in three times, troubleshooting, then restarting.
INSPECTION
1. APPEARANCE INSPECTION.
(a) Observe whether the battery appearance in good condition. Check if fixed terminal and wires are
connected firmly.
(b) Observe whether the battery shell and the center partition cracks, and use a wooden beat shell and
center partitions respectively, listen to the sound without breaking, especially the central baffle and shell
side of shell wall at the junction of four, prone to crack, should be carefully examined.
(c) Through mirrors, green for fully charged, red and white said lack of electricity and no electricity. Need of
the following capacity, voltage detection.
2. CAPACITY TEST.
(a) The excel tester is also known as the discharging tongs.

It consists of a DC voltmeter of three volts and one load
resistance.
(b) The tips of the two tongs shall be press on the anode and
the cathode tightly and maintain for five seconds in the
measurement. Observe the terminal voltage in the state
of the big load discharging and the discharging content
and the starting ability can be judged correctly.
(c) For the excel tester of different brands, the readings of
the current and the voltage shall be read according to the
regulations of the factory manual. Generally, the single
voltage of the battery in good state shall be above 1.5 V
and keep steady within five seconds. If the voltage drops
rapidly within five minutes or the voltage of one single
cell is 0.1 V lower than that of others, it indicates there
are troubles in the battery and it shall be repaired.
Below is the use of excel tester of discharge plan detection income cross-references.
Display Zone Determination Treatment


20B
3. VOLTAGE TEST
The following table is derived using the digital multimeter test table.

11.5 ~ 12.5 v Undercharge Additional charge
Under 112.5 v Over-discharge or internal fault To be further checked after charging


TROUBLESHOOTING
1. ELECTRICAL QUALITY OF ONE FULL-CHARGED BATTERY REDUCE WITHOUT USE FOR A
LONG PERIOD.
The full-charged battery without use will lose its electrical quality gradually and this phenomenon is
known as “self-discharge”. The important cause of self-discharge is the impure materials. If there are
impurities in the material of the polar plate or in the electrolyte, there will be a potential difference
between the impurity and the polar plate and between the impurities. A closed “local current” is formed
and would make the discharge of the battery.
For the battery which has discharged seriously, it can be discharged completely or excessively. This will
enable the impurities on the polar plate into the electrolyte. Then, pour the electrolyte out and clean the
battery with distilled water. Finally, inject the new electrolyte and re-charge the battery.
2. BATTERY EXPLODE.
The water in the electrolyte hydrolyzes into hydrogen or oxygen and a lot of bubbles are generated;
there are short circuit and vulcanization troubles in the battery; the temperature increases while
charging and large amount of water are evaporated. Then if the vent holes of the injection hole cover
are plugged or there are a lot of gases which are unable to escape, the battery will explode when the
inner pressure comes to a limit (or there are sparks).
(a) The vent holes of the injection hole cover shall be cleared.
(b) In order to avoid sparks, the wirings on the polar stud shall be fastened.
(c) The injection hole cover shall be opened first when check with the excel tester.
(d) Control the charging amount and do not over-charge in order to reduce the releasing amount of the
gases. Open flames are prohibited and the ventilation shall be ensured in the charging room.
3. RAPID DECREASE OF THE LIQUID LEVEL DURING THE USE PROCESS OF THE BATTery.
(a) Excessive charging current lead to evaporation of water.
(b) Battery shell broken.
(a) Add distilled water.
(b) Repair shell, add the electrolyte.
4. BATTERY COVER PRODUCE A YELLOW OR WHITE PASTE.
The yellow or white paste surrounding the battery cover and the polar stud is caused by the corrosion of
the polar studs, wiring clip and the fixed frame by the sulfuric acid sprayed.
In order to avoid these pastes, clean the electrolyte sprayed on the battery cover and the shell with a
cloth soaked with the soda solution of 10 percents. Then wipe with water and dry with a clean cloth.
The paste on the wire ends and the studs shall be wiped with the cloth soaked with soda solution. If
there are oxides of poor conductivity, scrape them with a little knife and clean them. It would be best to
smear a coat of Vaseline or butter on the cover after the polar studs and wiring clips are fastened.
REPLACEMENT
3. LOOSEN BATTERY CABLE RETAINING BOLTS AND

DISCONNECT BATTERY NEGATIVE/POSITIVE CABLE.
NOTE
Take off the negative battery cable first.
4. LOOSEN BATTERY HOLD DOWN RETAINING BOLTS.
5. REMOVE BATTERY HOLD DOWN. 20B
6. REMOVE BATTERY.
NOTE
Battery should be put up, placing upside down the battery is avoided.
7. REMOVE 4 BATTERY TRAY RETAINING BOLTS.
8. REMOVE 4 BATTERY TRAY BRACKET RETAINING

BOLTS.
9. TIGHTEN 4 BATTERY TRAY BRACKET RETAINING

BOLTS.
10. TIGHTEN 4 BATTERY TRAY RETAINING BOLTS.

11. POSITION BATTERY.

12. TIGHTEN BATTERY HOLD DOWN RETAINING BOLTS.

13. CONNECT BATTERY NEGATIVE/POSITIVE CABLE AND

TIGHTEN BATTERY CABLE RETAINING BOLTS.
NOTE
• If terminals has sediments, remove the impurities
then apply thin layer of grease to terminal.
• Connect positive battery cable first when installing.

20B
MEMO
FRONT SUSPENSION
31
FRONT SUSPENSION ....................................................................... 31-1
PRECAUTION.............................................................................. 31-1
PROBLEM SYMPTOMS TABLE.................................................. 31-2
ROAD TEST ................................................................................ 31-4 31
COMPONENTS ........................................................................... 31-5
ON-VEHICLE INSPECTION ........................................................ 31-7
FRONT WHEEL ALIGNMENT ........................................................... 31-8
ADJUSTMENT ............................................................................. 31-8 31
FRONT SHOCK ABSORBER .......................................................... 31-11
OVERHAUL ............................................................................... 31-11
TORSION BAR SPRING .................................................................. 31-14
REPLACEMENT ........................................................................ 31-14
UPPER CONTROL ARM.................................................................. 31-16
REPLACEMENT ........................................................................ 31-16
LOWER CONTROL ARM................................................................. 31-18
REPLACEMENT ........................................................................ 31-18
FRONT STABILIZER BAR............................................................... 31-20
REPLACEMENT ........................................................................ 31-20
STRUT ROD ..................................................................................... 31-23
REPLACEMENT ........................................................................ 31-23
11B
31
14B
14B
15B
FRONT SUSPENSION - FRONT SUSPENSION 31-1
FRONT SUSPENSION
FRONT SUSPENSION
PRECAUTION
1. FRONT SUSPENSION PRECAUTION. 31
(a) When installing rubber parts, the tires must be on the ground in no-load condition at final tightening. oil
will shorten the life of rubber liner. must clean the spilled oil out.
(b) After installing the suspension parts, check wheel alignment. If necessary, adjust it.
(c) When removing or installing brake lines, use the pipeline nut wrench.
(d) Always tighten brake lines when installing.
(e) Lock nut is not reusable. use new one at every installation. when replacing new parts, do not clean the
oil on the lock nut before tightening it.
31
31-2 FRONT SUSPENSION - FRONT SUSPENSION

cause of the problem. Check each part in order. If necessary, replace these parts
1. Lubrication Oil (Excess) -
2. Seals (Failure or damaged) -

Shock absorber oil leakage
Chapter 31 front suspension - front
3. Shock absorber (Failure) shock absorber, overhaul
Chapter 33 tire and wheel - tire and

1. Tire (Worn or improperly inflated) wheel, overhaul

2. Wheel alignment (Incorrect) wheel alignment, adjustment
Chapter 51 steering column - steering

3. Steering linkage (Loose or worn) column system, overhaul
Pulling to one side
Chapter 34 axle and propeller shaft -
4. Hub bearing (Worn) front wheel hub, overhaul
5. Steering gear (Maladjusted or Chapter 52 power steering - steering

damaged) gear, overhaul

6. Suspension parts (Worn) suspension, inspection
1. Vehicle (Overloaded) -
Bottoming
2. Shock absorber (Worn or damaged) shock absorber, overhaul


Sways/pitches
Chapter 31 front suspension -
3. Stabilizer bar (Bent or broken) stabilizer bar, replacement


31
2. Wheel (Out of balance) wheel, overhaul

3. Shock absorber (Worn) shock absorber, overhaul

Front wheel shimmy Chapter 31 front suspension - upper
5. Ball joint (Worn) and lower control arm, replacement

6. Hub bearing (Worn) hub and steering knuckle, on-vehicle
inspection

8. Steering gear (Maladjusted or Chapter 52 power steering - steering

damaged) gear, overhaul


Abnomal tire wear
3. Wheel (Out of balance) wheel, overhaul

4. Shock absorber (Worn) shock absorber, overhaul
31
ROAD TEST
NOTE
This is a flow chart for vehicle pull.
COMPONENTS
31
1 Strut Rod Assy 13 Upper Damping Block Assy 31

2 Nut 14 Lower Damping Block Assy
3 Spring Washer Front Shock Absorber Lower Retaining

15
Bolt
4 Strut Rod Bushing
16 Flat Washer
5 Strut Rod Rubber Washer Seat
17 Flat Washer
6 Strut Rod Rubber Washer
18 Bolt
7 Washer
19 Nut
8 Strut Rod
20 Washer
9 Hexagon Head Nut
21 Lower Control Arm Assy
10 Spring Washer
22 Lower Lateral Arm Camshaft Assy
11 Nut
23 Lower Lateral Arm Cam
12 Front Shock Absorber Assy
24 Nut
25 Stabilizer Bar Strut Support 29 Bolt
26 Stabilizer Bar Connecting Bolt 30 Front Suspension Lateral Stabilizer Bar
27 Rubber Bushing Front Suspension Landscape Orientation

31
Stabilizer Bar Assy
28 Clip
1 Cotter Pin 7 Torsion Bar Seat Assy
2 Nut 8 Torsion Bar Seat Short Bolt
3 Upper Control Arm Assy LH 9 Torsion Bar Seat Long Bolt
4 Upper Control Arm Assy RH 10 Torsion Bar Assy RH
5 Upper Control Arm Tightening Bolt 11 Torsion Bar Assy LH
6 Washer
1. CHECK TIRES FOR WEAR AND INFLATION PRESSURE.
(a) For vehicles equipped with 205/70 R15 tires, the front tire pressure is 240 KPa and rear tire pressure is
280 KPa. The allowable variation is ±5 KPa. 31
2. CHECK TIRES FOR RADIAL RUNOUT ERROR.
(a) The quantity of wheel sway is less than 1.2 mm.
3. CHECK FRONT WHEEL BEARING FOR LOOSENESS.
4. CHECK FRONT SUSPENSION PARTS FOR EXCESSIVE PLAY, CRACKS, WEAR AND OTHER
DAMAGE.
5. CHECK STEERING ROD FOR LOOSENESS.
6. CHECK BALL JOINTS FOR LOOSENESS.
7. PERFORM A STANDARD FLEXIBILITY TEST AND CHECK THAT SHOCK ABSORBER WORKS
NORMALLY.
8. MEASURE HEIGHT OF UNLOADED VEHICLE.
(a) Place the vehicle onto an inspection platform and bounce the vehicle to set the suspension system.
Bounce the front bumper for 5~10 times, then keep the bumper in free state. Measure ground
clearance at bumper center. Repeat the steps for another time. The difference between two
measurements shall be no more than 10 mm.
(b) For vehicles equipped with 205/70 R15 tires, measure the ground clearance at front center point of
lower arm adjusting bolt. The value is 256 mm (also use a self-made measurable tool to measure
height in pit). If the measured value is not within specified value, adjust the torsion mounting bolt to
meet the specified requirement.
31
31-8 FRONT SUSPENSION - FRONT WHEEL ALIGNMENT
FRONT WHEEL ALIGNMENT

ADJUSTMENT
1. INSPECT TIRE. (Refer to “Chapter 33 - tire and wheel, on-vehicle inspection”）
2. MEASURE HEIGHT OF WHEELS.
(a) For vehicles equipped with 205/70 R15 tires, measure the ground clearance at front center point of
NOTE
Before inspecting the wheel alignment, adjust the vehicle height to the specified value and maintain
steering wheel center.
If the vehicle height is not within the specified value, try to adjust it by pushing down or lifting the
body.
3. INSPECT TOE-IN.
Toe-in：
A+B: 0 ± 12′
Toe-in (total)
C-D: 0.5 ± 1 mm
If toe-in is out of the specification, adjust toe-in by the left and

right tie rods.
4. ADJUST TOE-IN.
(a) Remove protection shield clip.
(b) Loosen tie rod lock nut.
(c) Turn the outer tie rod RH/LH by an equal amount to

adjust the toe-in within the specified value.
NOTE
Measure the length of the left and right tie rod, and make
them in the same length. Length difference between the
right and left tie rod: 3.0 mm or less.
(d) Tighten the tie rod lock nut.
Torque: 88 N·m。
(e) Install the shield to the retainer and then tighten.
NOTE
Do not twist the shield.
FRONT SUSPENSION - FRONT WHEEL ALIGNMENT 31-9
5. INSPECT WHEEL ANGLE.

A：Inside
B：Outside
Turn the steering wheel fully and measure the turning angle. 31
Wheel turning angle：
Inside wheel 36°30′ - 40°30′
Outside wheel 34° - 38°
If the maximum steering angles are out of the specification,

adjust LH/RH tie rod length.
6. ADJUST WHEEL TURNING ANGLE.
(a) Remove the steering knuckle stop bolt cap.
(b) Loosen lock nut.
(c) Screw the steering knuckle stop bolt to the bottom.
(d) If steering angle of the left wheel is different from the right wheel, adjust the length of the tie rods to
eliminate the difference of steering angle.
(e) Rotate the steering wheel fully, and loosen the steering knuckle stop bolt until touching the lower arm.
(f) Make sure the value to the specifications and then tighten lock nut.
Torque: 44 N·m。
(g) Install the steering knuckle stop bolt cap.
(h) Check the toe-in.
If the front wheel steering angle is out of the specification after adjustment, check other steering parts.
7. INSPECT FRONT WHEEL CAMBER, KINGPIN

INCLINATION AND KINGPIN CASTER.
Front wheel camber, kingpin inclination and kingpin caster:
0′±30′ (Difference between left

Front Wheel Camber
and right ≤ 30′)
10°30′±30′ (Difference
Kingpin Inclination
between left and right ≤ 30′)
31
1°30′±30′ (Difference between
Kingpin Caster
left and right ≤ 30′)
If the kingpin caster is out of the specified value, adjust it by tur-

ing the strut rod nut.
NOTE
The range of adjusting bolt from the initial position can be
no more than 3 thread. Rotating one revolution is equal to a
change of approx. 30′ in kingpin caster.
31-10 FRONT SUSPENSION - FRONT WHEEL ALIGNMENT
8. ADJUST CAMBER.
(a) Adjust the front camber by rotating cam. Each scale of
cam means a 18′ change in camber. It is not allowed to
rotate cam from the center line over 4.5 scales.
FRONT SUSPENSION - FRONT SHOCK ABSORBER 31-11
FRONT SHOCK ABSORBER

OVERHAUL
1. REMOVE FRONT WHEEL LH ASSY. (Refer to “Chapter 33 tire and wheel - front tire and wheel, 31
replacement”)
2. REMOVE FRONT SHOCK ABSORBER LH.

(a) Remove the bolt attaching the front shock absorber LH to
the lower control arm.
(b) Remove the nut attaching the front shock absorber LH to

the lower frame.
(c) Take out the front shock absorber LH.
31
3. CHECK SHOCK ABSORBER FOR OIL LEAKAGE.

(a) If the oil leaks from the shock absorber, replace it with a new one.
4. CHECK SHOCK ABSORBER CONNECTING PARTS.
(a) Check the shock absorber connecting rod, bushing or other connecting parts for damage. If there is any
damage, replace it with a new one.
5. CHECK SHOCK ABSORBER EFFICIENCY.
(a) Compress and extend the shock absorber rod for 2~3 times and then check that there is no abnormal
resistance or unusual noise during operation. If there is any abnormality, replace the shock absorber
with a new one.
31-12 FRONT SUSPENSION - FRONT SHOCK ABSORBER
6. INSTALL FRONT SHOCK ABSORBER ASSY LH.

(a) Tighten the nut attaching the front shock absorber LH to
the lower frame.
(b) Tighten the bolt attaching the front shock absorber LH to

the lower control arm.
7. INSPECT AFTER INSTALLATION.

(a) After the vehicle is assembled, drive it on a bad road for a distance about ten kilometers and park it,
then touch the surfaces of the two shock absorbers with hands. If difference in temperature of the two
shock absorbers is large, correspondingly, difference in resistance of them is also large and the
absorber with a low temperature has small resistance. If the temperature of the two shock absorbers
doesn’t exceed air temperature, it indicates that the shock absorbers have no resistance and disabled.
It is necessary to replace with a new one.
(b) When the vehicle is running slowly and given an emergent brake, if the vehicle has an excessive
vibration, it indicates that there is a fault on shock absorber. Disassemble and erect the shock absorber,
keep the lower part jointing ring clamping the vise, pull and press the shock absorber rod for several
times. It should have stable resistance,the pull-up (restoration) resistance should be no less than pull-
down resistance. If the resistance is unstable or there is no resistance, the shock absorber may lack of
oil or the valve part is damaged. It is necessary to repair it or replace with a new part.
(c) After a fault or invalidation on shock absorber is determined, first check whether there is any oil leakage
or mark of oil leakage. Oil seal gasket and seal gasket are broken or damaged; nut of oil tank is loose.
The oil seal and seal gasket may be damaged and disabled, so it is necessary to replace with a new
sealing. If the oil leakage still exists, pull out the shock absorber, when a seizure or unbalance weight is
found, further check whether there is a wide clearance between piston and cylinder block or whether
the piston rod of the shock absorber is bent or whether there are cracks or drawing marks on surface of
piston rod and cylinder block.
FRONT SUSPENSION - FRONT SHOCK ABSORBER 31-13
(d) If the shock absorber has no oil leakage or mark of oil leakage, check whether there is any damage,
loose welding, crack or peeling off on connecting pins of shock absorber, connecting rod, connecting
hole and rubber spacer etc. If the above parts are in normal condition after check, further disassemble
the shock absorber to check whether there is a wide clearance between piston and cylinder block, 31
whether there is a strain on cylinder block, whether the valve sealing is in good status, whether the
valve flaps are tightly closed to the valve seat and whether the draw spring of the shock absorber is too
soft or broken. Repair or replace parts according to concrete situations.
(e) In addition, the shock absorber may produce noise during use, this is because the shock absorber is
crashed with spring, frame or shaft, rubber washer is damaged or fallen off, and dust wrapper is
deformed and oil is insufficient. It is necessary to find out the root of the fault and repair it.
(f) If it is impossible to conduct a test, we can take some experiential measures to check it: let an iron bar
passing through the lower hoisting ring, step the two ends with feet, hold the hoisting ring and pull up
and down for 2-4 times with hands. If there is large resistance when pulling up and almost no resistance
when pulling down, stretching resistance is restored compared with resistance before repair, and you
don’t feel no-running status, it indicates that the shock absorber is in normal condition.
8. REMOVE FRONT SHOCK ABSORBER RH.
NOTE
Remove the RH side by the same procedures as the LH side.
31
31-14 FRONT SUSPENSION - TORSION BAR SPRING
TORSION BAR SPRING

REPLACEMENT
1. REMOVE TORSION BAR SPRING ASSY LH.
(a) Remove the torsion bar spring adjustment nut.
(b) Remove 2 retaining bolts from the torsion bar spring LH.
(c) Remove the torsion bar spring LH.

FRONT SUSPENSION - TORSION BAR SPRING 31-15
2. INSTALL TORSION BAR SPRING LH.

(a) Position the torsion bar spring LH properly.
31
(b) Tighten 2 retaining bolts to the torsion bar spring LH .

(c) Tighten the torsion bar spring LH adjusting nut.

31
3. REMOVE TORSION BAR SPRING RH.

NOTE
31-16 FRONT SUSPENSION - UPPER CONTROL ARM
UPPER CONTROL ARM

REPLACEMENT
1. REMOVE FRONT WHEEL ASSY LH. (Refer to “Chapter 33 tire and wheel - front tire and wheel,
replacement”)
2. REMOVE FRONT BRAKE DISC ASSY LH. (Refer to “Chapter 35 brake - front brake disc,
overhaul”)
3. REMOVE FRONT UPPER CONTROL ARM ASSY LH.

(a) Remove 2 retaining bolts of the front wheel speed sensor
LH harness brackets.
(b) Set aside the front wheel speed sensor LH wire harness.
(c) Using a screwdriver, remove the cotter pin.

(d) Remove the nut attaching the front upper control arm ball
joint LH to the front steering knuckle LH.
(e) Remove the bolt attaching the front upper control arm LH
to the frame.
FRONT SUSPENSION - UPPER CONTROL ARM 31-17
4. INSTALL FRONT UPPER CONTROL ARM ASSY LH.

(a) Tighten 2 bolts attaching the front upper control arm LH
to the frame.
Torque: 130 ~ 160 N·m 31
(b) Tighten the nut attaching the front upper control arm ball
Torque: 130 ~ 160 N·m
(c) Install a new cotter pin and lock.
(d) Install the front wheel speed sensor LH wire harness.

(e) Tighten 2 retaining bolts of the front wheel speed sensor
LH wire harness brackets.
31
5. REMOVE UPPER CONTROL ARM RH.

NOTE:
6. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT. (Refer to “Chapter 31 front suspension -
front wheel alignment, adjustment”)
31-18 FRONT SUSPENSION - LOWER CONTROL ARM
LOWER CONTROL ARM

REPLACEMENT
1. REMOVE FRONT WHEEL ASSY LH. (Refer to “Chapter 33 tire and wheel - front tire and wheel,
replacement”)
2. REMOVE FRONT BRAKE DISC ASSY LH. (Refer to “Chapter 35 brake - front brake disc,
overhaul”)
3. REMOVE STRUT ROD. (Refer to “Chapter 31 front suspension - strut rod, replacement”)
4. REMOVE LOWER CONTROL ARM LH.

(a) Using a screwdriver, remove the cotter pin.
(b) Remove the nut attaching the front lower control arm ball
(c) Remove the nut attaching the front lower control arm LH
to the frame.
(d) Remove the front lower control arm LH
5. INSTALL LOWER CONTROL ARM LH.

(a) Position the front lower control arm LH properly.
(b) Tighten the nut attaching the front lower control arm LH
to the frame.
Torque: 160 ~ 200 N·m
(c) Tighten the nut attaching the front lower control arm ball
Torque: 130 ~ 160 N·m
(d) Install a new cotter pin and lock.
FRONT SUSPENSION - LOWER CONTROL ARM 31-19
6. INSTALL FRONT WHEEL ASSY LH. (Refer to “Chapter 33 tire and wheel - front tire and wheel,
replacement”)
7. INSTALL FRONT BRAKE DISC ASSY LH. (Refer to “Chapter 35 brake - front brake disc,
overhaul”) 31
8. INSTALL STRUT ROD. (Refer to “Chapter 31 front suspension - strut rod, replacement”)
9. REMOVE LOWER CONTROL ARM RH.
NOTE
31
31-20 FRONT SUSPENSION - FRONT STABILIZER BAR
FRONT STABILIZER BAR

REPLACEMENT
(a) Remove 8 mounting bolts of the engine lower guard
plate.
(b) Remove the engine lower guard plate.
2. REMOVE FRONT STABILIZER BAR.

(a) Remove the bolt attaching the stabilizer bar link LH to the
stabilizer bar.
(b) Remove 2 mounting bolts of the NO.1 bracket of the

stabilizer bar.
(c) Remove 2 mounting bolts of the NO.2 bracket of the

stabilizer bar.
FRONT SUSPENSION - FRONT STABILIZER BAR 31-21
(d) Remove the bolt attaching the stabilizer bar link RH to

the stabilizer bar.
(e) Carefully take out the stabilizer bar.
31
3. INSPECT STABILIZER BAR BUSHING.

(a) Inspect the stabilizer bar bushing for ageing. If there is any ageing, replace the bushing with new one.
4. INSTALL FRONT STABILIZER BAR.

(a) Position the stabilizer bar properly.
(b) Tighten the bolt attaching the stabilizer bar link RH to the
stabilizer bar.
(c) Tighten the bolt attaching the stabilizer bar link LH to the
stabilizer bar.
31
(d) Tighten 2 mounting bolts of the NO.1 bracket of the
stabilizer bar.
31-22 FRONT SUSPENSION - FRONT STABILIZER BAR
(e) Tighten 2 mounting bolts of the NO.2 bracket of the

stabilizer bar.

(a) Position the 8 bolts attaching lower guard plate.
(b) Tighten 8 retaining bolts of the engine lower guard plate.
FRONT SUSPENSION - STRUT ROD 31-23
STRUT ROD
REPLACEMENT
31
1. REMOVE STRUT ROD LH.
(a) Using a wrench, lock the head of the bolts (2) attaching
the strut rod LH to the lower control arm LH.
(b) Remove 2 nuts attaching the strut rod LH to the lower

control arm LH.
(c) Remove the nut attaching the strut rod LH to the frame.
(d) Take out the strut rod LH.
31
2. INSTALL STRUT ROD LH.
(a) Position the strut rod LH properly.
(b) Using a wrench, lock the head of the bolts (2) attaching
the strut rod LH to the lower control arm LH.
31-24 FRONT SUSPENSION - STRUT ROD
(c) Tighten 2 nuts connecting the strut rod LH to the lower

control arm LH.
Torque: 100 ~ 120 N·m
(d) Tighten the nut attaching the strut rod LH to the frame.
Torque: 120 ~ 150 N·m
3. REMOVE STRUT ROD RH.

NOTE:
REAR SUSPENSION
32
REAR SUSPENSION ......................................................................... 32-1
PRECAUTION.............................................................................. 32-1
COMPONENTS ........................................................................... 32-3 32
ON-VEHICLE INSPECTION ........................................................ 32-5
REAR WHEEL ALIGNMENT ............................................................. 32-6
ADJUSTMENT ............................................................................. 32-6
REAR SHOCK ABSORBER .............................................................. 32-7 32
OVERHAUL ................................................................................. 32-7
REAR COIL SPRING ....................................................................... 32-10
OVERHAUL ............................................................................... 32-10
REAR TRANSVERSE ARM ............................................................. 32-13
REPLACEMENT ........................................................................ 32-13
REAR STABILIZER BAR................................................................. 32-16
REPLACEMENT ........................................................................ 32-16
32
12B
14B
14B
15B
REAR SUSPENSION - REAR SUSPENSION 32-1
REAR SUSPENSION
REAR SUSPENSION
PRECAUTION
1. REAR SUSPENSION PRECAUTION. 32
(a) When installing rubber parts, the tires must be on the ground in no-load condition at final tightening. Oil
will shorten the life of rubber liner. must clean the spilled oil out.
(b) After installing the suspension parts, check wheel alignment. If necessary, adjust it.
(c) When removing or installing brake lines, use the pipeline nut wrench.
(d) Always tighten brake lines when installing.
(e) Lock nut is not reusable. Use new one at every installation. When replacing new parts, do not clean the
oil on the lock nut before tightening it.
32
32-2 REAR SUSPENSION - REAR SUSPENSION

1. Lubrication Oil (Excess) -
2. Seals (Failure or damaged) -

Shock absorber oil leakage
Chapter 32 rear suspension - rear

1. Tire (Worn or improperly inflated) wheel, on-vehicle inspection

Pulling to one side 2. Wheel alignment (Incorrect) wheel alignment, adjustment

3. Hub bearing (Worn) rear wheel hub, overhaul
1. Vehicle (Overloaded) -
Chapter 32 rear suspension - coil

Bottoming 2. Spring (Worn) spring, overhaul



Sways/pitches 2. Wheel (Out of balance) wheel, adjustment

3. Shock absorber (Worn or failure) shock absorber, overhaul


2. Wheel (Out of balance) wheel, adjustment
Rear wheel shimmy



Abnomal tire wear
3. Wheel (Out of balance) wheel, on-vehicle inspection

COMPONENTS
32
32
1 Rear Damping Block Assy 10 Rear Transverse Arm Tightening Bolt
2 Rear Coil Spring Upper Rubber Seat 11 Rear Transverse Arm Combination
3 Coil Spring 12 Bushing Combuination Component
4 Rear Coil Spring Lower Rubber Seat 13 Cam Adjusting Nut
Rear Shock Absorber Upper Retaining 14 Rear Transverse Arm Assy RH

5
Bolt
15 Rear Transverse Arm Assy LH
6 Washer
16 Bolt
7 Rear Shock Absorber Assy
17 Bearing Seat Dust Cover
Rear Shock Absorber Lower Retaining
8 18 Rear Suspension Stabilizer Bar Assy
Nut
Rear Transverse Arm Outer Point

9
Tightening Nut
32-4 REAR SUSPENSION - REAR SUSPENSION
1 Rear Suspension Stabilizer Bar 5 Stabilizer Bar Strut Support RH
2 Rubber Bushing 6 Bolt
3 Clip 7 Rear Suspension Stabilizer Bar Assy
4 Stabilizer Bar Strut Support LH

1. CHECK TIRES FOR WEAR AND INFLATION PRESSURE.
(a) For vehicles equipped with 205/70 R15 tires, the front tire pressure is 240 kPa and rear tire pressure is
280 kPa. The allowable variation is ±5 kPa. 32
2. CHECK TIRES FOR RADIAL RUNOUT ERROR.
(a) The quantity of wheel sway is less than 1.2 mm.
3. CHECK REAR WHEEL BEARING FOR LOOSENESS.
4. CHECK REAR SUSPENSION PARTS FOR EXCESSIVE PLAY, CRACKS, WEAR AND OTHER
DAMAGE.
5. PEFORM A STANDARD FLEXIBILITY TEST AND CHECK SHOCK ABSORBER WORKS
NORMALLY.
6. MEASURE HEIGHT OF UNLOADED VEHICLE.
(a) Place the vehicle onto an inspection platform and bounce the vehicle to set the suspension systems.
Bounce the front bumper for 5~10 times, then keep the bumper in free state. Measure ground
clearance at bumper center. Repeat the steps for another time. The difference between two
measurements shall be no more than 10 mm.
32
32-6 REAR SUSPENSION - REAR WHEEL ALIGNMENT
REAR WHEEL ALIGNMENT

ADJUSTMENT
1. INSPECT TIRE. (Refer to “Chapter 33 - tire and wheel, on-vehicle inspection”）
2. MEASURE VEHICLE HEIGHT.
(a) For vehicles equipped with 205/70 R15 tires, measure the ground clearance of front center point of
NOTE
Before inspecting the wheel alignment, adjust the vehicle height to the specified value.
3. INSPECT TOE-IN.
Toe-in：
A+B: 0°19′ ± 19′ （difference

between left and right ≤ 10′）
Toe-in （Total）
C-D: 2 ± 2 mm （difference
between left and right ≤ 1）
If toe-in is out of the specification, inspect and adjust the sus-

pension parts as necessary.
4. INSPECT CAMBER.
(a) Install the camber-caster-kingpin gauge or position the vehicle on wheel alignment tester.
(b) Inspect the camber.
Camber:
Camber 0°15′±45′ （difference between left and right ≤ 45′）
If the measured value is out of the specification, inspect the suspension parts for damage and/or wear and
replace them if necessary.
5. ADJUST CAMBER AND TOE-IN.

If camber and toe-in are out of the specification, adjust them by
rotating cam adjusting nut.
REAR SUSPENSION - REAR SHOCK ABSORBER 32-7
REAR SHOCK ABSORBER

OVERHAUL
1. REMOVE REAR WHEEL LH ASSY. (Refer to “Chapter 33 tire and wheel - rear tire and wheel, 32
replacement”)
2. REMOVE REAR SHOCK ABSORBER LH.

(a) Remove the upper retaining bolt of the rear shock
absorber.
(b) Remove the lower retaining nut of the rear shock

absorber.
(c) Carefully take out the rear shock absorber LH.
32
3. CHECK SHOCK ABSORBER FOR OIL LEAKAGE.
(a) If the oil leaks from the shock absorber, replace it with a new part.
4. CHECK SHOCK ABSORBER CONNECTING PARTS.
(a) Check the shock absorber connecting rod, bushing or other connecting parts for damage. If there is any
damage, replace it with a new one.
5. CHECK SHOCK ABSORBER EFFICIENCY.
(a) Compress and extend the shock absorber rod and then check that there is no abnormal resistance or
unusual noise during operation. If there is any abnormality, replace the shock absorber with a new one.
32-8 REAR SUSPENSION - REAR SHOCK ABSORBER
6. INSTALL REAR SHOCK ABSORBER LH.

(a) Position the rear shock absorber LH properly.
(b) Tighten the lower retaining nut of the rear shock absorber
LH.
(c) Tighten the upper retaining bolt of the rear shock

absorber LH.
7. INSPECT AFTER INSTALLATION.

(a) After the vehicle is assembled, drive it on a bad road for a distance about ten kilometers and park it,
then touch the surfaces of the two shock absorbers with hands. If difference in temperature of the two
shock absorbers is large, correspondingly, difference in resistance of them is also large and the
absorber with a low temperature has small resistance. If the temperature of the two shock absorbers
doesn’t exceed air temperature, it indicates that the shock absorbers have no resistance and disabled.
It is necessary to replace with a new one.
(b) When the vehicle is running slowly and given an emergent brake, if the vehicle has an excessive
vibration, it indicates that there is a fault on shock absorber. Disassemble and erect the shock absorber,
keep the lower part jointing ring clamping the vise, pull and press the shock absorber rod for several
times. It should have stable resistance,the pull-up (restoration) resistance should be no less than pull-
down resistance. If the resistance is unstable or there is no resistance, the shock absorber may lack of
oil or the valve part is damaged. It is necessary to repair it or replace with a new part.
(c) After a fault or invalidation on shock absorber is determined, first check whether there is any oil leakage
or mark of oil leakage. Oil seal gasket and seal gasket are broken or damaged; nut of oil tank is loose.
The oil seal and seal gasket may be damaged and disabled, so it is necessary to replace with a new
sealing. If the oil leakage still exists, pull out the shock absorber, when a seizure or unbalance weight is
found, further check whether there is a wide clearance between piston and cylinder block or whether
the piston rod of the shock absorber is bent or whether there are cracks or drawing marks on surface of
piston rod and cylinder block.
(d) If the shock absorber has no oil leakage or mark of oil leakage, check whether there is any damage,
loose welding, crack or peeling off on connecting pins of shock absorber, connecting rod, connecting
hole and rubber spacer etc. If the above parts are in normal condition after check, further disassemble
the shock absorber to check whether there is a wide clearance between piston and cylinder block,
whether there is a strain on cylinder block, whether the valve sealing is in good status, whether the
REAR SUSPENSION - REAR SHOCK ABSORBER 32-9
valve flaps are tightly closed to the valve seat and whether the draw spring of the shock absorber is too
soft or broken. Repair or replace parts according to concrete situations.
(e) In addition, the shock absorber may produce noise during use, this is because the shock absorber is
crashed with spring, frame or shaft, rubber washer is damaged or fallen off, and dust wrapper is 32
deformed and oil is insufficient. It is necessary to find out the root of the fault and repair it.
(f) If it is impossible to conduct a test, we can take some experiential measures to check it: let an iron bar
passing through the lower hoisting ring, step the two ends with feet, hold the hoisting ring and pull up
and down for 2-4 times with hands. If there is large resistance when pulling up and almost no resistance
when pulling down, stretching resistance is restored compared with resistance before repair, and you
don’t feel no-running status, it indicates that the shock absorber is in normal condition.
8. REMOVE REAR SHOCK ABSORBER RH.
NOTE:
32
32-10 REAR SUSPENSION - REAR COIL SPRING
REAR COIL SPRING

OVERHAUL
1. REMOVE REAR WHEEL ASSY. (Refer to “Chapter 33 tire and wheel - rear tire and wheel,
replacement”)
2. REMOVE REAR COIL SPRING LH.

(a) Support the rear axle beam with jack.
(b) Remove the upper retaining bolt of the rear shock

absorber LH.
(c) Remove the nut attaching the stabilizer bar strut support
LH to the rear transverse arm assy LH.
(d) Loosen but not remove the nut and bolt attaching the
rear transverse arm LH to the frame.
REAR SUSPENSION - REAR COIL SPRING 32-11
(e) Lower the jack.

(f) Take out the rear coil spring LH.
32
3. INSPECT REAR COIL SPRING LH.

(a) Inspect the coil spring for aging, flaw and rusting. Replace it with a new one if there is any abnormality.
4. INSTALL REAR COIL SPRING LH.

(a) Up the jack. Position the rear coil spring properly.
32
(b) Tighten the upper retaining bolt of the rear shock

absorber LH .
32-12 REAR SUSPENSION - REAR COIL SPRING
(c) Tighten the nut and bolt attaching the rear transverse
arm LH to the frame.
Torque:
Inner point: 120 ~ 150 N·m
Outer point: 145 ~ 175 N·m
(d) Tighten the nut attaching the stabilizer bar strut support
(e) Down the jack.
5. REMOVE REAR COIL SPRING RH.

NOTE
REAR SUSPENSION - REAR TRANSVERSE ARM 32-13
REAR TRANSVERSE ARM

REPLACEMENT
1. REMOVE REAR WHEEL ASSY. (Refer to “Chapter 33 tire and wheel - rear tire and wheel, 32
replacement”)
2. REMOVE REAR BRAKE DRUM. (Refer to “Chapter 35 brake - rear brake, overhaul”)
3. REMOVE REAR HUB ASSY. (Refer to “Chapter 34 axle and propeller shaft - hub, overhaul”)
4. REMOVE REAR HALF AXLE ASSY. (Refer to “Chapter 34 axle and propeller shaft - half axle,
overhaul”)
5. SUPPORT THE REAR AXLE BEAM WITH JACK.
6. REMOVE REAR TRANSVERSE ARM LH.

(a) Remove the retaining bolts of brackets of the rear speed
sensor cable and brake line. Set aside them.
(b) Remove the lower retaining nut of the rear shock

absorber LH.
32
(c) Remove the nut attaching the stabilizer bar strut support
32-14 REAR SUSPENSION - REAR TRANSVERSE ARM
(d) Slowly lower the jack and take out the rear coil spring LH.
(e) Remove the nut and bolt attaching the rear transverse
(f) Remove the rear transverse arm LH.
7. INSTALL REAR TRANSVERSE ARM LH.

(a) Slowly raise the jack.
(b) Tighten the nut and bolt attaching the rear transverse
Torque: Inside point 125 ~ 135 N·m
Outside point 145 ~ 175 N·m
(c) Position the rear coil spring properly.
(d) Tighten lower retaining nut of the rear shock absorber.

REAR SUSPENSION - REAR TRANSVERSE ARM 32-15
(e) Tighten the nut attaching the stabilizer bar strut support
32
(f) Position the rear speed sensor cable and brake line
properly.
(g) Tighten 4 retaining bolts of the brackets of the rear speed
sensor cable and brake line.
8. INSTALL REAR HALF AXLE ASSY. (Refer to “Chapter 34 axle and propeller shaft - half axle,
overhaul”)
9. INSTALL REAR HUB ASSY. (Refer to “Chapter 34 axle and propeller shaft - hub, overhaul”)
10. INSTALL REAR BRAKE DRUM. (Refer to “Chapter 35 brake - rear brake, overhaul”)
11. INSTALL REAR WHEEL ASSY . (Refer to “Chapter 33 tire and wheel - rear tire and wheel,
replacement”)
12. REMOVE REAR TRANSVERSE ARM RH.
NOTE
32
32-16 REAR SUSPENSION - REAR STABILIZER BAR
REAR STABILIZER BAR

REPLACEMENT
1. REMOVE STABILIZER BAR.
(a) Remove the bolt and nut attaching the stabilizer bar to
the support LH.
(b) Remove 2 retaining bolts of the NO.1 bracket of the

stabilizer bar.
(c) Remove 2 retaining bolts of the NO.2 bracket of the

stabilizer bar.
(d) Remove the bolt and nut attaching the stabilizer bar to
the support RH.
(e) Remove the rear stabilizer bar.
2. INSPECT STABILIZER BAR RUBBER BUSHING.

(a) Inspect the stabilizer bar bushing for aging. If there is any aging, replace it with new one.
REAR SUSPENSION - REAR STABILIZER BAR 32-17
3. INSTALL REAR STABILIZER BAR.

(a) Position the stabilizer bar properly.
(b) Tighten the bolt and nut attaching the stabilizer bar to the
support RH. 32
(c) Tighten the bolt and nut attaching the stabilizer bar to the
support LH.
(d) Tighten 2 retaining bolts of the NO.1 bracket of the

stabilizer bar.
(e) Tighten 2 retaining bolts of the NO.2 bracket of the 32

stabilizer bar.
MEMO
TIRE AND WHEEL
33
TIRE AND WHEEL SYSTEM ............................................................. 33-1
PRECAUTION.............................................................................. 33-1
ON-VEHICLE INSPECTION ........................................................ 33-3 33
ADJUSTMENT ............................................................................. 33-6
FRONT TIRE AND WHEEL................................................................ 33-7
COMPONENTS ........................................................................... 33-7
REPLACEMENT .......................................................................... 33-8 33
REAR TIRE AND WHEEL................................................................ 33-10
COMPONENTS ......................................................................... 33-10
REPLACEMENT ........................................................................ 33-11
33
11B
12B
14B
14B
15B
TIRE AND WHEEL - TIRE AND WHEEL SYSTEM 33-1
TIRE AND WHEEL SYSTEM

TIRE AND WHEEL
PRECAUTION
1. TIRE AND WHEEL SYSTEM PRECAUTION. 33
(a) Use special tools to remove the tires. Do not remove them by huge hammer or sharp tool.
(b) Do not use different type, size, speed rating, pressure and load index tire on the same axle.
(c) Please pay attention to the mark of rolling direction when installing directional thread pattern tire.
(d) Must rotate each tire once after runing 5000 ~ 6000 Km, make each tire wear well distributedly.
(e) After rotating tires, reset proper inflation pressure according to the tire position.
(f) Operate inflation according to this manual’s specification, and measure tire pressure at cold state by
tire gauge. Before inflating, check the tire valve whether matching valve core flatly and then clean the
dirt. Inflating air is not allowed to contain with water and oil spray. After inflating, tighten the tire valve
core, and check the tire leakage.
(g) Check inflation pressure according to the standard service data. It is not allowed that the tire pressure is
lower or higher.
(h) Termly check front wheel toe-in. Avoid unnecessary increase the running resistance, the fuel
consumption and excessive tire wear.
33
33-2 TIRE AND WHEEL - TIRE AND WHEEL SYSTEM


Chapter 31 front suspension - front wheel
1. Wheel toe-in (Improper value) alignment, adjustment
Chapter 33 tire and wheel - tire and wheel assy, on-

2. Tire ( Improperly inflated) vehicle inspection
Abnomal tire wear
Chapter 33 tire and wheel - tire and wheel assy,
3. Wheel (Out of balance) adjustment
Chapter 51 steering system - steering gear,

4. Steering system (Distortion) replacement
1. Front wheel (Different tire Chapter 33 tire and wheel - tire and wheel assy, on-
pressure) vehicle inspection
Chapter 33 tire and wheel - tire and wheel assy,

2. Wheel (Out of balance) adjustment
Front wheel swing
or vibration
Chapter 31 front suspension - front shock absorber,
3. Shock absorber (Wear or fault) overhaul
Chapter 51 steering system - steering gear,

4. Steering system (Wear serious) replacement
Chapter 33 tire and wheel - tire and wheel assy, on-

1. Tire (Exceed specified pressure) vehicle inspection
Uncomfortableness Chapter 31 front suspension - front shock absorber,

when running 2. Shock absorber (Failure) overhaul
Chapter 31 front suspension - torsion bar assy,

3. Coil spring weak (Failure) overhaul
1. Wheel toe-in (It is not within Chapter 31 front suspension - front wheel
specified value) alignment, adjustment
Front wheel side
slipping Chapter 33 tire and wheel - tire and wheel assy, on-
2. Tire (Inflating pressure is not
within specified value) vehicle inspection
1. MEASURE TIRE TREAD DEPTH.
Depth ≥ 1.6 mm
33
If the tire tread depth is less than 1.6 mm, replace it with new one.
NOTE
Rreplace a pair of tires at the same wheel side.
2. CHECK TIRES ABNORMAL WEAR.

(a) Visually inspect the tires shoulder wear. If the tire wears,
measure the inflation pressure. Inflate and rotate the
wheel if tire is less pressure or overloading.
(b) Visually inspect the wear tires at center. If the tire wears,
release exceed pressure and rotate the wheel assy.
33
(c) Visually inspect the tire inner edge (shoulder) wear. The
inner Edge (shoulder) wear is usually caused by
excessive toe-out and/or excessive negative camber,
suspension parts loose. Avoid running at high speed when
turning. Adjust and rotate the wheel assy.
(d) Visually inspect the tire outer edge (shoulder ) wear. The
outer edge (shoulder) wear is usually caused by excessive
toe-in and/or excessive positive camber, suspension parts
loose. Avoid running at high spped when turning. Adjust
and rotate the wheel assy.
(e) Visually inspect the tire feathering wear that occurs along
both inside and outside shoulder ribs. This kind of wear
is usually caused by excessive toe-in. Check/adjust the
wheel alignment and rotate the wheel assy.
(f) Visually inspect the tire corrugate wear. This kind of wear
is caused by improper inflation pressure, camber and
toe-in, hub bearing loose or worn. Adjust and rotate the
wheel assy. 33
3. MEASURE COLD TIRE INFLATION PRESSURE.
Tire Specification Front Tire Rear Tire Spare Tire

205/70R15-95H 2.4 bar 2.8 bar 3.0 bar
195/70R15C-104S 3.3 bar 4.5 bar 4.8 bar
If tire size or inflation pressure doesn’t match standard service data, adjust or replace it with new wheel as
necessary.
4. INSPECT TIRE CROWN, TIRE SHOULDER, TIRE EDGE.
Replace the tire with new one, if bent, cut, cracked, dented, deformation and abrasion exists.
5. INSPECT TIRE VALVE.
If air leaks from tire valve, replace it with new one.
6. INSPECT RIM. 33
Replace the rim with new one If it is deformation, corrosion and crack.
7. INSPECT WHEEL BOLT AND NUT.
Check the tightening torque one by one according to the standard service data.
ADJUSTMENT
1. TIRE ROTATION.
NOTE
Illustration arrow shows the front of vehicle.
(a) Illustration A is cross rotation every tire with spare tire.
(b) Illustration B is cross rotation every tire without spare tire.
2. WHEEL OFF-THE-CAR BALANCE.

(a) Clean dirt, stone and used balance block from measured
wheel.
(b) Measure tire pressure and inflate as recommended.
(c) Select the match cone based on size of rim center hole
to tighten by fast nut.
(d) Turn on the balance tester power.
(e) Measure rim width.
(f) Measure tire diameter.
(g) Measure the distance between the rim edge and the
balance tester.
(h) Pull off wheel protect cover and then start detection.
(i) After detection completed, fix balance block based on
measurement result.
(j) Repeat aforemetioned procedure , adjust till the data to
match specification.
(k) Demount wheel assy.
3. FRONT WHEEL TOE-IN.(Refer to Chapter 31 front suspention - front wheel alignment ,

adjustment )
TIRE AND WHEEL - FRONT TIRE AND WHEEL 33-7
FRONT TIRE AND WHEEL

COMPONENTS
33
33
1 Wheel Rim Cover 4 Tire Valve
2 Wheel Nut 5 Tire
3 Rim Assy
33-8 TIRE AND WHEEL - FRONT TIRE AND WHEEL
REPLACEMENT
1. RAISE VEHICLE.
2. REMOVE FRONT WHEEL LH ASSY.

(a) Using a screwdriver, remove the front wheel rim cover
LH.
(b) Remove 6 front wheel LH nuts.

NOTE
Loosen all front wheel LH nuts diagonally.
(c) Remove the front wheel LH assy.

TIRE AND WHEEL - FRONT TIRE AND WHEEL 33-9
3. INSTALL FRONT WHEEL LH ASSY.

(a) Install the front wheel LH assy.
33
(b) Tighten 6 front wheel LH nuts.

Torque : 90 ~ 120 N·m
NOTE
Tighten all front wheel LH nuts diagonally.
33
(c) Install the wheel rim cover.
4. REMOVE FRONT WHEEL RH ASSY.

NOTE
33-10 TIRE AND WHEEL - REAR TIRE AND WHEEL
REAR TIRE AND WHEEL

COMPONENTS
1 Wheel Rim Cover 4 Tire Valve
2 Wheel Nut 5 Tire
3 Rim Assy
TIRE AND WHEEL - REAR TIRE AND WHEEL 33-11
REPLACEMENT
1. RAISE VEHICLE.
2. OPERATE PARKING BRAKE.
33
3. REMOVE REAR WHEEL LH ASSY.
(a) Using a screwdriver, remove the rear wheel rim cover
LH.
(b) Remove 6 rear wheel LH nuts.

NOTE
Loosen all rear wheel LH nuts diagonally.
(c) Remove the rear wheel LH from vehicle.
33
33-12 TIRE AND WHEEL - REAR TIRE AND WHEEL
4. INSTALL REAR WHEEL LH ASSY.

(a) Install the rear wheel LH.
(b) Tighten 6 nuts of rear wheel LH.

NOTE
Tighten all rear wheel LH nuts diagonally.
(c) Install the wheel rim cover.
5. REMOVE REAR WHEEL RH ASSY.

NOTE
AXLE AND PROPELLER
34
PROPELLER SHAFT ASSY .............................................................. 34-1
PRECAUTION.............................................................................. 34-1
COMPONENTS ........................................................................... 34-3 34
INSPECTION ............................................................................... 34-4
OVERHAUL ................................................................................. 34-5
U-JOINT ............................................................................................. 34-8
COMPONENTS ........................................................................... 34-8 34
OVERHAUL ................................................................................. 34-9
CENTER SUPPORT BEARING ....................................................... 34-13
COMPONENTS ......................................................................... 34-13
OVERHAUL ............................................................................... 34-14
AXLE HUB AND STEERING KNUCKLE......................................... 34-18
PROBLEM SYMPTOMS TABLE................................................ 34-18
ON-VEHICLE INSPECTION ...................................................... 34-20
AXLE HUB ....................................................................................... 34-22
COMPONENTS ......................................................................... 34-22
REPLACEMENT ........................................................................ 34-24
STEERING KNUCKLE ..................................................................... 34-37
COMPONENTS ......................................................................... 34-37
OVERHAUL ............................................................................... 34-38
TRANSAXLE .................................................................................... 34-51
PRECAUTION............................................................................ 34-51
PROBLEM SYMPTOMS TABLE................................................ 34-53
COMPONENTS ......................................................................... 34-55 34
FINAL DRIVE OIL ............................................................................ 34-59
REPLACEMENT ........................................................................ 34-59
AXLE SHAFT ASSY......................................................................... 34-62
11B
REPLACEMENT ........................................................................ 34-62
FINAL DRIVE ASSY......................................................................... 34-64
COMPONENTS ......................................................................... 34-64
12B
REPLACEMENT ........................................................................ 34-66
DIFFERENTIAL ASSY ..................................................................... 34-72 14B
COMPONENTS ......................................................................... 34-72
INSPECTION AND ADJUSTMENT ........................................... 34-73 14B
OVERHAUL ............................................................................... 34-76
DRIVE PINION ................................................................................. 34-89 15B
INSPECTION ............................................................................. 34-89
OVERHAUL ............................................................................... 34-92
AXLE AND PROPELLER SHAFT - PROPELLER SHAFT ASSY 34-1
PROPELLER SHAFT ASSY

AXLE AND PROPELLER SHAFT
PRECAUTION
1. PROPELLER SHAFT ASSY PRECAUTION. 34
(a) Do not disassemble the propeller shaft assy unless absolutely necessary.
(b) If disassembly of propeller shaft assy is required, be sure to clean all separated parts before reassem-
bly.
(c) After disassembling of propeller shaft assy, be sure to check all separated parts one by one and
perform repairing or replacing when necessary.
34
34-2 AXLE AND PROPELLER SHAFT - PROPELLER SHAFT ASSY


1. Propeller shaft assy (Loose) propeller shaft assy, overhaul
2. Lubrication (Insufficient) -
Abnormal noise Chapter 34 axle and propeller shaft - U-joint,

of propeller shaft 3. U-joint (Worn or damaged) overhaul
assy
4. Center support bearing (Worn or Chapter 34 axle and propeller shaft - center
damaged) support bearing, overhaul

5. Slip spline (Worn) propeller shaft assy, inspection

1. Propeller shaft assy (Loose) propeller shaft assy, overhaul
Chapter 34 axle and propeller shaft - center

2. U-joint yoke (Incorrectly installation) support bearing, overhaul

3. Propeller shaft assy (Bent or twisted) propeller shaft assy, overhaul
Propeller shaft
assy vibration Chapter 34 axle and propeller shaft -
4. Propeller shaft assy (Unbalanced) propeller shaft assy, overhaul
5. Center support bearing rubber grommet Chapter 34 axle and propeller shaft - center
(Aging or damaged) support bearing, overhaul
6. Center suppor bearing (Worn or Chapter 34 axle and propeller shaft - center
damaged) support bearing, overhaul
1. Center support with rubber grommet Chapter 34 axle and propeller shaft - center
(Incorrectly installation) support bearing, overhaul
Center support
2. Lubrication (Insufficient) -
bearing overheat
Chapter 34 axle and propeller shaft - center
3. Oil seal (Too tight) support bearing, overhaul
COMPONENTS
34
34
1 Propeller Shaft Assy 4 Spring Washer
2 Bolt 5 Nut
3 Bolt
INSPECTION
1. INSPECT VIBRATION OF POWERTRAIN.
(a) Check front wheels for dynamic balance. (Refer to “Chapter 33 tire and wheel - tire and wheel assy,
adjustment”)
(b) Check rear wheels for dynamic balance. (Refer to “Chapter 33 tire and wheel - tire and wheel assy,
adjustment”)
(c) Perform the road test. Check the powertrain for vibration when vehicle is moving or stopped.
2. INSPECT PROPELLER SHAFT ASSY DIAMETER

RUNOUT.
(a) Using V-block and dial indicator, measure the diameter
runout of propeller shaft assy.
Limit: ≤ 0.5 mm
If the diameter runout is out of the specification, correct the
propeller shaft assy using press machine. If the diameter runout is
still out of the specification after correction, replace with a new
propeller shaft assy. (Chapter 34 axle and propeller shaft -
propeller shaft assy, overhaul)
3. INSPECT PROPELLER SHAFT ASSY DYNAMIC

BALANCE.
(a) Using dynamic balancer, check the propeller shaft assy.
Dynamic unbalance: ≤ 30 g.cm (3200 r/min)
If the dynamic unbalance is out of the specification, weld balance
blocks at the corresponding position on the both ends of propeller
shaft assy.
NOTE
• It is no more than 3 balance blocks at each end if weld-
ing.
• Perform step (a) again to check whether dynamic
unbalance is within the specification.
4. INSPECT SLIP SPLINE CLEARANCE.

(a) Using feeler gauge, measure the tangential clearance
between sleeve yoke and spline on transmission output
shaft.
Standard: 0.15 mm
Limit: 0.35 mm
If the clearance is out of the specification, replace with a new
propeller shaft assy. (Refer to “Chapter 34 axle and propeller
shaft - propeller shaft assy, overhaul”)
OVERHAUL
1. PRECAUTION. (Refer to “Chapter 34 axle and propeller shaft - propeller shaft assy, precaution”)
2. REMOVE PROPELLER SHAFT ASSY. 34

(a) Mark on the front propeller shaft U-joint and transmission
dust-proof cover.
CAUTION
Make sure the marks are clear.
(b) Mark on the rear propeller shaft U-joint and pinion flange.
CAUTION
(c) Loosen 4 bolts.

WARNING
Discard the loose bolts.
34
(d) Lower the propeller shaft and set it aside.

NOTE
When performing this operation, another operator who holds
the propeller shaft up is required.
(e) Loosen 2 bolts.

WARNING
NOTE
(f) Lower the center support with rubber grommet.

NOTE
(g) Pull out the sleeve yoke from transmission dust-proof

cover and remove the propeller shaft assy.
CAUTION
Be sure to store the propeller assy carefully.
3. INSPECT PROPELLER SHAFT ASSY. (Refer to “Chapter 34 axle and propeller shaft - propeller
shaft assy, inspection”)
4. INSPECT U-JOINT. (Refer to “Chapter 34 axle and propeller shaft - U-joint, overhaul”)
5. INSTALL PROPELLER SHAFT ASSY.

(a) Insert the sleeve yoke into transmission dust-proof cover
according to the marks.
CAUTION
Be sure to perform this operation according to the marks.
NOTE
(b) Position the center support with rubber grommet

properly.
NOTE
When performing this operation, another operator who holds 34
(c) Tighten 2 bolts.

Torque: 60 ～ 70 N•m
WARNING
Be sure to use new bolts.
NOTE
(d) Position the propeller shaft properly according to the

marks.
CAUTION
NOTE
Align the marks by rotating the pinion flange when
necessary. 34
(e) Tighten 4 bolts.

Torque: 70 ～ 78 N·m
WARNING
34-8 AXLE AND PROPELLER SHAFT - U-JOINT
U-JOINT
COMPONENTS
1 Sleeve / Tube / End / Flange Yoke 4 Snap Ring
2 Round Bearing 5 Tube / End Yoke
3 Dust-proof Cover 6 Cross Spider

AXLE AND PROPELLER SHAFT - U-JOINT 34-9
OVERHAUL
2. REMOVE PROPELLER SHAFT ASSY. (Refer to “Chapter 34 axle and propeller shaft - propeller
34
shaft assy, overhaul”)
3. DISASSEMBLE MIDDLE U-JOINT OF PROPELLER

SHAFT ASSY.
(a) Mark on the end yoke, cross spider and tube yoke.
CAUTION
(b) Using snap ring pliers, remove 4 snap rings.

WARNING
Discard the removed snap rings.
(c) Using a copper rod, hammer the round bearing.

CAUTION 34
Do not hammer the round bearing and not clamp the
propeller shaft with vice directly.
(d) Remove 4 round bearings and 4 dust-proof covers.

WARNING
Discard the removed dust-proof cover.
(e) Remove the cross spider.
(f) Separate the end yoke from tube yoke.
4. DISASSEMBLE FRONT U-JOINT OF PROPELLER SHAFT ASSY.

NOTE
Disassemble the front U-joint by the same procedures as the middle U-joint.
5. DISASSEMBLE REAR U-JOINT OF PROPELLER SHAFT ASSY.
NOTE
Disassemble the rear U-joint by the same procedures as the middle U-joint.
6. INSPECT CROSS SPIDER.
(a) Check the cross spider for wear and tear.
(b) Using micrometer calipers, measure the cross spider

journal.
Standard: 18.440 mm
Limit: 18.425 mm
If the cross spider is excessively worn, replace with a new part.
(c) Using a dial indicator, measure the clearance between

round bearing and yoke.
Clearance: 0 mm (Interferencefit)
If clearance exits, replace with new round bearing and yoke.
NOTE
Insert the round bearing into the yoke. Measure the
clearance by shaking bearing along radial direction lightly.
(d) Using vice and dial indicator, measure the radial

clearance between round bearing and cross spider.
Radial clearance: 0.01 ～ 0.06 mm
If the radial clearance is out of the specification, replace with
new round bearing and cross spider.
CAUTION
Wrap the cross spider with rag to prevent the spider where
is clamped by vice from being damaged.
NOTE
Hitch the cross spider with round bearing. Measure the radial
clearance by shaking bearing along radial direction lightly.
AXLE AND PROPELLER SHAFT - U-JOINT 34-11
(e) Using dial indicator, measure the axial clearance between

round bearing and cross spider.
Axial clearance: 0.10 ～ 0.30 mm
If the radial clearance is out of the specification, replace with 34
new round bearing and cross spider.
NOTE
Hitch the cross spider with round bearing. Measure the radial
clearance by shaking bearing along axial direction lightly.
7. REASSEMBLE MIDDLE U-JOINT OF PROPELLER SHAFT ASSY.

(a) Coat the grease on the mating surfaces of cross spider and round bearing.
Grease: lithium base grease No.2
(b) Position the end yoke and tube yoke properly according to
the marks.
(c) Install 4 round bearings and 4 dust-proof covers.
(d) Install the cross spider.
(e) Using a copper rod and hammer, install 4 round bearings
and 4 dust-proof covers.
WARNING
Be sure to use new dust-proof covers.
CAUTION
34
(f) Using snap ring pliers, install 4 snap rings.

WARNING
Be sure to use new snap rings.
8. REASSEMBLE FRONT U-JOINT OF PROPELLER SHAFT ASSY.

NOTE
Reassemble the front U-joint by the same procedures as the middle U-joint.
9. REASSEMBLE REAR U-JOINT OF PROPELLER SHAFT ASSY.
NOTE
Reassemble the rear U-joint by the same procedures as the middle U-joint.
10. INSTALL PROPELLER SHAFT ASSY. (Refer to “Chapter 34 axle and propeller shaft - propeller
AXLE AND PROPELLER SHAFT - CENTER SUPPORT BEARING 34-13
CENTER SUPPORT BEARING

COMPONENTS
34
1 Nut 5 Center Support Bearing
2 Flat Washer 6 Bearing Cup
3 End Yoke Center Support With Rubber Grommet 34

7
Assy
4 Oil Seal
8 Middle Propeller Shaft
34-14 AXLE AND PROPELLER SHAFT - CENTER SUPPORT BEARING
OVERHAUL
2. REMOVE PROPELLER SHAFT ASSY. (Refer to “Chapter 34 axle and propeller shaft - propeller
3. DISASSEMBLE MIDDLE U-JOINT OF PROPELLER SHAFT ASSY. (Refer to “Chapter 34 axle and
propeller shaft - U-joint, overhaul”)
4. REMOVE END YOKE.

(a) Loosen the nut.
WARNING
Discard the loose nut.
(b) Remove the flat washer.
(c) Mark on the end yoke and spline.

CAUTION
NOTE
Make sure the yoke direction of 3 U-joint is consistent.
(d) Using a puller, remove the end yoke.

5. REMOVE CENTER SUPPORT WITH RUBBER GROMMET

ASSY.
CAUTION
Do not damage the rubber grommet. 34
6. REMOVE CENTER SUPPORT BEARING.

(a) Using a puller, remove the center support bearing assy.
(b) Remove 2 oil seals on both side.

WARNING
Discard the removed oil seals.
34
(c) Using hammer and copper rod, remove the center

suppor bearing from bearing cup.
7. INSPECT CENTER SUPPORT BEARING.

(a) Check whether the center support bearing can be rotated freely.
(b) Check whether the center support bearing is worn excessively.
(c) If any fault is found, replace with a new part.
34-16 AXLE AND PROPELLER SHAFT - CENTER SUPPORT BEARING
8. INSTALL CENTER SUPPORT BEARING ASSY.

(a) Coat the grease on the center support bearing and bearing cup.
(b) Using hammer and copper rod, install the center suppor
bearing to bearing cup.
(c) Coat the grease on the oil seal lip.

WARNING
Be sure to use new oil seals.
(d) Install 2 oil seals on both side.
(e) Install the center support bearing assy.
9. INSTALL CENTER SUPPORT WITH RUBBER GROMMET

ASSY.
CAUTION
Do not damage the rubber grommet.
10. INSTALL END YOKE.

(a) Position the end yoke properly according to the marks.
CAUTION
34
NOTE
Make sure the yoke direction of 3 U-joint is consistent.
(b) Install the flat washer.
(c) Tighten the nut.

Torque: 157 ～ 216 N·m
WARNING
Be sure to use a new nut.
34
11. INSPECT CENTER SUPPORT BEARING.

(a) Check whether the center support with rubber grommet can be rotated freely without deviation when
rotating it by hands.
(b) Replace with new center support bearing, bearing cup and support with rubber grommet assy when
necessary.
12. REASSEMBLE MIDDLE U-JOINT OF PROPELLER SHAFT ASSY. (Refer to “Chapter 34 axle and
propeller shaft - U-joint, overhaul”)
13. INSTALL PROPELLER SHAFT ASSY. (Refer to “Chapter 34 axle and propeller shaft - propeller
34-18 AXLE AND PROPELLER SHAFT - AXLE HUB AND STEERING KNUCKLE
AXLE HUB AND STEERING KNUCKLE


Chapter 33 tire and wheel - tire and wheel
1. Tire type (Incorrect) assy, on-vehicle inspection

2. Tire (Worn) assy, on-vehicle inspection

3. Tire pressure (Incorrect) assy, on-vehicle inspection
Chapter 32 rear suspension - rear wheel

4. Wheel alignment (Incorrect) alignment, adjustment
Wandering / Chapter 34 axle and propeller shaft - axle

Pulling 5. Axle hub bearing (Worn) hub and steering knuckle, on-vehicle
inspection
Chapter 31 front suspension - front shock

6. Front shock absorber (Damaged) absorber, overhaul
7. Suspension (Loose or damaged) -
Chapter 52 power steering - steering gear

8. Steering tie rod (Loose or worn) assy, overhaul
Chapter 32 rear suspension - rear stabilizer

9. Stabilizer bar (Bent or fractured) bar, replacement

1. Wheel (Unbalanced or worn excessively) assy, on-vehicle inspection
Chapter 34 axle and propeller shaft - axle

2. Axle hub bearing (Worn) hub and steering knuckle, on-vehicle
inspection
Chapter 31 front suspension - front shock

3. Shock absorber (Worn or damaged) absorber, overhaul
Wheel vibration Chapter 32 rear suspension - rear spiral

4. Rear spiral spring (Loose) spring, overhaul

5. B-joint (Worn) steering knuckle, overhaul

6. Steering tie rod (Loose or worn) assy, overhaul

7. Steering gear assy (Damaged) assy, overhaul
AXLE AND PROPELLER SHAFT - AXLE HUB AND STEERING KNUCKLE 34-19

Chapter 52 power steering - power steering
1. Power steering fluid level (Low) system, on-vehicle inspection
34
2. Steering knuckle (Worn) steering knuckle, overhaul

Abnormal noise 3. Steering propeller shaft (Worn) propeller shaft assy, overhaul
Chapter 52 power steering - power steering

4. Power steering pump (Worn or damaged) system, on-vehicle inspection

5. Steering gear assy (Damaged) assy, overhaul
34
34-20 AXLE AND PROPELLER SHAFT - AXLE HUB AND STEERING KNUCKLE
1. INSPECT FRONT AXLE HUB.
(a) Remove the front wheel assy. (Refer to “Chapter 33 tire and wheel - front tire and wheel, replacement”)
(b) Remove the front disk brake caliper assy. (Refer to “Chapter 35 brake - front brake, overhaul”)
(c) Using a screwdriver, remove the front axle hub grease

cap.
CAUTION
Do not press the spherical sureface to prevent deformation.
NOTE
Pry the grease cap out lightly along the edge.
(d) Using dial indicator, measure the back lash around the
center of front axle hub.
Back lash: ≤ 0.05 mm
If the back lash is out of the specification, replace with new front
axle hub bearings.
NOTE
Measure the back lash by shaking the front axle hub along
the axial direction lightly.
(e) Using dial indicator, measure the deviation at the edge of

front axle hub.
Deviation: ≤ 0.07 mm
If the deviation is out of the specification, replace with a new front
axle hub.
NOTE
Measure the deviation by rotating the front axle hub slowly.
(f) Using hammer and copper rod, install the front axle hub
grease cap.
CAUTION
Do not press the spherical surface to prevent deformation.
NOTE
Hammer the grease cap with copper rod lightly along the
edge to install it properly.
(g) Install the front disk brake caliper assy. (Refer to “Chapter
35 brake - front brake, overhaul”)
(h) Install the front wheel assy. (Refer to “Chapter 33 tire and
wheel - front tire and wheel, replacement”)
AXLE AND PROPELLER SHAFT - AXLE HUB AND STEERING KNUCKLE 34-21
2. INSPECT REAR AXLE HUB.

(a) Remove the rear wheel assy. (Refer to “Chapter 33 tire and wheel - rear tire and wheel, replacement”)
(b) Remove the rear brake drum. (Refer to “Chapter 35 brake - rear brake, overhaul”)
34
(c) Using dial indicator, measure the back lash around the
center of rear axle hub.
If the back lash is out of the specification, replace with new rear
axle hub bearings.
NOTE
Measure the back lash by shaking the rear axle hub along
the axial direction lightly.
(d) Using dial indicator, measure the deviation at the edge of

rear axle hub.
If the deviation is out of the specification, replace with a new rear
axle hub.
NOTE
Measure the deviation by rotating the rear axle hub slowly.
(e) Install the rear brake drum. (Refer to “Chapter 35 brak -

rear brake, overhaul”)
(f) Install the rear wheel assy. (Refer to “Chapter 33 tire and
34
wheel - rear tire and wheel, replacement”)
34-22 AXLE AND PROPELLER SHAFT - AXLE HUB
AXLE HUB
COMPONENTS
FRONT AXLE HUB
1 Front Axle Hub Grease Cap 8 Front Brake Disk
2 Front Axle Hub Nut Cover 9 Front Brake Caliper
3 Cotter Pin 10 Washer
4 Front Axle Hub Nut 11 Plug
5 Front Axle Hub Washer 12 Brake Fluid Tube
6 Front Axle Hub Bearing 13 Bolt
7 Front Axle Hub

AXLE AND PROPELLER SHAFT - AXLE HUB 34-23
REAR AXLE HUB
34
34
1 Cotter Pin 12 C-washer
2 Hole Plug Rear Brake Automatic Adjusting Lever

13
Spring
3 Rear Axle Hub
14 Rear Brake Automatic Adjusting Lever
4 Rear Brake Backing Plate
15 Rear Brake Drum
5 Leading Shoe
16 Dust Boot
6 Parking Brake Shoe Strut Set
17 Piston
7 Hold Spring
18 Rubber Cover
8 Hold Spring Cover
19 Bolt
9 Return Spring
20 Rear Wheel Brake Cylinder
10 Trailing Shoe
21 Bleeding Plug
11 Parking Brake Shoe Lever
22 Spring
REPLACEMENT
FRONT AXLE HUB
1. REMOVE FRONT AXLE HUB LH.
(a) Remove the front wheel assy LH. (Refer to “Chapter 33 tire and wheel - front tire and wheel, replace-
ment”)
(b) Remove the front disk brake caliper assy LH. (Refer to “Chapter 35 brake - front brake, overhaul”)
(c) Using a screwdriver, remove the front axle hub grease

cap.
CAUTION
NOTE
Pry the grease cap out lightly along the edge.
(d) Remove the cotter pin.

WARNING
Discard the removed cotter pin.
(e) Remove the front axle hub nut cover.
(f) Loosen the front axle hub nut.

WARNING
Discard the loose front axle hub nut.
(g) Remove the front axle hub washer.
34
(h) Remove the front brake disk with axle hub assy LH.
(i) Remove inner and outer bearings of front axle hub LH.
CAUTION
Store the bearings carefully to prevent them from being
missing.
34
(j) Loosen 6 bolts.

WARNING
(k) Separate the front axle hub LH from the front brake disk
LH.
(l) Using hammer and copper rod, remove inner and outer
bearing supports.
2. REMOVE FRONT AXLE HUB RH.

NOTE
3. INSTALL FRONT AXLE HUB LH.

(a) Using hammer and copper rod, install inner and outer
bearing supports.
(b) Connect the front axle hub LH to front brake disk LH.
(c) Tighten 6 bolts by the sequence shown in the illustration.

WARNING
34
NOTE
Tighten the bolts after intalling them all.
(d) Coat the grease on inner and outer bearings of the front
axle hub LH.
NOTE
Fill the grease into the bearings for less than 1/2.
(e) Install the inner and outer bearings to the front axle hub
LH. 34
(f) Coat the grease on the steering knuckle LH.

NOTE
Coat the grease to cover the entire surface of steering
knuckle LH.
(g) Install the front brake disk with axle hub assy LH.
NOTE
Rotate the front axle hub LH to make sure it is positioned
properly.
(h) Install the front axle hub washer.
(i) Tighten the front axle hub nut.

Torque: 320 ～ 350 N·m
WARNING
(j) Rotate the front axle hub LH by 2 ～ 3 turns.

(k) Using a sprin g scale, measure the primal rotating force
of front axle hub LH.
Primal rotating force: ≤ 5 N·m
If the primal rotating force is out of the specification, adjust the front
axle hub nut.
(l) Using dial indicator, measure the back lash around the
center of front axle hub LH.
If the back lash is out of the specification, replace with new front
axle hub bearings.
NOTE
Measure the back lash by shaking the front axle hub LH
along the axial direction lightly.
(m) Using dial indicator, measure the deviation at the edge of

front axle hub LH.
If the deviation is out of the specification, replace with a new front
axle hub LH.
NOTE
Measure the deviation by rotating the front axle hub LH
slowly.
(n) Coat the grease on the front axle hub nut.
(o) Coat the grease on the front axle hub cover.

(p) Install the front axle hub cover. 34
(q) Install the cotter pin.

WARNING
Be sure to use a new cotter pin.
(r) Using hammer and copper rod, install the front axle hub
grease cap.
CAUTION
NOTE 34
(s) Install the front disk brake caliper LH. (Refer to “Chapter
35 brake - front brake, overhaul”)
(t) Install the front wheel assy LH. (Refer to “Chapter 33 tire
and wheel - front tire and wheel, replacement”)
4. INSTALL FRONT AXLE HUB RH.

NOTE
Install the RH side by the same procedures as the LH side.
REAR AXLE HUB

1. REMOVE REAR AXLE HUB LH.
(a) Remove the rear tire and wheel assy LH. (Refer to “Chapter 33 tire and wheel - rear tire and wheel,
replacement”)
(b) Using a screwdriver, remove the rear axle hub grease cap.
CAUTION
NOTE
Pry the grease cap lightly along the edge.
(c) Remove the cotter pin.

WARNING
(d) Remove the rear axle hub nut cover.
(e) Loosen the rear axle hub nut.

WARNING
Discard the loose nut.
(f) Remove the rear brake drum LH.
34
(g) Using a puller, remove the rear axle hub LH.
(h) Loosen 6 nuts.

WARNING
Discard the loose 6 nuts.
34
(i) Lower the axle shaft assy LH.

NOTE
• Pull out the axle shaft assy LH away from the output
flange LH.
• Set the axle shaft assy LH aside and hold it up.
(j) Pull out the axle shaft assy LH from the rear trailing arm
LH.
(k) Remove the axle shaft assy LH.
CAUTION
Store the axle shaft assy LH carefully.
(l) Disconnect the brake fluid tube from the rear wheel
brake cylinder LH.
(m) Loosen 4 bolts and remove the backing plate with rear
brake assy LH.
CAUTION
Store the backing plate carefully. Do not drag the rear
parking brake cable assy LH.
NOTE
The rear parking brake cable assy LH is not connected
during this operation.
(n) Using snap ring pliers, remove the snap ring from the
groove in rear trailing arm LH.
WARNING
Discard the removed snap ring.
(o) Using hammer and copper rod, remove the rear axle hub
bearing.
2. REMOVE REAR AXLE HUB RH.

NOTE
3. INSTALL REAR AXLE HUB LH.
(a) Using hammer and copper rod, install the rear axle hub bearing.
(b) Using snap ring pliers, install the snap ring to the groove in rear trailing arm LH.
WARNING
Make sure to use new snap ring.
(c) Install the backing plate with rear brake assy LH and
tighten 4 bolts.
Torque: 100 ～ 120 N·m
CAUTION 34
Do not drag the parking brake cable assy LH.
(d) Connect the brake fluid tube to the rear wheel brake
cylinder LH.
(e) Coat the grease on the spline of axle shaft assy LH.
(f) Insert the axle shaft assy LH in the rear trailing arm LH.
NOTE
Hold the axle shaft assy LH up.
34
(g) Coat the sealant on the bolts of final drive output flage
LH.
Sealant:：LOCTITE 204
(h) Position the axle shaft assy LH properly.

NOTE
Align the axle shaft assy LH and final drive output flange LH
properly.
(i) Tighten 6 nuts.

WARNING
Be sure to use new nuts.
(j) Install the rear axle hub LH.

CAUTION
Do not damage the rear axle hub bearing.
(k) Install the rear brake drum LH.
(l) Tighten the rear axle hub nut.

Torque: 320 ～ 350 N·m
WARNING
(m) Rotate the rear axle hub LH 2 ～ 3 turns.

(n) Using a spring scale, measure the primal rotating force of
rear axle hub LH.
Primal rotating force: ≤ 5 N·m
If the primal rotating force is out of the specification, adjust the
rear axle hub nut.
(o) Using dial indicator, measure the back lash around the
center of rear axle hub LH.
If the back lash is out of the specification, replace with new rear 34
axle hub bearings.
NOTE
Measure the back lash by shaking the rear axle hub LH
along the axial direction lightly.
(p) Using dial indicator, measure the deviation at the edge of

rear axle hub LH.
If the deviation is out of the specification, replace with a new
rear axle hub LH.
NOTE
• Measure the deviation by rotating the rear axle hub
LH slowly.
(q) Coat the grease on the rear axle hub nut.
(r) Coat the grease on the rear axle hub nut cover.
(s) Install the rear axle hub nut cover.
34
(t) Install the cotter pin.

WARNING
(u) Using hammer and copper rod, install the rear axle hub
grease cap.
CAUTION
NOTE
(v) Install the rear wheel assy LH. (Refer to “Chapter 33 tire
and wheel - rear tire and wheel, replacement”)
4. INSTALL REAR AXLE HUB RH.

NOTE
AXLE AND PROPELLER SHAFT - STEERING KNUCKLE 34-37
STEERING KNUCKLE
COMPONENTS
34
34
1 Splash Shield 7 Steering Tie Rod
2 Bolt 8 Steering Knuckle
3 Cotter Pin 9 Lower Control Arm
4 Slotted Nut 10 Lower Control Arm B-joint
5 Upper Control Arm 11 Nut
6 Steering Knuckle Arm 12 Bolt

34-38 AXLE AND PROPELLER SHAFT - STEERING KNUCKLE
OVERHAUL
1. REMOVE STEERING KNUCKLE LH.
(a) Remove front wheel assy LH. (Refer to “Chapter 33 tire and wheel - front tire and wheel, replacement”)
(b) Remove the front disk brake caliper assy LH. (Refer to “Chapter 35 brake - front brake, overhaul”)
(c) Remove the front brake disk with axle hub assy LH. (Refer to “Chapter 34 axle and propeller shaft -
axle hub, replacement”)
(d) Loosen the bolt.
(e) Pull out the front wheel speed sensor with wire harness
and bracket assy LH.
(f) Remove 2 cotter pins.

WARNING
Discard the removed cotter pins.
(g) Loosen 2 slotted nuts.
WARNING
Discard the loose slotted nuts.
NOTE
Taking 2 bolts down is not required.
(h) Separate the steering tie rod B-joint LH from the steering
knuckle arm LH.
• Remove the cotter pin.
WARNING
• Loosen the slotted nut.

WARNING
Discard the loose slotted nut.
34
• Set the steering tie rod LH aside.
(i) Remove the splash shield LH.

• Remove the bolt.
34
• Pull 2 bolts out.

NOTE
• These 2 bolts are loose.
• Remove the steering knuckle arm LH simultaneously.

• Remove the splash shield LH.
(j) Remove the lower control arm B-joint LH.

• Loosen 4 sets of bolts and nuts.
WARNING
Discard the loose bolts and nuts.

WARNING

WARNING
Discard the loose slotted nut. 34
• Using hammer and copper rod, remove the lower control

arm B-joint LH.
34
(k) Separate the steering knuckle LH from the upper control

arm B-joint LH.
WARNING

WARNING
Discard the loose slotted nut.
• Using hammer and copper rod, remove the steering knuckle

LH.
34
2. REMOVE STEERING KNUCKLE RH.

NOTE
3. INSPECT B-JOINT.
(a) Check the contact area between steering tie rod B-joint 34
and steering knuckle arm.
• Apply red lead evently to the steering tie rod B-joint shaft and
hole of steering knuckle arm.
• Insert the steering tie rod B-joint shaft into the hole of
steering knuckle arm, then pull it out again. Check the
contact area.
Standard: red area ≤ 3/4 shaft length,evenly
If any problem is found, replace with a new steering gear assy
and steering knuckle arm. (Refer to “Chapter 52 power steering -
steering gear assy, overhaul”, “Chapter 34 axle and propeller
shaft - steering knuckle, overhaul”)
(b) Check the contact area between lower control arm B-joint
and steering knuckle.
• Apply red lead evently to the lower control arm B-joint
shaft and hole of steering knuckle.
• Insert the lower control arm B-joint shaft into the hole of
steering knuckle, then pull it out again. Check the contact
area.
If any problem is found, replace with a new lower control arm B-
joint and steering knuckle. (Refer to “Chapter 31 front
suspension - lower control arm, replacment”, “Chapter 34 axle

and propeller shaft - steering knuckle, overhaul”)
(c) Check the contact area between upper control arm B-joint
.
and steering knuckle.

• Apply red lead evently to the upper control arm B-joint
shaft and hole of steering knuckle.
• Insert the upper control arm B-joint shaft into the hole of
steering knuckle, then pull it out again. Check the contact
area.
If any problem is found, replace with a new lower control arm B-
joint and steering knuckle. (Refer to “Chapter 31 front
suspension - upper control arm, replacment”, “Chapter 34 axle
and propeller shaft - steering knuckle, overhaul”)
4. INSTALL STEERING KNUCKLE LH.

(a) Install the steering knuckle LH.
• Using hammer and copper rod, position the steering
knuckle LH properly.
• Tighten the slotted nut.

Torque: 135 ～ 145 N·m
WARNING
Be sure to use a new slotted nut.
34
• Install the cotter pin.

WARNING
34
(b) Install the lower control arm B-joint LH.

• Using hammer and cooper rod, position the lower control
arm B-joint LH properly.
NOTE
Align the holes of B-joint and lower control arm LH.

Torque: 137 ～ 147 N·m
WARNING

WARNING
34
• Tighten 4 sets of bolts and nuts.

WARNING
Be sure to use new bolts and nuts.
34
(c) Install the splash shield LH.

• Position the splash shield LH properly.
• Insert 2 bolts.
WARNING
NOTE
• Simultaneously position the steering knuckle arm LH
properly.
• Installing 2 slotted nuts is not required during this
operation.
• Tighten the bolt.
(d) Conntect the steering tie rod LH to the steering knuckle

arm LH.
• Insert the steering tie rod B-joint LH into the hole in
steering knuckle arm LH.

WARNING

WARNING
34
(e) Tighten 2 slotted nuts.

WARNING
Be sure to use new slotted nuts.
(f) Install 2 cotter pins.
WARNING
Be sure to use new cotter pins.
(g) Install the front wheel speed sensor with wire harness
and bracket assy LH.
34
(h) Tighten the bolt.
(i) Install the front brake disk with axle hub assy LH. (Refer
to “Chapter 34 axle and propeller shaft - axle hub,
replacement”)
(j) Install the front disk brake caliper assy LH. (Refer to
“Chapter 35 brake - front brake, overhaul”)
(k) Install the front wheel assy. (Refer to “Chapter 33 tire and
wheel - front tire and wheel, replacement”)
5. INSTALL STEERING KNUCKLE RH.

NOTE
6. INSPECT FRONT WHEEL ANGLE. (Refer to “Chapter 31 front suspension - front wheel
alignment, adjustment”)
AXLE AND PROPELLER SHAFT - TRANSAXLE 34-51
TRANSAXLE
PRECAUTION
1. PRECAUTION ON MAITAINING FINAL DRIVE OIL. 34
(a) Be sure to use the specified final drive oil.
Final drive oil:
Viscosity
Type Grade Capacity
≤ 18 ℃ ＞ 18 ℃
Hypoid gear oil API GL - 5 SAE 80W SAE 90W 1.2 L
(b) Be sure to replace the final drive oil regularly. (Refer to “Chapter 34 axle and propeller shaft - final drive
oil, replacement”)
• Replace with new gear oil during the primal Level2 maintenance.
• Replace with new gear oil in the primal 40000 Km or 24 months.
• Replace with new gear oil in the primal 80000 Km or 48 months. Then repeat this operation in each
following 50000 Km.
(c) Check regularly, at least every 4 times for Level2 maitenances:
• Check the gear oil for discolouration, thinning, etc.
If any fault is found, replace with new gear oil. (Refer to “Chapter 34 axle and propeller shaft - final drive
oil, replacement”)
2. PRECAUTION ON MAINTAINING FINAL DRIVE ASSY.

(a) Be sure to check the vent plug regularly. Clean it when
necessary.
NOTE 34
• Remove and clean the vent plug during each Level1
maintenance.
• The stuffy vent plug may raise the oil pressure inside
the final drive assy, even cause leakage.
• Check the final drive oil level simultaneously.
(b) Disassemble and clean the final drive assy during the
Level3 maintenance. Then reassemble the final drive
assy according to the specification.
(c) Check the rear brake shoe and brake drum regularly for
wear and tear. (Refer to “Chapter 35 brake - rear brake,
on-vehilce inspection”)
34-52 AXLE AND PROPELLER SHAFT - TRANSAXLE
3. SERVICING PRECAUTION ON FINAL DRIVE ASSY.

(a) Be sure to replace the mating parts as a set.
(b) Discard all removed rubber parts (O-rings, oil seal, grommet, etc. ).
(c) With the method of visual check, red lead, etc., check all parts carefully for faults below:
Uneven wear Eccentric wear Scratch Crack
Deformation Bend Loose Rusting
Invalidation or weakness
Discolouration Abnormal noise (Bearing) Deterioration (Brake shoes)
(Spring)
(d) When reassembling the final drive assy, make sure all parts are clean without oil fouling and metal
scrap. Unless special introduction, coat the final drive oil on the parts for lubrication before performing
operations.
Final drive oil:
Viscosity
Type Grade Capacity
≤ 18 ℃ ＞ 18 ℃
4. PRECAUTION ON VEHICLE DRIVING.

(a) Never overload.
(b) Never release the clutch pedal too quickly.
CAUTION
Releasing the clutch pedal too quickly will strick the gear even cause damage.

34
Symptom Suspect area Reference
Continuous 1. Side pinion thrust washer (Worn) differential assy, overhaul
knocking
(Turning) Chapter 34 axle and propeller shaft -
2. Side pinion (Worn) differential assy, overhaul
1. Drive pinion, crown gear (Excessive back Chapter 34 axle and propeller shaft -
Continuous lash or worn) differential assy, inspection and adjustment
knocking
(At high speed) 2. Drive pinion, crown gear (Undersize back Chapter 34 axle and propeller shaft -
lash) differential assy, inspection and adjustment
Continuous lash or worn) differential assy, inspection and adjustment
knocking
(Accelerating) 2. Drive pinion, crown gear (Undersize back Chapter 34 axle and propeller shaft -
1. Axle shaft spline (Excessive back lash or Chapter 34 axle and propeller shaft - axle
worn) shaft assy, replacement
Intermittent
knocking
lash or worn) differential assy, inspection and adjustment
(Running)
Chapter 34 axle and propeller shaft - final
3. Final drive assy (Impurity entry) drive oil, replacement
Chapter 34 axle and propeller shaft - 34

1. Vent plug (Jam) transaxle, precaution

2. Final drive oil leve (High) transaxle, on-vehicle inspection

3. Bolts (Loose or worn) differential assy, overhaul
Leakage
(Final drive) 4. Drive pinion oil seal (Damaged or Chpater 34 axle and propeller shaft - drive
invalidate) pinion, overhaul
5. Output flange oil seal (Damaged or Chapter 34 axle and propeller shaft -
invalidate) differential assy, overhaul

6. Final drive housing (Crack or fracture) transaxle, on-vehicle inspection
Symptom Suspect area Reference

1. Final drive oil level (Low) transaxle, on-vehicle inspection
2. Drive pinion, crown gear (Undersize back Chapter 34 axle and propeller shaft -
Overheat Chapter 34 axle and propeller shaft -

(Final drive) 3. Output flange oil seal (Too tight) differential assy, overhaul

4. differential bearing (Too tight) differential assy, overhaul
Chapter 36 parking brake - parking brake

5. Rear brake (Stuck) cable assy, replacement
COMPONENTS
34
34
1 Transaxle Longitudinal Hanger Assy 5 Axle Shaft
2 Final Drive Assy 6 Transaxle Transverse Hanger Assy
3 Rear Trailing Arm LH 7 Rear Brake Assy RH
4 Rear Brake Assy LH 8 Rear Trailing Arm RH

1. INSPECT TRANSAXLE BASH LASH.
(a) Park the vehicle on level road with applying parking brake.
(b) Shift in the neutral position.
(c) Lift rear wheels off the ground with jack or lift.
(d) Separate the propeller shaft assy from pinion flange.

• Mark on the rear propeller shaft U-joint and pinion flange.
CAUTION
Make the marks are clear.
• Loosen 4 bolts.
WARNING
• Lower the propeller shaft and set it aside.

NOTE
Support the propeller shaft with a bracket or equivalent.
(e) Measure the transaxle back lash.

• Rotate counterclockwise the pinion flange until it
becomes hard to rotate.
• Mark on the final drive housing and pinion flange.
CAUTION
• Rotate clockwise the pinion flange until it becomes hard

to rotate.
• Measure the transaxle back lash (the distance between
the 2 marks). 34
If the transaxle back lash is out of the specification, remove final
drive assy and perform overhauling.
(f) Connect the propeller shaft to pinion flange.

• Position the propeller shaft properly according to the
marks.
CAUTION
NOTE
necessary.
• Tighten 4 bolts.
WARNING
34
2. CHECK FINAL DRIVE OIL LEVEL.

(a) Using an allen wrench (key), remove the filler plug.
(b) Check the distance between the filler hole of final drive
and gear oil level.
CAUTION
Fill or drain the final drive oil when necessary. (Refer to
“Chapter 34 axle and propeller shaft - final drive oil,
replacement”)
(c) Using an allen wrench (key), install the filler plug.

3. INSPECT FINAL DRIVE HOUSING.

(a) Check the final drive housing for crack, leakage, etc. Replace it when necessary.
AXLE AND PROPELLER SHAFT - FINAL DRIVE OIL 34-59
FINAL DRIVE OIL

REPLACEMENT
1. PRECAUTION. (Refer to “Chapter 34 axle and propeller shaft - transaxle, precaution”) 34
2. DRAIN FINAL DRIVE OIL.

(a) Remove the vent plug.
(b) Using an allen wrench (key), remove the drain plug.

34
34-60 AXLE AND PROPELLER SHAFT - FINAL DRIVE OIL
(c) Drain the final drive oil completely.

NOTE
Use a container for final drive oil when performing this
operation.
(d) Using an allen wrench (key), install the drain plug.
3. FILL FINAL DRIVE OIL.

(a) Using an allen wrench (key), remove the filler plug.
(b) Fill the final drive oil.

Final drive oil:
Viscosity
Type Grade Capasity
≤ 18 ℃ ＞ 18 ℃
AXLE AND PROPELLER SHAFT - FINAL DRIVE OIL 34-61
(c) Check the distance between the filler hole of final drive
and gear oil level.
CAUTION
Fill or drain the final drive oil when necessary. (Refer to 34
“Chapter 34 axle and propeller shaft - final drive oil,
replacement”)
(d) Using an allen wrench (key), install the filler plug.

34
(e) Install the vent plug.

34-62 AXLE AND PROPELLER SHAFT - AXLE SHAFT ASSY
AXLE SHAFT ASSY

REPLACEMENT
1. REMOVE AXLE SHAFT ASSY LH.
(a) Remove the rear wheel assy LH. (Refer to “Chapter 33 tire and wheel - rear tire and wheel,
replacement”)
(b) Remove the rear axle hub LH. (Refer to “Chapter 34 axle and propeller shaft - axle hub, replacement”)
(c) Loosen 6 nuts.

WARNING
(d) Lower the axle shaft assy LH.

NOTE
flange LH.
• Set the axle shaft assy LH aside and hold it up.
(e) Pull out the axle shaft assy LH from the rear trailing arm
LH.
(f) Remove the axle shaft assy LH.

CAUTION
Store the axle shaft assy LH carefully.
2. REMOVE AXLE SHAFT ASSY RH.

NOTE
AXLE AND PROPELLER SHAFT - AXLE SHAFT ASSY 34-63
3. INSTALL AXLE SHAFT ASSY LH.

(a) Coat the grease on the spline of axle shaft assy LH.
(b) Insert the axle shaft assy LH in the rear trailing arm LH. 34
NOTE
Hold the axle shaft assy LH up.
(c) Coat the sealant on the bolts of output flange LH.
(d) Position the axle shaft assy LH properly.
(e) Tighten 6 nuts.

34
WARNING
4. INSTALL AXLE SHAFT ASSY RH.

NOTE
34-64 AXLE AND PROPELLER SHAFT - FINAL DRIVE ASSY
FINAL DRIVE ASSY

COMPONENTS
AXLE AND PROPELLER SHAFT - FINAL DRIVE ASSY 34-65
1 Pinion Nut 15 Oil Seal
2 Pinion Flange 16 Output Flange
3 Oil Seal 17 Drain Plug 34
4 Washer 18 Gasket
5 Pinion Outer Bearing 19 Crown Gear
6 Collapsible Spacer 20 Differential Bearing Cap
7 Pinion Inner Bearing 21 Spring Washer
8 Pinion Adjusting Shim 22 Bolt
9 Drive Pinion 23 Rear Cover
10 Differential Assy 24 Bolt
11 Lock Plate 25 Gasket
12 Differential Bearing 26 Filler Plug
13 Bolt 27 Vent Plug
14 Differential Bearing Adjusting Washer 28 Final Drive Housing
34
REPLACEMENT
1. PRECAUTION. (Refer to “Chapter 34 axle and propeller shaft - transaxle, precaution”)
2. REMOVE FINAL DRIVE ASSY.

(a) Separate the propeller shaft assy from pinion flange.
• Mark on the rear propeller shaft U-joint and pinion flange.
CAUTION
• Loosen 4 bolts.
WARNING
• Lower the propeller shaft and set it aside.

NOTE
Support the propeller shaft with a bracket or equivalent.
(b) Separate the axle shaft assy LH from output flange LH.
• Loosen 6 nuts.
WARNING
Discard the loose nuts.
• Lower the axle shaft assy LH.

NOTE
flange LH. 34
• Support the axle shaft assy LH with a bracket or
equivalent.
(c) Loosen the bolt and nut.

WARNING
• Be sure to support the final drive assy with a jack or
equivalent.
• Discard the loose bolt and nut.
(d) Loosen 2 nuts.

WARNING
equivalent.
• Discard the loose bolt and nut.
NOTE
34
Simultaneously remove washers and rubber cushions.
(e) Remove the final drive with transverse and longitudinal

hanger assy.
WARNING
Take care because the final drive assy is quite heavy.
CAUTION
• Be sure to lower the jack or equivalent slowly.
• Make sure there is no interference between final drive
and parts around.
(f) Loosen 2 studs.

WARNING
Discard the loose studs.
(g) Loosen 2 nuts.

WARNING
Discard the loose nuts.
(h) Remove the transverse hanger assy.
(i) Loosen 2 sets of bolts and nuts.

WARNING
Discard the loose bolts and nuts.
(j) Remove the longitudinal hanger assy.
3. INSTALL FINAL DRIVE ASSY.

(a) Position the longitudinal hanger assy properly.
(b) Coat the sealant on 2 bolts.

Sealant: LOCTITE 204
WARNING
Be sure to use new bolts. 34
(c) Tighten 2 sets of bolts and nuts.
Torque: 120 N·m
WARNING
(d) Position the transverse hanger assy properly.
(e) Coat the sealant on 2 bolts.

WARNING
(f) Tighten 2 bolts.
Torque: 120 N·m
34
(g) Coat the sealant on 2 studs.

(h) Tighten 2 studs.
Torque: 140 ～ 170 N·m
WARNING
Be sure to use new studs.
(i) Position the final drive with transverse and longitudinal

hanger assy properly.
WARNING
Take care because the final drive assy is quite heavy.
CAUTION
• Be sure to raise the jack or equivalent slowly.
• Make sure there is no interference between final
drive and parts around.
(j) Tighten 2 nuts.

WARNING
equivalent.
• Be sure to use new nuts and rubber cushions.
NOTE
Simultaneously install the washers and rubber cushions.
(k) Coat the sealant on the bolt and nut.

WARNING
Be sure to use new bolt and nut.
(l) Tighten the bolt and nut.
Torque: 120 ～ 140 N·m
WARNING
Be sure to support the final drive with a jack or equivalent.
(m) Connect the axle shaft assy LH to output flange LH.
• Coat the sealant on the bolts of output flange LH.
• Position the axle shaft assy LH properly.
• Tighten 6 nuts.
WARNING
(n) Connect the propeller shaft to pinion flange.

• Position the propeller shaft properly according to the
marks.
CAUTION 34
NOTE
necessary.
• Tighten 4 nuts.
WARNING
34
34-72 AXLE AND PROPELLER SHAFT - DIFFERENTIAL ASSY
DIFFERENTIAL ASSY
COMPONENTS
1 Pinion Shaft Retainer 5 Differential Pinion
2 Differential Gear Thrust Washer 6 Differential Pinion Thrust Washer
3 Differential Gear 7 Differential Case
4 Pinion Shaft
AXLE AND PROPELLER SHAFT - DIFFERENTIAL ASSY 34-73
INSPECTION AND ADJUSTMENT

1. INSPECT CROWN GEAR DEVIATION.
(a) Using dial indicator, measure the deviation at the surface 34
mating with differential case along the edge.
crown gear. (Refer to “Chapter 34 axle and propeller shaft -
differential assy, overhaul”)
NOTE
Measure the deviation by rotating the crown gear slowly.
2. INSPECT CROWN GEAR BACK LASH.

(a) Rotate the crown gear counterclockwise and clockwise
several turns.
(b) Using dial indicator, measure the back lash at 4 points
distributed uniformly on the circumference.
Back lash: 0.13 ～ 0.18 mm
If the back lash is out of the specification, check the contact area
between drive pinion and crown gear. Perform adjustment pro-
cedures if necessary. (Refer to “Chapter 34 axle and propeller
shaft - differential assy, inspection and adjustment”)
NOTE
• Measure the back lash by rotating the crown gear
counterclockwise and clockwise.
• Make sure the dial indicator is perpendicular to the tooth
surface. 34
3. INSPECT CONTACT AREA.

(a) Apply red lead to 3 ～ 4 teeth of 3 different positions on
the crown gear.
(b) Rotate the crown gear counterclockwise and clockwise
several turns.
(c) Check the red area.
Locate: center of the tooth surface, the distance
away from small end ≥ 2 mm
Length：≥ 60% tooth length
Width：≥ 60% tooth width
If the red area is out of the specification, replace the differential
bearing adjusting washer and drive pinion adjusting shim. (Refer
to “Chapter 34 axle and propeller shaft - differential assy,
overhaul”, “Chapter 34 axle and propeller shaft - drive pinion,
overhaul”)
CAUTION
Be sure to replace differential bearing adjusting washer LH
and RH at the same time. Equalize the washer thickness
changes of both sides to keep the preload of differntial
bearing stay the same.
4. ADJUST CONTACT AREA.
Contact area Causation Measures
1. Make crown gear farther away

Drive pinion is too far away from from drive pinion.
crown gear. 2. Make drive pinion closer to
crown gear.
1. Make crown gear closer to drive

Drive pinion is too close to crown pinion.
gear. 2. Make drive pinion farther away
from crown gear.
1. Make crown gear farther away

Drive pinion is too close to crown from drive pinion.
gear. 2. Make drive pinion farther away
from crown gear.
1. Make crown gear closer to drive

Drive pinion is too far away from pinion.
crown gear. 2. Make drive pinion closer to
crown gear.
NOTE
• Adjust the crown gear. (Replace the differential bearing adjusting washer. Refer to “Chapter 34
axle and propeller shaft - differential assy, overhaul”)
• Adjust the drive pinion. (Replace the drive pinion adjusting shim. Refer to “Chapter 34 axle and
propeller shaft - drive pinion, overhaul”)
• Check the contact area again. Perform adjustment when necessary until the contact area is within
the specification.
5. INSPECT DIFFERENTIAL GEAR AND PINION BACK LASH.

(a) Using dial indicatot, measure the back lash at the center
of tooth surface.
If the back lash is out of the specification, inspect the differential
gear clearance. (Refer to “Chapter 34 axle and propeller shaft -
differential assy, inspection and adjustment”)
NOTE
• Make the differential gears and pinions close to the
differential case and secure one of the gears.
surface.
• Perform this operation on 3 points of each gear.
6. INSPECT DIFFERENTIAL GEAR CLEARANCE.

(a) Using feeler gauge, measure the differential gear
clearance.
Differential gear clearance: 0 ～ 0.15 mm 34
NOTE
• The differential gear clearance of both sides should
be same as far as possible.
• If the differential gear clearance is out of the
specification and if there is abnormal noise when
turning, disassemble the diffterential assy and
replace with new thrust washers of differential gear
and pinion. (Refer to “Chpater 34 axle and propeller
shaft - differential assy, overhaul”)
• If the differential gear clearance is within the
specification and if there is no abnormal noise when
turning, disassembling the differential assy is not
required.
34
OVERHAUL
1. PRECAUTION. (Refer to “Chapter 34 axle and propeller shaft - transaxle, precaution”)
2. DRAIN FINAL DRIVE OIL. (Refer to “Chapter 34 axle and propeller shaft - final drive oil,
replacement”)
3. REMOVE FINAL DRIVE ASSY. (Refer to “Chapter 34 axle and propeller shaft - final drive assy,
replacement”)
4. REMOVE REAR COVER.

(a) Loosen 8 bolts.
(b) Remove the rear cover.
5. REMOVE DIFFERENTIAL BEARING CAP.

(a) Mark on the final drive housing and differential bearing cap
one side.
CAUTION
(b) Loosen 4 bolts.
34
(c) Remove 2 differential bearing caps.
6. REMOVE OUTPUT FLANGE.

(a) Pull 2 output flanges out.
34
(b) Using snap ring pliers, remove 2 snap rings.

WARNING
Discard the removed snap rings.
(c) Remove 2 oil seals.

WARNING
Discard the removed oil seals.
7. REMOVE DIFFERENTIAL ASSY.

(a) Remove the differential assy.
(b) Remove 2 differential bearing cups.

NOTE
• Store the differential bearing cups carefully.
• Use a tag to separate right and left bearing cups.
(c) Remove 2 differential bearing adjusting washer.

NOTE
Store the adjusting washer separated by right and left with
bearing cup together.
8. Remove crown gear.

(a) Release 5 lock plates.
(b) Loosen 10 bolts.
34
(c) Remove 5 lock plates.
34
(d) Remove the crown gear.

9. INSPECT DIFFERENTIAL GEAR AND PINION BACK

LASH.
of tooth surface.
gear clearance. (Refer to “Chapter 34 axle and propeller shaft -
NOTE
surface.

clearance.
Differential gear clearance: 0 ～ 0.15 mm
NOTE
• The differential gear clearance of both sides should be
same as far as possible.
• If the differential gear clearance is out of the
specification and if there is abnormal noise when
turning, disassemble the diffterential assy and
replace with new thrust washers of differential gear
and pinion. (Refer to “Chpater 34 axle and propeller
shaft - differential assy, overhaul”)
• If the differential gear clearance is within the
specification and if there is no abnormal noise when
turning, disassembling the differential assy is not
required.
11. DISASSEMBLE DIFFERENTIAL ASSY.

(a) Using hammer and copper rod, remove the pinion shaft
retainer.
CAUTION
Discard the removed pinion shaft retainer.
(b) Using hammer and copper rod, remove the pinion shaft.
34
(c) Remove the differetial gear, differential pinion and thrust

washer.
NOTE
• Store the gears and washers carefully.
• Use a tag to separate right / left and upper / lower wash-
ers.
(d) Using vice and dial indicator, measure the radial

clearance between differential pinion and pinion shaft.
Clearance: 0.05 ～ 0.13 mm
If the clearance is out of the specification, check the differential
pinion and pinion shaft for wear and tear. Replace with new parts
when necessary. (Refer to “Chapter 34 axle and propeller shaft -
differential assy, overhaul”) 34
CAUTION
Do not clamp the pinion shaft without any wrap with the
vice directly.
(e) Using vice and dial indicator, measure the radial

clearance between differential gear and differential case.
Clearance: 0.05 ～ 0.11 mm
If the clearance is out of the specification, check the differential
case and gear for wear and tear. Replace with new parts when
necessary. (Refer to “Chapter 34 axle and propeller shaft -
(f) Using vice and dial indicator, measure the output flange
back lash.
If the back lash is out of the specification, check the differential
gear and output flange for wear and tear. Replace with new parts
when necessary. (Refer to “Chapter 34 axle and propeller shaft -
CAUTION
Do not clamp the output flange without any wrap with the
vice directly.
(g) Measure the thrust washer thickness of differential gear

and pinion.
Thickness:
Thickness
Thrust washer
Standard
Differential gear 0.6 mm
1.6 mm
Differential pinion 1.7 mm
1.8 mm
(h) If the thickness is out of the standard, replace with new

thrust washers of differential gear and pinion. (Refer to
“Chapter 34 axle and propeller shaft - differential assy,
overhaul”)
NOTE
Be sure to select the correct differential gear thrust washer
according to the colour marks on the differential gear.
12. REMOVE DIFFERENTIAL BEARING.

(a) Using a puller, remove 2 differential bearings from the
differential case.
NOTE
Be sure to store the removed differential bearing by right and
left with bearing cup together.
13. INSTALL DIFFERENTIAL BEARING.

(a) Install 2 differential bearings to the differential case.
CAUTION
Be sure to perform this operation according to the tag.
14. REASSEMBLE DIFFERENTIAL ASSY.

(a) Install the differential gear, differential pinion and thrust
washer.
CAUTION
• Be sure to perform this operation according to the
tag.
• Be sure to select the correct differential gear washer
according to the colour marks on the differential
gear when replacing with new parts.
• Do not install more than a thrust washer at each side.
(b) Using hammer and copper rod, install the pinion shaft.
34
(c) Using hammer and copper rod, install the pinion shaft
retainer.
CAUTION
Be sure to use a new pinion shaft retainer.
15. INSPECT DIFFERENTIAL GEAR AND PINION BACK

LASH.
of tooth surface.
gear clearance. (Refer to “Chapter 34 axle and propeller shaft - 34
NOTE
surface.

clearance.
Differential gear clearance: 0 ～ 0.15 mm
NOTE
The differential gear clearance of both sides should be
same as far as possible.
17. INSTALL CROWN GEAR.

(a) Check the tooth surface for wear and tear. Perform repairing or replacement when necessary. (Refer to
“Chapter 34 axle and propeller shaft - differential assy, overhaul”)
CAUTION
Be sure to replace with new drive pinion and crown gear together at the same time.
NOTE
• Repair it when there is only micro-crack on the tooth surface.
• Replace it when there is scoring, spalling, rusting, fracture or excessive wear on the tooth
surface.
(b) Position the crown gear properly.
(c) Position 5 lock plates properly.
(d) Coat the sealant on 10 bolts.

(e) Tighten 10 bolts by the sequence show in the illustration.
(f) Apply 5 lock plates to “LOCK”.
34
18. INSTALL DIFFERENTIAL ASSY.

(a) Position 2 differential bearing cup properly.
CAUTION
Be sure to perform this operation according to the tag.
(b) Position the differential assy properly.

34
(c) Measure the thickness of differential bearing adjusting

washer.
If the thickness is out of the specification, replace with new
differential bearing adjusting washer. (Refer to “Chapter 34 axle
and propeller shaft - differential assy, overhaul”)
(d) Measure the clearance between 2 mating surface of final

drive housing and differential bearing.
(e) Select / install 2 differential bearing adjusting washer.
CAUTION
• When reusing the removed adjusting washers, be sure
to perform this operation according to the tag.
• When replacing with new adjusting washers, make
sure the washer thickness of both sides are same.
NOTE
The thickness of differential bearing adjusting washer
should be 0 ～ 0.02 mm more than the clearance obtained in
step (d).
19. INSTALL OUTPUT FLANGE.

(a) Coat the grease on the output flange oil seal lip.
(b) Coat the sealant on the outer surface of output flange oil
seal.
(c) Coat the grease on the inner surface of output flange oil
seal.
WARNING
Be sure to use a new output flange oil seal.
(d) Install 2 output flange oil seals.
(e) Using snap ring pliers, install 2 snap rings.

WARNING
Be sure to use new snap rings.
(f) Coat the grease on the surface mating with the oil seal.
(g) Insert 2 output flanges.
WARNING
Make sure the snap rings enter into the slots on the
differential gears.
20. INSTALL DIFFERENTIAL BEARING CAP.

(a) Positiong 2 differential bearing caps properly according
to the marks.
CAUTION 34
(b) Coat the sealant on 4 bolts.

(c) Tighten 4 bolts.
Torque: 85 N·m
21. INSPECT CROWN GEAR DEVIATION.

(a) Using dial indicator, measure the deviation at the surface 34
mating with differential case along the edge.
crown gear. (Refer to “Chapter 34 axle and propeller shaft -
NOTE
Measure the deviation by rotating the crown gear slowly.
22. INSPECT CONTACT AREA. (Refer to “Chapter 34 axle and propeller shaft - differential assy,
inspection and adjustment”)
23. INSPECT PRELOAD. (Refer to “Chapter 34 axle and propeller shaft - drive pinion, inspection”)
24. INSTALL REAR COVER.

(a) Coat the sealant on the mating surface of rear cover and
final drive housing.
(b) Position the rear cover properly.
(c) Coat the sealant on 8 bolts.

(d) Tighten 8 bolts by the sequence shown in the illustration.
25. INSTALL FINAL DRIVE ASSY. (Refer to “Chapter 34 axle and propeller shaft - final drive assy,
replacement”)
26. FILL FINAL DRIVE OIL. (Refer to “Chapter 34 axle and propeller shaft - final drive oil,
replacement”)
AXLE AND PROPELLER SHAFT - DRIVE PINION 34-89
DRIVE PINION
INSPECTION
34
1. INSPECT PINION FLANGE.
(a) Using dial indicator, measure the pinion flange back lash.
If the back lash is out of the specification, replace with new
pinion inner and outer bearing and collapsible spacer. (Refer to
“Chapter 34 axle and propeller shaft - drive pinion, overhaul”)
(b) Using dial indicator, measure the pinion flange deviation.

pinion flange. (Refer to “Chapter 34 axle and propeller shaft -
drive pinion, overhaul”)
2. INSPECT PRELOAD.
(a) Pry the lock plate out.
(b) Loosen the pinion nut.
34
(c) Tighten the pinion nut.

Torque: 196 N·m
34-90 AXLE AND PROPELLER SHAFT - DRIVE PINION
(d) Using a torque wrench, measure the primal rotating force

of drive pinion.
Primal rotating force: 1.3 ～ 2.2 N·m
WARNING
Never loosen the pinion nut to reduce the primal rotating
force of drive pinion.
NOTE
• If the primal rotating force is more than the
specification, replace with a new collapsible spacer.
(Refer to “Chapter 34 axle and propeller shaft - drive
pinion, overhaul”)
• If the primal rotating force is less than the
specification, perform the following operations.
(e) Tighten the pinion nut further.

Torque (Increment): 13 N·m
Torque (Maximum): 343 N·m
(f) Using a torque wrench, measure the primal rotating force

of drive pinion again.
NOTE
• If the primal rotating force is still less than the
specification, repeat step (e) ～ (f) until the primal
rotating force is within the specification.
specification when the pinion nut retaining torque
exceeds the maximum, replace with a new collapsible
spacer. (Refer to “Chapter 34 axle and propeller shaft -
(g) Fold the lock plate up.
34
34
OVERHAUL
1. PRECAUTION. (Refer to “Chapter 34 axle and propeller shaft - tranxaxle, precaution”)
2. DRAIN FINAL DRIVE OIL. (Refer to “Chapter 34 axle and propeller shaft - final drive oil,
replacement”)
3. REMOVE FINAL DRIVE ASSY. (Refer to “Chapter 34 axle and propeller shaft - final drive assy,
replacement”)
4. REMOVE DRIVE PINION.

(a) Pry the lock plate out.
(b) Loosen the pinion nut.
(c) Mark on the pinion flange and final drive housing.

CAUTION
(d) Using a puller, pull the pinion flange out.

(e) Remove the oil seal.

WARNING
Discard the removed oil seal.
34
(f) Remove the washer.
(g) Remove the pinion outer bearing.
34
(h) Remove the differential assy. (Refer to “Chapter 34 axle

and propeller shaft - differential assy, overhaul”)
(i) Remove the drive pinion.

(j) Remove the collapsible spacer.
(k) Remove the pinion inner bearing.
(l) Remove the drive pinion adjusting shim.
(m) Using hammer and copper rod, remove the pinion inner
and outer bearing cups inside the final drive housing.
5. INSPECT DRIVE PINION.

(a) Check tooth surface of the drive pinion for wear and tear, repair or replace it when necessary. (Refer to
“Chapter 34 axle and propeller shaft - differential assy, overhaul.”)
CAUTION
Be sure to replace with new drive pinion and crown gear together at the same time.
NOTE
• Repair it when there is only micro-crack on the tooth surface.
• Replace it when there is scoring, spalling, rusting, fracture or excessive wear on the tooth
surface.
(b) Check journal of the drive pinion for wear and tear.
If excessive wear is found, replace with new drive pinion and crown gear.
6. INSTALL DRIVE PINION.

(a) Using hammer and copper rod, install the pinion inner and outer bearing cup into the final drive
housing.
34
(b) Measure the thickness of drive pinion adjusting shim.
If the thickness is out of the specification, replace with a new drive
pinion adjusting shim. (Refer to “Chapter 34 axle and propeller
shaft - drive pinion, overhaul”)
(c) Install the drive pinion adjusting shim.
(d) Install the pinion inner bearing.
(e) Install the collapsible spacer.
34
(f) Insert the drive pinion.
(g) Install the differential assy. (Refer to “Chapter 34 axle and

propeller shaft - differential assy, overhaul”)
(h) Install the pinion outer bearing.
(i) Install the washer.
(j) Coat the grease on the oil seal lip.

(k) Coat the sealant on outer surface of oil seal.
(l) Coat the grease on inner surface of oil seal.
WARNING
Be sure to use a new oil seal.
(m) Install the oil seal.

(n) Install the pinion flange according to the marks.

CAUTION
34
(o) Tighten the pinion nut.

Torque: 196 N·m
(p) Using a torque wrench, measure the primal rotating force

of drive pinion. 34
WARNING
Never loosen the pinion nut to reduce the primal rotating
force of drive pinion.
NOTE
• If the primal rotating force is more than the
specification, replace with a new collapsible spacer.
(Refer to “Chapter 34 axle and propeller shaft - drive
pinion, overhaul”)
• If the primal rotating force is less than the
specification, perform the following operations.
(q) Tighten the pinion nut further.

Torque (Increment): 13 N·m
Torque (Maximum): 343 N·m
(r) Using a torque wrench, measure the primal rotating force

of drive pinion again.
NOTE
specification, repeat step (e) ～ (f) until the primal
rotating force is within the specification.
specification when the pinion nut retaining torque
exceeds the maximum, replace with a new collapsible
spacer. (Refer to “Chapter 34 axle and propeller shaft -
(s) Fold the lock plate up.
7. INSPECT PINION FLANGE.

(a) Using dial indicator, measure the pinion flange back lash.
If the back lash is out of the specification, replace with new
pinion inner and outer bearing and collapsible spacer. (Refer to
“Chapter 34 axle and propeller shaft - drive pinion, overhaul”)
(b) Using dial indicator, measure the pinion flange deviation.

pinion flange. (Refer to “Chapter 34 axle and propeller shaft -
8. INSPECT CONTACT AREA. (Refer to “Chapter 34 axle and propeller shaft - differentila assy,
inspection and adjustment”)
9. INSTALL FINAL DRIVE ASSY. (Refer to “Chapter 34 axle and propeller shaft - final drive assy,
replacement”) 34
10. FILL FINAL DRIVE OIL. (Refer to “Chapter 34 axle and propeller shaft - final drive oil,
replacement”)
34
MEMO
BRAKE
35
BRAKE SYSTEM ............................................................................... 35-1
PRECAUTION.............................................................................. 35-1
BRAKE FLUID.................................................................................... 35-4 35
BLEEDING ................................................................................... 35-4
BRAKE PEDAL .................................................................................. 35-6
COMPONENTS ........................................................................... 35-6
ADJUSTMENT ............................................................................. 35-7 35
REPLACEMENT .......................................................................... 35-9
BRAKE MASTER CYLINDER ASSY............................................... 35-13
COMPONENTS ......................................................................... 35-13
OVERHAUL ............................................................................... 35-14
BRAKE VACUUM BOOSTER ASSY............................................... 35-18
COMPONENTS ......................................................................... 35-18
REPLACEMENT ........................................................................ 35-21
FRONT BRAKE................................................................................ 35-24
COMPONENTS ......................................................................... 35-24
OVERHAUL ............................................................................... 35-25
REAR BRAKE .................................................................................. 35-36
COMPONENTS ......................................................................... 35-36
OVERHAUL ............................................................................... 35-38 35
ABS ACTUATOR ............................................................................. 35-51
COMPONENTS ......................................................................... 35-51
REPLACEMENT ........................................................................ 35-53
WHEEL SPEED SENSOR................................................................ 35-58
COMPONENTS ......................................................................... 35-58
REPLACEMENT ........................................................................ 35-59
11B
12B
14B
14B
15B
BRAKE - BRAKE SYSTEM 35-1
BRAKE SYSTEM
BRAKE
PRECAUTION
1. BRAKE SYSTEM CAUTION. 35
(a) Care must be taken to replace each part properly, because it could affect the performance of the brake
system and result in a driving hazard. Replace with the parts which have the same part number or
equivalent.
(b) It is very important to keep parts and the area clean when repairing the brake system.
(c) In order to prevent brake stive, be careful not to clean the part by sanding, dry brush or compressed air.
It should be cleaned by water-dipped towel.
35
35-2 BRAKE - BRAKE SYSTEM

cause of the problem. Check each part in order. If necessary, replace these parts
1. Brake fluid (Lacking) Chapter 35 brake - brake fluid, bleeding
2. Brake system (Leakage) -
3. Brake pad (Worn) Chapter 35 brake - front brake, overhaul

Low pedal or spongy pedal
4. Brake master cylinder assy Chapter 35 brake - brake master cylinder assy,
(Failure) overhaul
5. Brake system (Air in system) Chapter 35 brake - brake fluid, bleeding
6. Brake caliper (Failure) Chapter 35 brake - front brake, overhaul
1. Brake system (Air in system) -
2. Brake cylinder (Sticking) Chapter 35 brake - rear brake, overhaul
3. Brake caliper (Sticking) Chapter 35 brake - front brake, overhaul

Brake drag Chapter 34 axle and propeller shaft - wheel
4. Axle hub bearing (Loose) axle hub assy and front axle assy, on vehicle
inspection
5. Brake pedal free play Chapter 35 brake - brake pedal, adjustment

(Undersize)

1. Tire (Improperly inflated) system, on vehicle inspection
2. Brake shoe (Oily) -
3. Brake shoe (Worn) Chapter 35 brake - rear brake, overhaul
4. Brake pad (Oily) -

Pull to one side
6. Disk (Warping) Chapter 35 brake - front brake, overhaul
7. Brake drum (Warping) Chapter 35 brake - front brake, overhaul
8. Brake caliper (Brake force Chapter 35 brake - front brake, overhaul

unequal)
9. Brake cylinder (Brake force Chapter 35 brake - rear brake, overhaul

unequal)
2. Brake caliper (Bolt loose) Chapter 35 brake - front brake, overhaul
Braking instability 3. Brake caliper mounting (Bolt Chapter 35 brake - front brake, overhaul
loose)
4. Brake caliper (Sticking) Chapter 35 brake - front brake, overhaul
5. Brake cylinder (Sticking) Chapter 35 brake - rear brake, overhaul

BRAKE - BRAKE SYSTEM 35-3
Lack of braking force 2. Brake shoe (Worn) Chapter 35 brake - rear brake, overhaul 35
3. Brake system (Air in system) Chapter 35 brake - brake fluid, bleeding
35
35-4 BRAKE - BRAKE FLUID
BRAKE FLUID
BLEEDING
NOTE
• If any work is done on the brake system or if air in the brake line is suspected, bleed the air from
the system.
• Be careful not to splash the brake fluid to person and painted surface, otherwise it must be
washed off immediately.
1. FILL THE FLUID RESERVOIR WITH BRAKE FLUID.

Brake fluid: DOT3
NOTE
Be careful not to splash the brake fluid to person and
painted surface, otherwise it must be washed off
immediately.
2. BLEED BRAKE MASTER CYLINDER ASSY.

NOTE
If the brake cylinder has been removed or if the brake fluid
reservoir assy becomes empty, bleed the air from the
master cylinder assy.
(a) Disconnect the brake lines from the brake master
cylinder.
(b) Slowly depress the brake pedal and hold it.
(c) Block off the outer holes with fingers, and release the
brake pedal.
(d) Repeat step (b) and (c) 3 or 4 times until all the air in the
fluid has been bled out.
BRAKE - BRAKE FLUID 35-5
3. BLEED BRAKE LINE.

(a) Connect the hose to the bleeding plug of front disk brake
caliper.
(b) Depress the brake pedal several times, then loosen the 35
bleeding plug.
(c) When brake fluid stops coming out, tighten the bleeding
plug, then release the brake pedal.
Torque: 5.8 ~ 9.8 N•m
(d) Repeat step (b) and (c) 3 or 4 times until all the air in the
(e) Connect the hose to the bleeding plug of rear wheel

brake cylinder.
(f) Depress the brake pedal several times, then loosen the
bleeding plug.
(g) When brake fluid stops coming out, tighten the bleeding
plug, then release the brake pedal.
Torque: 5.8 ~ 9.8 N•m
(h) Repeat step (f) and (g) 3 or 4 times until all the air in the
(i) Repeat the above procedures to bleed the air out of the 35
brake line for each wheel.
4. CHECK FLUID LEVEL IN BRAKE FLUID RESERVOIR.

(a) Check the fluid level and fill the fluid reservoir with brake
fluid if necessary.
Brake fluid: DOT3
35-6 BRAKE - BRAKE PEDAL
BRAKE PEDAL
COMPONENTS
1 Bolt 6 Nut
2 Spring Washer 7 Bushing
3 Washer 8 Cotter Pin
4 Brake Pedal Support 9 Vacuum Booster Push Rod Pin
5 Brake Pedal Pin 10 Brake Pedal

BRAKE - BRAKE PEDAL 35-7
ADJUSTMENT
1. INSPECT BRAKE PEDAL HEIGHT.
(a) Inspect the height between brake pedal and floor L.
35
Specification: 125 ~ 135 mm
2. ADJUST BRAKE PEDAL HEIGHT.

(a) Remove stop lamp switch.(Refer to “Chapter 35 brake - brake pedal, replacement”)
(b) Disconnect the push rod from the brake pedal.(Refer to “Chapter 35 brake - brake pedal, replacement”)
(c) Loosen the lock nut, then adjust the brake pedal by
truning push rod clevis. Tighten the lock nut after
adjusting.
35
(d) Connect the push rod to the brake pedal.(Refer to

“Chapter 35 brake - brake pedal, replacement”)
(e) Install stop lamp switch. (Refer to “Chapter 35 brake -
brake pedal, replacement”)
(f) Push the brake pedal down about 5 ~ 10 mm and turn
the stop lamp switch in the position where the stop lamp
goes off, then tighten the lock nut.
(g) After installing, check that stop lamp comes on when
depressing the brake pedal about 5 ~ 10 mm.
3. INSPECT BRAKE PEDAL FREE PLAY.

(a) Stop the engine and depress the brake pedal several
times until there is no more vacuum left in the vacuum
booster.
(b) Depress brake pedal until the pedal resistance begin to
be felt, then inspect the brake pedal free play L.
(c) Measure the brake pedal free play
Specification: 5 ~ 10 mm
4. INSPECT BRAKE PEDAL RESERVE DISTANCE.

(a) Release the parking brake operation handle.
(b) With engine running, depress the brake pedal at 490 N
and then measure the brake pedal reserve distance.
Specification: ≥ 75 mm
NOTE
If brake pedal reserve distance is not incorrect, inspect the
brake syetem.
REPLACEMENT
1. REMOVE VACUUM BOOSTER PUSH ROD PIN.
(a) Remove the cotter pin from vacuum booster push rod 35
pin.
(b) Remove vacuum booster push rod pin and bushing and
then disconnect the push rod clevis from brake pedal.
35
2. REMOVE STOP LAMP SWITCH.

(a) Disconnect the connector from stop lamp switch.
(b) Loosen the lock nut of stop lamp switch.
(c) Remove the stop lamp switch.
3. REMOVE BRAKE PEDAL PIN AND BUSHING.
4. REMOVE BRAKE PEDAL.

5. INSTALL BRAKE PEDAL PIN AND BUSHING.

NOTE
Apply grease to the bushing before installing it.
Grease: Mitsubishi genuine grease Part NO:0101011 35
or equivalent.
6. INSTALL STOP LAMP SWITCH.

(a) Install stop lamp switch and tighten the nut lock of stop
lamp switch.
35
(b) Connect the connector to stop lamp switch.
(c) Adjust the distance between stop lamp and brake pedal.(Refer to “Chapter 35 brake - brake pedal,
adjustment”)
7. INSTALL VACUUM BOOSTER PUSH ROD PIN.

(a) Connect the push rod clevis to brake pedal and then
install vacuum booster push rod pin and bushing.
(b) Install the cotter pin to vacuum booster push rod pin.
8. INSPECT AND ADJUST BRAKE PEDAL HEIGHT. (Refer to “Chapter 35 brake - brake pedal,
adjustment”)
9. INSPECT BRAKE PEDAL FREE PLAY. (Refer to “Chapter 35 brake - brake pedal, adjustment”)
10. INSPECT BRAKE PEDAL RESERVE DISTANCE. (Refer to “Chapter 35 brake - brake pedal,
adjustment”)
BRAKE - BRAKE MASTER CYLINDER ASSY 35-13
BRAKE MASTER CYLINDER ASSY

COMPONENTS
35
35
1 Brake Fluid Reservoir Assy 4 Clamp
2 Brake Master Cylinder Assy 5 Vacuum Booster Assy
3 Vacuum Hose
35-14 BRAKE - BRAKE MASTER CYLINDER ASSY
OVERHAUL
1. DRAIN BRAKE FLUID COMPLETELY.
NOTE
Be careful not to splash the brake fluid to person and painted surface, otherwise it must be washed off
immediately.
2. REMOVE BRAKE MASTER CYLINDER ASSY.

(a) Remove the clamp and hose of brake fluid reservoir
assy.
(b) Remove the clip and disconnect the connector from

brake fluid level sensor.
(c) Loosen 2 nuts and disconnect 2 brake master cylinder

tubes from brake master cylinder.
(d) Remove 2 nuts and brake master cylinder assy.

3. REMOVE BRAKE FLUID RESERVOIR ASSY.

(a) Remove the screw of brake fluid reservoir assy.
35
(b) Remove the brake fluid reservoir assy.
4. DISASSEMBLE BRAKE MASTER CYLINDER ASSY.

(a) Hold the brake master cylinder in the vise. Push in the
piston and remove the snap ring with snap ring pliers.
35
(b) Remove the limiting bolt and washer.

(c) Pull out 2 pistons and springs horizontally.
NOTE
Pull straight out not with an angle or the piston cylinder
bore may be damaged.
5. INSPECT BRAKE MASTER CYLINDER.

(a) Check the cylinder bore for rust or scoring.
6. Clear up each part of brake master cylinder assy.

35-16 BRAKE - BRAKE MASTER CYLINDER ASSY
7. ASSEMBLE BRAKE MASTER CYLINDER ASSY.

(a) Apply grease to the piston. Hold the brake master
cylinder in the vise and install 2 springs and pistons.
NOTE
Push straight in not with an angle or the piston cylinder
bore may be damaged.
(b) Install the limiting bolt and washer.
(c) Push in the piston and install the snap ring with snap ring
pliers.
8. INSTALL BRAKE FLUID RESERVOIR ASSY.

(a) Install the brake fluid reservoir assy.
(b) Tighten the screw of brake fluid reservoir.
Torque: 3 ~ 5 N•m
9. INSTALL BRAKE MASTER CYLINDER ASSY.

(a) Position brake master cylinder properly and then tighten
2 nuts of brake master cylinder assy.
(b) Connect 2 brake master cylinder tubes to brake master

cylinder and then tighten 2 nuts.
(c) Connect the connector to brake fluid level sensor.
35
(d) Install the hose of brake fluid reservoir assy and clamp.
10. FILL THE FLUID RESERVOIR WITH BRAKE FLUID. (Refer to “Chapter 35 brake - brake fluid,
bleeding”)
11. BLEED BRAKE MASTER CYLINDER ASSY. (Refer to “Chapter 35 brake - brake fluid, bleeding”)
12. BLEED BRAKE LINE. (Refer to “Chapter 35 brake - brake fluid, bleeding”)
13. CHECK FLUID LEVEL IN BRAKE FLUID RESERVOIR. (Refer to “Chapter 35 brake - brake fluid, 35
bleeding”)
14. CHECK BRAKE FLUID FOR LEAKAGE.
35-18 BRAKE - BRAKE VACUUM BOOSTER ASSY
BRAKE VACUUM BOOSTER ASSY

COMPONENTS
1 Brake Fluid Reserve Assy 4 Washer
2 Brake Master Cylinder Assy 5 Nut
3 Vacuum Booster Assy

BRAKE - BRAKE VACUUM BOOSTER ASSY 35-19
1. INSPECT BRAKE VACUUM BOOSTER FOR AIRTIGHTNESS.
(a) Start the engine and stop it after 1 or 2 minutes. Depress 35
the brake pedal several times slowly.
NOTE
If the pedal goes down farthest at the 1st time, but gradually
rises after the 2nd or 3rd time, the booster is operating
properly.
(b) Depress the brake pedal while the engine is running, and
stop the engine with the pedal depressed.
NOTE
If there is no change in the pedal reserve distance after
holding the pedal for 30 seconds, the booster is operating
properly.
2. OPERATION CHECK.
(a) Turn the ignition switch LOCK and then depress the
brake pedal several times. Check that there is no change
in the pedal reserve distance.
(b) Depress the pedal and start the engine.
NOTE
If the pedal goes down slightly, the booster is operating
properly.
35
3. INSPECT VACUUM CHECK VALVE.

(a) Remove the clamp and vaccum hose.
(b) Remove the vaccum check valve.

(c) Check that there is ventilation from the booster to engine,

and no ventilation from the engine to the booster. If any
fault is found, replace with a new part.
REPLACEMENT
NOTE 35
immediately.
2. REMOVE BRAKE FLUID RESERVOIR HOSE.
3. REMOVE VACUUM HOSE.

(a) Remove the clamp and vacuum hose.
(b) Remove the vaccum check valve.
35
4. REMOVE BRAKE MASTER CYLINDER ASSY. (Refer to “Chapter 35 brake - brake master
cylinder assy, overhaul”)
5. REMOVE BRAKE VACUUM BOOSTER ASSY.

(a) Disconnect the push rod clevis from brake pedal. (Refer to “Chapter 35 brake - brake pedal, overhaul”)
(b) Remove 4 nuts from brake vacuum booster.

(c) Remove brake vacuum booster assy.
6. INSTALL BRAKE VACUUM BOOSTER ASSY.

(a) Tighten 4 nuts of brake vacuum booster assy.
(b) Connect the push rod clevis to brake pedal. (Refer to

“Chapter 35 brake - brake pedal, overhaul”)
7. INSTALL BRAKE MASTER CYLINDER ASSY. (Refer to “Chapter 35 brake - brake master cylinder
assy, overhaul”)
8. INSTALL VACUUM HOSE.

(a) Install the vaccum check valve.
(b) Install the vacuum hose and clamp.

9. INSTALL BRAKE FLUID RESERVOIR HOSE.

bleeding”) 35
13. INSPECT AND ADJUST BRAKE PEDAL HEIGHT. (Refer to “Chapter 35 brake - brake pedal,
adjustment”)
14. INSPECT BRAKE PEDAL FREE PLAY. (Refer to “Chapter 35 brake - brake pedal, adjustment”)
15. INSPECT BRAKE PEDAL RESERVE DISTANCE. (Refer to “Chapter 35 brake - brake pedal,
adjustment”)
16. CHECK FLUID LEVEL IN BRAKE FLUID RESERVOIR. (Refer to “Chapter 35 brake - brake fluid,
bleeding”)
35
35-24 BRAKE - FRONT BRAKE
FRONT BRAKE
COMPONENTS
1 Front Axle Hub Grease Cap 8 Front Brake Disk
2 Front Axle Hub Nut Cover 9 Front Brake Caliper
3 Cotter Pin 10 Washer
4 Front Axle Hub Nut 11 Plug
5 Front Axle Hub Washer 12 Brake Tube
6 Front Axle Hub Bearing 13 Bolt
7 Front Axle Hub

BRAKE - FRONT BRAKE 35-25
OVERHAUL
1. REMOVE FRONT WHEEL LH. (Refer to “Chapter 33 tire and wheel - front tire and wheel,
replacement”)
35
NOTE
immediately.
3. REMOVE FRONT DISK BRAKE CALIPER ASSY LH.

(a) Remove plug and brake fluid hose from front disk brake
caliper assy LH.
(b) Remove 2 nuts and front disk brake caliper assy LH.
35
4. REMOVE BRAKE PAD ASSY.

(a) Remove outer brake pad assy LH.
(b) Remove inner brake pad assy LH.
5. REMOVE FRONT DISK BRAKE CALIPER MOUNTING

LH.
(a) Remove 2 nuts and front disk brake caliper mounting LH.
6. DISASSEMBLE FRONT DISK BRAKE CALIPER ASSY

LH.
(a) Remove the set ring and dust boot.
(b) Remove the bleeding plug. 35
(c) Remove the piston from front disk brake caliper by using
compressed air.
NOTE
• Be careful not to place your fingers in front of the
piston when using compressed air.
• Be careful not to spatter the brake fluid.
(d) Remove the piston seal.
7. INSPECT BRAKE CYLINDER.

(a) Inspect the cylinder bore for rust or scuffing.
8. INSPECT PISTON.
35
(a) Inspect the piston for rust or scuffing.
9. INSPECT BRAKE PAD THICKNESS.

(a) Measure the brake pad thickness.
Specification: 10 mm
Ultimate value: 1.6 mm
10. INSPCET DISK THICKNESS.

(a) Measure the disk thickness.
Specification: 28 mm
11. REMOVE FRONT DISK.

(a) Make a mark on the front disk and front axle hub.
(b) Remove front axle hub cap.
(c) Remove the cotter pin.

(d) Remove the front axle nut cover.
35
(e) Remove the front axle hub nut.
35
(f) Remove the front axle hub washer.

(g) Remove the outer bearing of front axle hub.
(h) Remove front disk with front axle hub.

(i) Remove 6 bolts and front disk.
12. INSPECT FRONT DISC RUNOUT.

(a) Temporarily fasten the front disk with knuckle nut.
(b) Measure the disk runout at the position where is 10 mm
away from the outer edge of the disk.
(c) If the disk runout is the maximum value or is outside the
maximum value, inspect the clearance of axle hub and
axle hub runout. If the clearance of axle hub and axle
hub runout are nomal, adjust the disk runout or grind it on
a “On-vehical” brake lathe.
13. REMOVE FRONT BRAKE RH.

NOTE
35
14. INSTALL FRONT DISK.
NOTE
Select the installation position which the front disk has the
minimum runout.
(a) Install the front disk to front axle hub.
(b) Install front disk with front axle hub and the outer bearing
of front axle hub.
35
(c) Install the front axle hub washer.

(d) Tighten the front axle hub nut.

Torque: 150 ~180 N•m
(e) Install the front axle nut cover.
(f) Install the cotter pin.

NOTE
Install a new cotter pin.
(g) Install front axle hub cap.
35
15. CLEAN UP EACH PARTS OF FRONT DISK BRAKE CALIPER ASSY LH.
16. ASSEMBLE FRONT DISK BRAKE CALIPER ASSY LH.
(a) Install the piston seal.
NOTE
• Apply grease to the seal before installing it.
• Install a new oil seal to ensure great sealability.
(b) Instal the piston to front disk brake caliper.
NOTE
• Apply grease to the seal before installing it. 35
• Do not screw the piston forcedly in the disk brake cylinder.
(c) Install the dust boot and set ring.

NOTE
• Install the dust boot properly to the grooves of the
cylinder and piston.
• Be careful not to damage dust boot.
(d) Install the bleeding plug.

17. INSTALL FRONT DISK BRAKE CALIPER MOUNTING

LH.
(a) Install front disk brake caliper mounting LH with 2 nuts.
Torque: 100 ~ 120 N•m
18. INSTALL BRAKE PAD ASSY.

(a) Install inner brake pad assy LH.
NOTE
• Replace the anti-squeal shim when replacing the
brake pad.
• Keep the friction surface of brake pad and front disk
always away from oil and grease.
(b) Install outer brake pad assy LH.

NOTE
• Replace the anti-squeal shim when replacing the
brake pad.
• Keep the friction surface of brake pad and front disk
always away from oil and grease.
19. INSTALL FRONT DISK BRAKE CALIPER MOUNTING

LH.
(a) Install the front disk brake caliper assy LH properly and
tighten 2 nuts. 35
Torque: 100 ~ 120 N•m
(b) Install brake fluid hose and plug to disk brake caliper
assy LH.
35
20. INSTALL FRONT BRAKE RH.

NOTE
bleeding”)
bleeding”)
26. INSATLL FRONT WHEEL LH. (Refer to “Chapter 33 tire and wheel - front tire and wheel,
replacement”)
NOTE
35-36 BRAKE - REAR BRAKE
REAR BRAKE
COMPONENTS
1 Cotter Pin 12 C-washer
2 Hole Plug Rear Brake Automatic Adjusting Lever

13
Spring
3 Rear Axle Hub
14 Rear Brake Automatic Adjusting Lever
4 Rear Brake Backing Plate
15 Rear Brake Drum
5 Leading Shoe
16 Dust Boot
6 Parking Brake Shoe Strut Set
17 Piston
7 Hold Spring
18 Rubber Cover
8 Hole Spring Cover
19 Bolt
9 Return Spring
20 Rear Wheel Brake Cylinder
10 Trailing Shoe
21 Bleeding Plug
11 Parking Brake Shoe Lever
22 Spring
BRAKE - REAR BRAKE 35-37
1. INSPECT BRAKE SHOE THICKNESS.
(a) Remove the hole plug and measure the brake shoe 35
thickness through the hole.
35
OVERHAUL
1. RELEASE PARKING BRAKE.
2. REMOVE REAR WHEEL LH. (Refer to “Chapter 33 tire and wheel - rear tire and wheel,
replacement”)
NOTE
immediately.
4. REMOVE REAR BRAKE DRUM LH.

(a) Remove cotter pin.
(b) Remove rear axle nut cover.

(c) Remove rear axle hub nut.
35
(d) Remore rear brake drum LH.
35
5. REMOVE PARKING BRAKE SHOE TENSION SPRING.
(a) Remove parking brake shoe strut set and tension spring.
WARNING
Parking brake tension spring has a heavy spring force, be
careful not to be hurt when removing it.
(b) Remove parking brake tension spring from parking brake

shoe strut set.
6. REMOVE RETURN SPRING.
7. REMOVE LEADING SHOE.

(a) Remove leading shoe hold spring.
WARNING
Leading shoe hold spring has a heavy spring force, be
(b) Remove leading shoe.

Specification: 6.0 mm
CAUTION
If the thickness is at the minimum thickness or less, or if it
appears severe uneven wear, replace the brake shoe with a
new part.
9. REMOVE TRAILING SHOE.

(a) Remove trailing shoe hold spring.
WARNING
Trailing shoe hold spring has a heavy spring force, be
35
(b) Remove rear parking brake cable assy LH.
35
(c) Remove trailing shoe.
10. REMOVE REAR BRAKE AUTOMATIC ADJUSTING

LEVER AND PARKING BRAKE SHOE LEVER.
(a) Remove automatic adjusting spring.
(b) Remove C-washer.

(c) Remove rear brake automatic adjusting lever.
(d) Remove rear brake shoe lever.

CAUTION
If the thickness is at the minimum thickness or less, or if it
appears severe uneven wear, replace the brake shoe with a
new part.
12. INSPECT REAR BRAKE DRUM INSIDE DIAMETER.

Ultimate value: 270 mm
CAUTION
If the inside diameter is outside ultimate value, replace the
rear brake drum with a new part.
13. INSPECT REAR BRAKE DRUM AND BRAKE SHOE

FOR PROPER CONTACT.
(a) Apply chalk to the inside surface of the rear brake drum,
then grind brake shoe on the surface of the drum. If the 35
contact between the rear brake drum and the brake shoe
is improper, repair brake shoe by a brake shoe grinder or
replace the rear brake drum.
14. REMOVE REAR WHEEL BRAKE CYLINDER ASSY

LH.
(a) Loosen the nut and disconnect the brake fluid tube from
rear wheel brake cylinder.
35
(b) Remove the bleeding plug from rear wheel brake
cylinder.
(c) Remove 2 bolts from rear wheel brake cylinder.
(d) Remove rear wheel brake cylinder.
15. INSTALL REAR WHEEL BRAKE CYLINDER ASSY LH.

(a) Install 2 bolts to rear wheel brake cylinder.
(b) Install the bleeding plug to rear wheel brake cylinder.

Torque: 5.88 ~ 9.8 N•m
35
(c) Connect the brake fluid tube to rear wheel brake cylinder
and tighten the nut.
35
16. INSTALL REAR BRAKE AUTOMATIC ADJUSTING

LEVER AND PARKING BRAKE SHOE LEVER.
(a) Install rear brake shoe lever.
(b) Install rear brake automatic adjusting lever.
(c) Install C-washer.
(d) Install automatic adjusting spring.
17. INSTALL TRAILING SHOE.

(a) Install rear parking brake cable assy LH.
(b) Install trailing shoe.
(c) Install trailing shoe hold spring.

WARNING
Trailing shoe hold spring has a heavy spring force, be
careful not to be hurt when installing it.
CAUTION
Apply the heat resisting grease to friction surface between
brake shoe and brake bottom plate before installing.
18. INSTALL LEADING SHOE.

(a) Install leading shoe.
(b) Install leading shoe hold spring.
35
WARNING
Leading shoe hold spring has a heavy spring force, be
careful not to be hurt when installing it.
CAUTION
Apply the heat resisting grease to friction surface between
brake shoe and brake bottom plate before installing.
19. INSTALL RETURN SPRING.
35
20. INSTALL PARKING BRAKE SHOE TENSION SPRING.
(a) Assemble parking brake shoe strut set.
CAUTION
Apply the heat resisting grease to the position as arrows
show.
(b) Install parking brake tension spring to parking brake shoe

strut set.
(c) Install parking brake shoe strut set with tension spring to
brake shoes.
WARNING
Parking brake tension spring has a heavy spring force, be
21. INSTALL REAR BRAKE DRUM LH.

(a) Install rear brake drum LH.
(b) Tighten rear axle hub nut.

Torque: 320 ~ 350 N•m
(c) Install rear axle nut cover.

(d) Install cotter pin.

NOTE
Install a new cotter pin.
35
22. INSPECT BRAKE SHOES AND REAR BRAKE DRUM

INSTALLATION.
(a) Check that each part is installed properly.
(b) Measure the inside diameter of rear brake drum and the
diameter of brake shoes. Inspect the clearance between
rear brake drum and brake shoes.
Specification: 0.2 ~ 0.5 mm
NOTE
There should be no oil or grease adhering to the friction
surface between brake shoe and rear brake drum. 35
23. ADJUST CLEARANCE BETWEEN REAR BRAKE

DRUM AND BRAKE SHOES.
(a) Remove the hole plug.
(b) Adjust the clearance between brake shoes and rear
brake drum.
24. INSTALL REAR BRAKE DRUM RH.

NOTE
bleeding”)
bleeding”)
30. INSTALL REAR WHEEL LH. (Refer to “Chapter 33 tire and wheel - rear tire and wheel,
replacement”)
31. INSPECT PARKING BRAKE OPERATION HANDLE STROKE. (Refer to “Chapter 36 parking brake
- parking brake system, adjustment”)
32. ADJUST PARKING BRAKE OPERATION HANDLE STROKE. (Refer to “Chapter 36 parking brake
BRAKE - ABS ACTUATOR 35-51
ABS ACTUATOR
COMPONENTS
35
35
35-52 BRAKE - ABS ACTUATOR
1 Front Wheel Speed Sensor 5 ABS Support
2 ABS Connecting Oil Pipe Assy 6 Rear Wheel Speed Sensor
3 Actuator 7 Bolt
4 Pipe Clamp
REPLACEMENT
35
NOTE
immediately.
3. REMOVE FRONT BUMPER ASSY. (Refer to”Chapter 88 exterior and interiore trim - front bumper
assy, replacement)
4. REMOVE FRONT COMBINATION LAMP ASSY RH. (Refer to “Chapter 64 lighting - front
combinationg lamp assy LH, replacement”)
5. REMOVE INTAKE AIR FILTER ASSY. (Refer to “Chapter 14 intake air - intake air filter assy,
replacement”)
6. REMOVE ABS ACTUATOR.

(a) Disconnect the connector from ABS actuator.
35
(b) Disconnect the ABS connecting fluid pipe assy from ABS
actuator.
NOTE
Make marks on the ABS actuator connecting fluid pipe assy
in order to install them properly.
(c) Remove the blot and pipe clamp.
(d) Remove the bolt of ABS actuator by right side.
(e) Remove the bolt of ABS actuator by left side.

(f) Remove the bolt of ABS actuator by downside.
35
(g) Remove the ABS actuator with ABS support assy.
7. INSTALL ABS ACTUATOR.

(a) Install the bolt of ABS actuator by left side.
35
(b) Install the bolt of ABS actuator by right side.

(c) Install the bolt of ABS actuator by downside.
(d) Connect the ABS connecting fluid pipe assy to ABS

actuator as the marks show.
(e) Install the pipe clamp and blot .

(f) Connect the connector to ABS actuator.
35
8. INSTALL INTAKE AIR FILTER ASSY. (Refer to “Chapter 14 intake air - intake air filter assy,
replacement”)
9. INSTALL FRONT COMBINATION LAMP ASSY RH. (Refer to “Chapter 64 lighting - front
combination lamp assy LH, replacement”)
10. INSTALL FRONT BUMPER ASSY. (Refer to”Chapter 88 exterior and interiore trim - front bumper
assy, replacement)
bleeding”) 35
bleeding”)
17. INSPECT ABS ACTUATOT BY SCAN TOOL. (Refer to “Chapter 04 diagnostics - anti-lock brake
system, pre-check”)
35-58 BRAKE - WHEEL SPEED SENSOR
WHEEL SPEED SENSOR

COMPONENTS
1 Front Wheel Speed Sensor RH 3 Rear Wheel Speed Sensor RH
2 Fron Wheel Speed Sensor LH 4 Rear Wheel Speed Sensor LH

BRAKE - WHEEL SPEED SENSOR 35-59
REPLACEMENT
1. REMOVE FRONT WHEEL SPEED SENSOR LH.
(a) Remove the bolt of front wheel speed sensor LH. 35
(b) Remove front wheel speed sensor LH.
(c) Disconnect the connector of front wheel speed sensor

LH.
35
2. REMOVE REAR WHEEL SPEED SENSOR LH.

(a) Remove the bolt of rear wheel speed sensor LH.
(b) Remove rear wheel speed sensor LH.
(c) Remove clamps of rear wheel speed sensor LH.

(d) Disconnect the connector of rear wheel speed sensor

LH.
35
3. INSTALL REAR WHEEL SPEED SENSOR LH.

(a) Connect the connector of rear wheel speed sensor LH.
(b) Install clamps of rear wheel speed sensor LH.
35
(c) Position rear wheel speed sensor LH properly.

(d) Tighten the bolt of rear wheel speed sensor LH.

4. INSTALL FRONT WHEEL SPEED SENSOR LH.

(a) Position front wheel speed sensor LH properly.
(b) Tighten the bolt of front wheel speed sensor LH.

(c) Connect the connector of front wheel speed sensor LH.
35
5. CHECK WHEEL SPEED SENSOR SIGNAL. (Refer to “Chapter 04 diagnostics - anti-lock brake
system, C0200”, “Chapter 04 diagnostics - anti-lock brake system, C0205”, “Refer to “Chapter
04 diagnostics - anti-lock brake system, C0210”, “Refer to “Chapter 04 diagnostics - anti-lock
brake system, C0215”)
35
MEMO
PARKING BRAKE
36
PARKING BRAKE SYSTEM.............................................................. 36-1
ADJUSTMENT ............................................................................. 36-2
PARKING BRAKE OPERATION HANDLE ASSY ............................ 36-3 36
COMPONENTS ........................................................................... 36-3
REPLACEMENT .......................................................................... 36-4
PARKING BRAKE CABLE ASSY ..................................................... 36-7
COMPONENTS ........................................................................... 36-7 36
REPLACEMENT .......................................................................... 36-8
36
PARKING BRAKE - PARKING BRAKE SYSTEM 36-1
PARKING BRAKE SYSTEM

PARKING BRAKE

Use the table below to help you find the cause of the problem. The numbers indicate the priority of 36
the likely cause of the problem. Check each part in order. If necessary, replace these parts.
1. Parking brake operation handle Chapter 36 parking brake - parking brake

stroke (Maladjusted) system, adjustment
2. Parking brake pull cabel (Sticking) -
3. Parking brake shoe clearance Chapter 35 brake - rear brake, overhaul

(Maladjusted)
Brake drag
4. Return spring (Damaged) Chapter 35 brake - rear brake, overhaul
5. Parking brake tension spring Chapter 35 brake - rear brake, overhaul

(Damaged)
6. Parking brake return spring Chapter 35 brake - rear brake, overhaul

(Damaged)
36
36-2 PARKING BRAKE - PARKING BRAKE SYSTEM
ADJUSTMENT
1. REMOVE FRONT WHEEL LH. (Refer to “Chapter 33 tire and wheel - front tire and wheel,
replacement”)
2. INSPECT BRAKE SHOES AND REAR BRAKE DRUM INSTALLATION. (Refer to “Chapter 35
brake - rear brake, overhaul”)
3. ADJUST CLEARANCE BETWEEN REAR BRAKE DRUM AND BRAKE SHOES. (Refer to “Chapter
35 brake - rear brake, overhaul”)
4. INSTALL FRONT WHEEL LH. (Refer to “Chapter 33 tire and wheel - front tire and wheel,
replacement”)
5. INSPECT PARKING BRAKE OPERATION HANDLE STROKE.
(a) Pull the parking brake operation handle to the fully applied position, and count the number of clicks.
PARKING BRAKE OPERATION HANDLE STROKE: Pull slowly the parking brake operation
handle at 294 N. Parking brake will completely function and produce specific brake force when
2/3 operation control (9 ~ 11 clicks).
WARNNING
ADJUST PARKING BRAKE OPERATION HANDLE STROKE IF NECESSARY.
6. ADJUST PARKING BRAKE OPERATION HANDLE

STROKE.
(a) Remove middle platform. (Refer to “Chapter 83
instrument panel - middle paltform, replacement”)
(b) Remove the adjusting nut of front parking brake cable
until the parking brake operation handle stroke is correct.
(c) Install middle platform. (Refer to “Chapter 83 instrument
panel - middle paltform, replacement”)
PARKING BRAKE - PARKING BRAKE OPERATION HANDLE ASSY 36-3
PARKING BRAKE OPERATION HANDLE ASSY

COMPONENTS
36
1 Parking Brake Switch 4 Fixing Clip
2 Bolt 5 Parking Brake Front Cable Assy
3 Parking Brake Operation Handle Assy

36
36-4 PARKING BRAKE - PARKING BRAKE OPERATION HANDLE ASSY
REPLACEMENT
1. REMOVE MIDDLE PLATFORM. (Refer to “Chapter 83 instrument panel - middle platform,
replacement”)
2. REMOVE FRONT PARKING BRAKE CABLE.

(a) Remove the adjusting nut of front parking brake cable.
(b) Remove the clip and disconnect the front parking brake
cable from parking brake operation handle assy, then
remove the front parking brake cable.
3. DISCONNECT PARKING BRAKE SWITCH CONNECTOR

FROM PARKING BRAKE SWITCH.
4. REMOVE PARKING BRAKE SWITCH.

(a) Remove the screw and parking brake switch.
PARKING BRAKE - PARKING BRAKE OPERATION HANDLE ASSY 36-5
5. REMOVE PARKING BRAKE OPERATION HANDLE

ASSY.
(a) Loosen 2 bolts of parking brake operation handle assy.
(b) Remove parking brake operation handle assy. 36
6. INSTALL PARKING BRAKE OPERATION HANDLE

ASSY.
(a) Position parking brake operation handle assy properly,
then tighten 2 bolts of parking brake operation handle
assy.
36
7. INSTALL PARKING BRAKE SWITCH.

(a) Position parking brake switch properly, then tighten the
screw.
8. CONNECT PARKING BRAKE SWITCH CONNECTOR

TO PARKING BRAKE SWITCH.
36-6 PARKING BRAKE - PARKING BRAKE OPERATION HANDLE ASSY
9. INSTALL FRONT PARKING BRAKE CABLE.

(a) Install front parking brake cable and connect front
parking brake cable to parking brake operation handle
assy, then install the clip.
(b) Install front parking brake cable assy and tighten the
adjusting nut.
12. INSTALL MIDDLE PLATFORM. (Refer to “Chapter 83 instrument panel - middle paltform, replace-
ment”)
PARKING BRAKE - PARKING BRAKE CABLE ASSY 36-7
PARKING BRAKE CABLE ASSY

COMPONENTS
36
36
1 Bolt 6 Return Spring
2 Parking Brake Operation Handle Assy 7 Middle Pull Rod And Bracket Assy
3 Fixing Clip 8 Parking Brake Rear Cable Assy LH
4 Parking Brake Front Cable Assy 9 Parking Brake Rear Cable Assy RH
5 Fixing Clip
36-8 PARKING BRAKE - PARKING BRAKE CABLE ASSY
REPLACEMENT
1. REMOVE FRONT PARKING BRAKE CABLE ASSY.
(a) Disconnect the front parking brake cable from parking brake operation handle assy. (Refer to” Chapter
36 parking brake - parking brake operation handle assy, replacement”)
(b) Remove the clip of front parking brake cable.
(c) Disconnect front parking brake cable from middle pull rod
with bracket assy.
(d) Remove front parking brake cable assy.
2. REMOVE REAR PARKING BRAKE CABLE ASSY LH.

(a) Remove clips and disconnect the rear parking brake cable assy LH from middle pull rod with bracket
assy.
36
(b) Disconnect rear parking brake cable assy LH from brake

shoe LH. (Refer to “Chapter 35 brake - rear brake,
overhaul”)
36
(c) Loosen 2 bolts, then disconnect rear parking brake cable
assy LH from brake bottom plate.
(d) Remove rear parking brake cable assy LH.
3. INSTALL REAR PARKING BRAKE CABLE ASSY LH.

(a) Connect rear parking brake cable assy LH to brake
bottom plate, then tighten 2 bolts.
(b) Connect rear parking brake cable assy LH from brake

shoe LH. (Refer to “Chapter 35 brake - rear brake,
overhaul”)
(c) Install clips and connect the rear parking brake cable
assy LH to middle pull rod with bracket assy.
36-10 PARKING BRAKE - PARKING BRAKE CABLE ASSY
4. INSTALL FRONT PARKING BRAKE CABLE ASSY.

(a) Connect front parking brake cable to middle pull rod with
bracket assy.
(b) Install the clip of front parking brake cable.
(c) Connect the front parking brake cable to parking brake

operation handle assy. (Refer to “Chapter 36 parking
brake - parking brake operation handle assy,
replacement”)
5. ADJUST CLEARANCE BETWEEN REAR BRAKE DRUM AND BRAKE SHOES. (Refer to “Chapter
35 brake - rear brake, overhaul”)
- parking brake system, adjustment”) 36
36
MEMO
TRANSMISSION
41A
TRANSMISSION OPERATION MECHANISM ASSY ...................... 41A-1
COMPONENTS ......................................................................... 41A-1
REPLACEMENT ........................................................................ 41A-2
TRANSMISSION ASSY.................................................................... 41A-6 41A
COMPONENTS ......................................................................... 41A-8
REPLACEMENT ...................................................................... 41A-11
OVERHAUL ............................................................................. 41A-17 41A
OUTPUT SHAFT ............................................................................ 41A-53
COMPONENTS ....................................................................... 41A-53
OVERHAUL ............................................................................. 41A-55
COUNTER SHAFT ......................................................................... 41A-66
COMPONENTS ....................................................................... 41A-66
REPLACEMENT ...................................................................... 41A-67
INPUT SHAFT AND REVERSE IDLER GEAR SHAFT ................. 41A-69
COMPONENTS ....................................................................... 41A-69
REPLACEMENT ...................................................................... 41A-70
41A
TRANSMISSION (R5M21-Z-GBA5) - TRANSMISSION OPERATION MECHANISM ASSY 41A-1
TRANSMISSION OPERATION MECHANISM ASSY

TRANSMISSION (R5M21-Z-GBA5)
COMPONENTS
41A
41A
Transmission Operation Mechanism 9 Nut

1
Handle Assy
10 Bolt
2 Dust Boot
11 Fixing Rod Bracket Assy
3 Transmission Operation Mechanism Assy
12 Fixing Rod Assy
4 Bolt
13 Washer
5 Return Spring
14 Spring Washer
6 Gearshift Connecting Rod Assy
15 Nut
7 Nut
8 Gear Selector Connecting Rod Assy

41A-2 TRANSMISSION (R5M21-Z-GBA5) - TRANSMISSION OPERATION MECHANISM ASSY
REPLACEMENT
1. PARK VEHICLE ON LEVELGROUND WITH PARKING BRAKE AND STOP THE ENGINE.
2. REMOVE NUT AND DISCONNECT FIXING ROD ASSY

FROM TRANSMISSION OPERATION MECHANISM
ASSY.

WARNING
Adopt protective measures to prevent from injuring by
return spring when removing it.
4. DISCONNECT GEAR SELECTOR CONNECTING ROD

ASSY AND GEARSHIFT CONNECTING ROD ASSY
ASSY.
(a) Remove the nut and disconnect the gear selector
connecting rod assy from gear selector vertical arm.
NOTE
Tape the gear selector connecting rod and put it aside after
removing it.
(b) Remove the nut and disconnect the gearshift connecting

rod assy from gearshift vertical arm.
NOTE
Tape the gearshift connecting rod and put it aside after 41A
removing it.
5. REMOVE MIDDLE PLATFORM. (Refer to “Chapter 83 instrument panel - middle platform)
6. REMOVE TRANSMISSION OPERATION MECHANISM

ASSY.
(a) Remove 4 bolts and spring washers.
(b) Remove transmission operation mechanism assy. 41A
7. INSTALL TRANSMISSION OPERATION MECHANISM

ASSY.
(a) Install a new transmission operation mechanism assy.
(b) Install 4 bolts and spring washers.
41A-4 TRANSMISSION (R5M21-Z-GBA5) - TRANSMISSION OPERATION MECHANISM ASSY
8. CONNECT GEAR SELECTOR CONNECTING ROD

TO TRANSMISSION OPERATION MECHANISM ASSY.
(a) Connect the gear selector connecting rod assy to gear
selector vertical arm and tighten the nut.
NOTE
• Adjust the tip of gear selector connecting rod assy to
the proper length before installing it.
• Make sure that the transmission operation
mechanism is in neutral position before connecting
the gear selector connecting rod to it.
(b) Connect the gearshift connecting rod assy to gearshift

vertical arm and tighten the nut.
NOTE
• Make sure that the transmission operation
mechanism is in neutral position before connecting
the gearshift connecting rod to it.

WARNING
return spring when install it.
10. CONNECT FIXING ROD ASSY TO TRANSMISSION

OPERATION MECHANISM ASSY AND INSTALL NUT.
41A
11. INSPECT TRANSMISSION OPERATION MECHANIZE ASSY FOR SMOOTH SHIFTING.

12. INSTALL MIDDLE PLATFORM. (Refer to “Chapter 83 instrument panel - middle platform)
41A
41A-6 TRANSMISSION (R5M21-Z-GBA5) - TRANSMISSION ASSY
TRANSMISSION ASSY
Use the table below to help you find the cause of the problem. The numbers indicate the priority of
the likely cause of the problem. Check each part in order. If necessary, replace these parts. .
1. Transmission fluid (Low -

viscosity)
2. Transmission fluid (Level low) -
Chapter 41 transmission (ZM001AJ2) -

3. Bearing (Worn or damaged) transmission assy, overhaul

4. Gearshift fork and synchronizer transmission assy, overhaul
Noisy sleeve (Improper engagement) Chapter 41 transmission (ZM001AJ2) - output
shaft assy, overhaul

5. Synchronizer (Worn or transmission assy, overhaul
damaged) Chapter 41 transmission (ZM001AJ2) - output

6. Gear tooth (Damaged) transmission assy, overhaul
7. Transmission case (Warping) -
1. Transmission fluid (High -

viscosity)
Chapter 42 clutch - clutch pedal, adjustment

2. Clutch (Does not disengage) Chapter 42 clutch - clutch sub - assy, overhaul


Hard to shift or does transmission assy, overhaul
not shift 4. Synchronizer (Damaged) Chapter 41 transmission (ZM001AJ2) - output
5. Gearshift fork (Warping or Chapter 41 transmission (ZM001AJ2) -

damaged) transmission assy, overhaul

6. Gearshift (Warping or damaged) transmission assy, overhaul

7. Steel ball (Worn) transmission assy, overhaul
TRANSMISSION (R5M21-Z-GBA5) - TRANSMISSION ASSY 41A-7
1. Gear (Excessive radial Chapter 41 transmission (ZM001AJ2) -

clearance) transmission assy, overhaul
41A
2. Engage side (Worn) transmission assy, overhaul

transmission assy, overhaul
3. Synchronizer (Damaged) Chapter 41 transmission (ZM001AJ2) - output
Jump out of gear Chapter 41 transmission (ZM001AJ2) -
4. Bearing （Axial moving） transmission assy, overhaul
5. Gearshift fork (Warping or Chapter 41 transmission (ZM001AJ2) -

6. Locating spring (Failure or Chapter 41 transmission (ZM001AJ2) -



Erratic shifting 1. Inter-lock pin (Worn) transmission assy, overhaul 41A
1. Transmission fluid (Excess) -
2. Sealing parts (Failure or -

damaged)
Oil leakage -
3. Fastener (Loose)
5. Sealant (uneven) -
COMPONENTS
41A
41A
1 Output Shaft Gears 11 Control Adjuster
2 Counter Shaft Gears 12 Lock Nut
Reverse Idler Gear Shaft And Reverse 13 Limit Control Mechamism Assy
3
Idler Gear Sub-assy
Under Cover, Under Cover Gasket And
14
4 Extension Housing Sub-assy Drain Plug
5 Transmission Case Front Bearing Retainer And Inputshaft

15
Assy
6 Shift Mechanism
16 Washer
7 Poppet Plug
17 Counter Shaft Bearing Cap
8 Poppet Spring
18 Output Shaft Middle Bearing
9 Steel Ball
19 Output Shaft
10 O-sealing Ring
20 Counter Shaft
REPLACEMENT
1. STOP THE ENGINE. PARK VEHICLE ON LEVELGROUND WITH PARKING BRAKE AND SHIFT IN
NEUTRAL POSITION.
41A
3. REMOVE DRAIN PLUG BY DOWNSIDE AND DRAIN

TRANSMISSION FLUID COMPLETELY. TIGHTEN
DRAIN PLUG.
NOTE
• Keep vent plug unblocked and loosen the filler plug
before draining fluid. In order to drain transmission
fluid completely, drain the fluid when it is hot.
• Use container for transmission fluid when draining.
4. DISCONNECT TRANSMISSION ASSY FROM OTHER 41A

PARTS.
(a) Disconnect gear selector connecting rod from
transmission assy.
NOTE
removing it.
(b) Disconnect gearshift connecting rod from transmission

assy.
NOTE
Tape the gearshift connecting rod and put it aside after
removing it.
(c) Remove clutch slave cylinder assy. (Refer to “Chapter 42

clutch - clutch slave cylinder assy, overhaul”)
(d) Remove back-up lamp switch.
(e) Remove odometer sensor.
(f) Remove propeller shaft assy. (Refer to “Chapter 34 axle

and propeller shaft - propeller shaft assy, overhaul”)
(g) Remove 4 nuts and disconnect the transmission from

lifting lug.
WARNING
Use jack to support transmission assy and adopt protective
measures to prevent from injuring before operation.
(h) Remove 2 bolts and disconnect the exhaust pipe from

transmission assy.
WARNING
Be careful not to be scalded by exhaust pipe. 41A
(i) Remove 8 nuts and disconnect transmission assy from

engine. Remove the transmission assy.
5. CONNECT OTHER PARTS TO TRANSMISSION ASSY.

41A
(a) Support the transmission assy by jack and shift in one of
forward gears. Rotate the input shaft and align with the
spline of clutch disk at the same time. Then insert the
input shaft completely and shift in neutral position.
WARNING
Adopt protective measures to prevent from injuring when
supporting by jack.
(b) Install 8 bolts by hand.
(c) Support the transmission assy by jack and connect the

transmission assy to lifting lug. Install 4 bolts by hand.
WARNING
supporting by jack.
(d) Tighten 4 nuts of lifting lug.
(e) Connect transmission assy to engine and tighten 8 bolts.
NOTE
Diagonally tighten all bolts in order to combined closely.
(f) Connect the exhaust pipe to the transmission assy and

tighten 2 bolts.
(g) Install propeller shaft assy. (Refer to “Chapter 34 axle

(h) Install odometer sensor.
(i) Install back-up switch.
(j) Install clutch slave cylinder assy. (Refer to “Chapter 42

(k) Connect gearshift connecting rod to transmission assy.

41A
(l) Connect gear selector connecting rod to transmission

assy.
41A
6. FILL TRANSMISSION FLUID AND TIGNTEN FILLER

PLUG.
Torque: 34.3 ~ 39.4 N•m
CAUTION
• According to demand to fill transmission fluid GL-5 75W/
90, GL-5 80w/90 or GL-5 85W/90 for 2.0 L.
• Do not to mix different kind of transmission fluid.
• Parking the vehicle on the levelground when checking fluid
level. The fluid level must be with in 5 mm from the lowest
position of the filler plug.
7. TRANSMISSION RUNNING-IN TEST.

(a) Keep the rotate speed around 1500 r/min; keep the fluid temperature upper 15 centidegree; without
load; keep transmission run more than 15 min in neutral position; keep transmission run more than 15
min in other positions.
(b) Inspect transmission for smooth shifting.
(c) Check there is no fricative and clash during running-in test.
(d) Check there is no leakage around trasmission.
(e) Drain out transmission fluid and clean inside of transmission after running-in test. Fill transmission fluid
according to specification.
OVERHAUL
1. REMOVE EXTENSION HOUSING.
(a) Remove extension housing dust-proof cover and oil seal 41A
from extension housing.
(b) Remove 8 bolts and extension housing.
41A
(c) Remove the extension housing gasket.
CAUTION
Check the extension housing gasket for damage. Replace
with a new part if necessary.
(d) Remove vent plug.

2. REMOVE ODOMETER DRIVEN GEAR.

(a) Remove lock nut and sleeve clamp.
(b) Remove the odometer driven gear bracket and pull the
spring pin out of the bracket. Remove the odometer
driven gear and O-sealing ring.
3. REMOVE UNDER COVER SUB-ASSY.

(a) Remove 12 bolts and under cover.
(b) Remove under cover gasket.

CAUTION
Check the under cover gasket for damage. Replace with a
new part if necessary.
4. REMOVE CHANGE SHIFT ADJUSTOR.

(a) Remove the change shift adjustor lock nut, change shift
adjustor and O-sealing ring.
41A
5. REMOVE SNAP RING ON RESERVE SHIFTER WITH

SNAP RING PLIERS BY LIMIT MECHANISM SUB-
ASSY SIDE.
41A
6. REMOVE SPRING PIN OF ADJUSTING ARM.

7. REMOVE SPRING PIN ON RESERVE SHIFTER BY

CONTROL LEVER SUB-ASSY SIDE.
8. CAREFULLY REMOVE RESERVE SHIFTER, ADJUSTING

ARM, SPACE SPRING, RETURN SPRING AND WASHER.
9. REMOVE SPRING PIN OF OD-R SPEED GEARSHIFT

BLOCK.
10. REMOVE PIN ON CHANGE SHIFTER BY CONTROL

LEVER SUB-ASSY SIDE.
(a) Put OD-R speed gearshift block aside and rise up the
control lever sub-assy. Rotate the change shifter for a
half round and remove the lock pin.
11. REMOVE SNAP RING ON CHANGE SHIFTER WITH

ASSY SIDE.
41A
12. REMOVE SNAP RING ON CHANGE SHIFTER WITH

SNAP RING PLIERS BY WASHER SIDE.
13. CAREFULLY REMOVE CHANGE SHIFTER, LIMIT

41A
MECHANISM SUB-ASSY, CONTROL LEVER SUB-ASSY
AND WASHER.
14. REMOVE POPPET PLUG, POPPET SPRING AND

STEEL BALL.
15. REMOVE SPRING PIN OF 3RD-4TH SPEED GEARSHIFT

FORK.
16. REMOVE SPRING PIN OF 1ST-2ND SPEED

GEARSHIFT FORK.
17. REMOVE SPRING PIN OF 3RD-4TH SPEED

GEARSHIFT BLOCK.
18. REMOVE SPRING PIN OF 1ST-2ND SPEED

GEARSHIFT BLOCK.
19. REMOVE SPRING PIN OF OD-R SPEED GEARSHIFT

FORK.
20. REMOVE EACH GEARSHIFT, GEARSHIFT BLOCK AND

GEARSHIFT FORK.
CAUTION
Be careful not to lose the inter-lock pin. 41A
21. INSPECT GEAR AND GEAR PAIRS FOR WEAR.

(a) Make red marks on each of gear pair. Check that engaging position occupies more than 60% of each
gear end-face. Replace with a new part if necessary.
(b) Check that the wear of each gear end-face is less than 15%. Replace with a new part if necessary.
22. REMOVE ODOMETER DRIVING GEAR.

(a) Remove the odometer driving gear upper snap ring with
snap ring pliers.
41A
(b) Remove the odometer driving gear.

CAUTION
Be careful not to lose steel ball.
(c) Remove the odometer driving gear lower snap ring with
snap ring pliers.
23. REMOVE COUNTER SHAFT LOCK NUT.

CANTION
Counter shaft lock nut can not be used again after it
removed.
24. REMOVE COUNTER SHAFT OVERDRIVE SPEED

GEAR.
(a) Remove counter shaft rear bearing.
(b) Remove counter shaft overdrive speed gear.
(c) Remove counter shaft overdrive speed gear bearing

sleeve.
25. REMOVE REVERSE IDLER GERA SUB-ASSY.

(a) Pull the cotter pin out and remove the slotted nut.
(b) Remove the thrust washer.
41A
(c) Remove the reverse idler gear sub-assy.
(d) Remove the needle roller bearing.

41A
26. REMOVE OUTPUT SHAFT REAR BEARING.

(a) Remove output shaft rear bearing upper snap ring with
snap ring pliers.
(b) Remove output shaft rear bearing.

(c) Remove output shaft rear bearing lower snap ring with
snap ring pliers.
27. REMOVE OUTPUT SHAFT OVERDRIVE SPEED

GEAR SUB-ASSY.
(a) Remove snap ring with snap ring pliers.
(b) Remove the washer.

CAUTION
Be careful not to lose the steel ball.
(c) Remove output shaft overdrive gear sub-assy.
(d) Remove overdrive gear needle roller bearing.

(e) Remove output shaft overdrive gear sleeve.
41A
28. REMOVE OD-R SPEED SYNCHRONIZER ASSY.

(a) Remove output shaft lock nut.
CANTION
Output shaft lock nut can not be used again after it
removed.
(b) Remove ovedrive synchronizer ring.

41A
(c) Remove od-r speed synchronizer assy.

(d) Remove synchronizer sleeve, synchronizer hub,

synchronizer ring and synchronizer key.
29. REMOVE OUTPUT SHAFT REVERSE GEAR SUB-

ASSY.
(a) Remove reverse gear sub-assy.
(b) Remove reverse gear needle roller bearing and bearing

sleeve.
(c) Remove the washer.

30. REMOVE COUNTER SHAFT REVERSE GEAR.

(a) Remove counter shaft reverse gear.
41A
(b) Remove the washer.
31. REMOVE OUTPUT SHAFT REAR BEARING BAFFLE.

41A
(a) Remove 4 bolts and output shaft rear bearing baffle.
32. REMOVE REVERSE IDLER GEAR SHAFT.

(a) Remove 4 bolts and reverse idler gear shaft.
33. REMOVE CLUTCH RELEASE BEARING AND

CLUTCH RELEASE FORK.
(a) Remove clutch release bearing hub clip.
(b) Remove clutch release bearing.
(c) Remove clutch release fork.
34. REMOVE INPUT SHAFT ASSY.

(a) Remove front bearing retainer, front bearing gasket, oil
seal and washer.
(b) Remove input shaft snap ring with snap ring pliers.
(c) Remove input shaft bearing snap ring with snap ring
pliers.
41A
(d) Remove input shaft bearing, input shaft assy and 4th
synchronizer ring.
35. REMOVE COUNTER SHAFT ASSY.

41A
(a) Remove counter shaft front bearing cap.
(b) Remove counter shaft rear bearing cap.
(c) Remove counter shaft assy.

36. REMOVE OUTPUT SHAFT ASSY.

(a) Remove output shaft front needle roller bearing.
(b) Remove output shaft middle bearing snap ring with snap
ring pliers.
(c) Remove output shaft middle bearing.
(d) Remove output shaft assy.
37. INSTALL OUTPUT SHAFT ASSY.

(a) Install output shaft assy to transmission case.
(b) Install output shaft middle bearing.

CAUTION
Check the internal surface and outside surface of bearing.
Replace with a new part if necessary. 41A
(c) Install output shaft middle bearing snap ring with snap
ring pliers.
CAUTION
Check snap ring for warping before installing. Replace with
a new part if necessary.
(d) Install output shaft front needle roller bearing.

41A
CAUTION
• Check the needle roller bearing should not be higher
than gear end-face. Inspect the assemble position or
replace with a new part if necessary.
• Shake and check the needle roller bearing.
NOTE
Apply grease to needle roller bearing to prevent dry friction.
Replace with a new part if necessary.
38. INSTALL COUNTER SHAFT ASSY.

(a) Install counter shaft assy to transmission case.
(b) Install counter shaft front bearing cap.

(c) Install counter shaft rear bearing cap.
(d) Install counter shaft washer.

• Press the bearing cap and gears in proper position.
• Use feeler gauge to comfirm the thickness of washer.
• Select an appropriate washer.
Specification: 0 ~ 0.05 mm
39. INSTALL INPUT SHAFT ASSY.

(a) Inspect the 4th synchronizer ring for wear and damage.
(b) Turn the 4th synchronizer ring in one direction while
pushing it to the gear cone. Check the braking effect of
the synchronizer ring. If the braking effect is insufficient,
apply a small amount of the fine lapping compound
between the synchronizer ring and gear cone. Lightly rub
the synchronizer ring and gear cone together.
(c) Inspect axial clearance between 4th synchronizer ring

and 4th speed gear.
CAUTION
If the clearance is out of specification, replace with a new
synchronizer ring or (and) gear.
(d) Inspect radial clearance between 4th synchronizer ring

and 4th speed gear.
CAUTION 41A
(e) Install 4th synchronizer ring, input shaft assy and input
shaft bearing.
NOTE
Apply grease to synchronizer ring to prevent dry friction.
(f) Install input shaft bearing snap ring with snap ring pliers.
41A
CAUTION
(g) Install input shaft snap ring with snap ring pliers.
。
CAUTION
NOTE
Select and install an appropriate snap ring in order to
ensure the axial clearance be within specification.
(h) Install the washer.

• Put 2 solder sticks about 10mm in length and 1.6 mm
diameter on the bearing as the illustration show.
• Install the front bearing retainer and tighten nuts to the
specified torque.
• Remove the front bearing retainer and solder sticks.
NOTE
If the solder sticks have not crushed, use the solder stick
with 3mm in diameter.
• Measure the thickness of the crushed solder with a
micrometer and select an appropriate washer
according to this thickness in order to ensure the
axial clearance within specification.
(i) Install the oil seal to front bearing retainer.

CAUTION
• Apply grease to oil seal before installing.
Grease: Mitsubishi genuine grease Part NO: 0101011
or equivalent.
(j) Apply grease to both side of front bearing retainer gasket

and install the front bearing retainer gasket.
or equivalent.
(k) Install the front bearing retainer.

Sealant: 3M NO.4170 or equivalent.
Torque: 29 ~ 41 mm
40. INSTALL CLUTCH RELEASE BEARING AND

(a) Install clutch release fork.
CAUTION 41A
Fasten the clutch release fork to the release fork support.
(b) Install clutch release bearing.

CAUTION
(c) Install clutch release bearing hub clip.

41A
41. INSTALL REVERSE IDLER GEAR SHAFT.

(a) Install reverse idler gear shaft with 4 bolts. Apply sealant
to 4 bolts before installing.
Torque: 17 ~ 22 mm
42. INSTALL OUTPUT SHAFT RAER BEARING BAFFLE.

(a) Install output shaft rear bearing baffle and 4 bolts. Apply
sealant to 4 bolts before installing.
Torque: 17 ~ 22 mm
43. INSTALL COUNTER SHAFT REVERSE GEAR.

(a) Install the washer.
(b) Install counter shaft reverse gear.
44. INSTALL OUTPUT SHAFT REVERSE GEAR SUB-

ASSY.
(a) Install the washer.
(b) Install reverse gear needle roller bearing and bearing

sleeve.
CAUTION
• Check the needle roller bearing should not be higher 41A
NOTE
(c) Install reverse gear sub-assy.
41A
45. INSTALL OD-R SPEED SYNCHRONIZER ASSY.

(a) Inspect the sliding condition between synchronizer
sleeve and synchronizer hub.
(b) Inspect the clearance between synchronizer sleeve and

gearshift fork.
(c) Install synchronizer sleeve, synchronizer hub,

NOTE
When installing the synchronizer ring, make sure that the
steps of synchronizer rings are positioned on synchronizer
key but not on the same one.
(d) Install od-r speed synchronizer assy to output shaft.
(e) Inspect the synchronizer ring for wear and damage.

(f) Turn the synchronizer ring in one direction while pushing
it to the gear cone. Check the braking effect of the
synchronizer ring. If the braking effect is insufficient,
(g) Inspect axial clearance between synchronizer ring and gear.

CAUTION
If the clearance is out of specification, replace with a new 41A
(h) Inspect radial clearance between synchronizer ring and

gear.
CAUTION
(i) Install overdrive synchronizer ring.

41A
NOTE
(j) Tighten output shaft lock nut.

Specification: 245 ~ 265 N•m
CAUTION
Replace with a new part.
(k) Stake the lock nut and make sure that overdrive gear
work smoothly.
46. INSTALL OUTPUT SHAFT OVERDRIVE SPEED GEAR

SUB-ASSY.
(a) Install output shaft overdrive gear sleeve.
(b) Install overdrive gear needle roller bearing.

CAUTION
NOTE
(c) Install output shaft overdrive gear sub-assy.
(d) Install the washer.
(e) Install snap ring with snap ring pliers.

47. INSTALL OUTPUT SHAFT REAR BEARING.

(a) Install output shaft rear bearing lower snap ring with snap
ring pliers.
41A
CAUTION
(b) Install output shaft rear baring.

CAUTION
(c) Install output shaft rear bearing upper snap ring with 41A
snap ring pliers.
CAUTION
48. INSTALL REVERSE IDLER GERA SUB-ASSY.

(a) Intall the reverse idler gear needle roller bearing.
CAUTION
NOTE
(b) Intall the reverse idler gear sub-assy.
(c) Install thrust washer.

NOTE
Apply grease to thrust washer to prevent dry friction.
(d) Install the slotted nut and cotter pin.

49. INSTALL COUNTER SHAFT OVERDRIVE SPEED

GEAR.
(a) Install counter shaft overdrive speed gear bearing
sleeve.
(b) Install counter shaft overdrive speed gear.

(c) Install counter shaft rear bearing.

CAUTION
Replace with a new part if necessary. 41A
50. INSTALL COUNTER SHAFT LOCK NUT.

(a) Tighten the counter shaft lock nut.
Torque: 157 ~ 186 N•m
CAUTION
Replace with a new part.
(b) Stake the lock nut and make sure that overdrive gear
41A
work smoothly.
51. INSTALL ODOMETER DRIVING GEAR.

(a) Install the odometer driving gear lower snap ring with
snap ring pliers.
CAUTION
(b) Install the steel ball and odometer driving gear.

(c) Install the odometer driving gear upper snap ring with
snap ring pliers.
CAUTION
52. REMOVE EACH GEARSHIFT, GEARSHIFT BLOCK,

GEARSHIFT FORK AND INTER-LOCK PIN.
CAUTION
• Inspect each gearshift for wear and warping. Replace
• Inspect each inter-lock pin for wear and warping.
53. INSPECT SPRING PIN OF OD-R SPEED GEARSHIFT

FORK.
54. INSPECT SPRING PIN OF 1ST-2ND SPEED

GEARSHIFT BLOCK.
55. INSPECT SPRING PIN OF 3RD-4TH SPEED

GEARSHIFT BLOCK.
41A
56. INSPECT SPRING PIN OF 1ST-2ND SPEED

GEARSHIFT FORK.
57. INSPECT SPRING PIN OF 3RD-4TH SPEED

41A
GEARSHIFT FORK.
58. INSTALL POPPET PLUG, POPPET SPRING AND

STEEL BALL.
(a) Insert the poppet spring with small end on ball side.
CAUTION
Check the steel ball for wear and damage. Replace with a
(b) Apply sealant to poppet spring and install the steel ball.
Sealant: 3M ATDNO.8660 or equivalent.
59. CAREFULLY INSTALL CHANGE SHIFTER, LIMIT

MECHANISM SUB-ASSY, CONTROL LEVER SUB-ASSY
AND WASHER.
60. INSTALL SNAP RING ON CHANGE SHIFTER WITH

ASSY SIDE.
CAUTION
• Select and install an appropriate snap ring in order
to ensure the axial clearance within specification.
• Check snap ring for warping before installing.
Specification:
LIMIT MECHANISM SUB-ASSY SIDE: 0.1 ~ 0.4 mm
61. INSTALL SNAP RING ON CHANGE SHIFTER WITH

SNAP RING PLIERS BY WASHER SIDE.
CAUTION
to ensure the axial clearance be within specification.
Specification:
WASHER SIDE: 0.1 ~ 0.45 mm
62. INSTALL PIN ON CHANGE SHIFTER BY CONTROL

LEVER SUB-ASSY SIDE.
63. INSTALL SPRING PIN OF OD-R SPEED GEARSHIFT

BLOCK.
64. CAREFULLY INSTALL RESERVE SHIFTER, ADJUSTING

ARM, SPACE SPRING, RETURN SPRING AND WASHER.
65. INSTALL SPRING PIN ON RESERVE SHIFTER BY

CONTROL LEVER SUB-ASSY SIDE.
41A
66. INSTALL SPRING PIN OF ADJUSTING ARM.
41A
67. INSTALL SNAP RING ON RESERVE SHIFTER WITH

ASSY SIDE.
CAUTION
to ensure the axial clearance be within specification.
68. INSTALL CHANGE SHIFT ADJUSTOR.

(a) Remove the O-sealing ring, change shift adjustor and
change shift adjustor lock nut.
Torque: 29.4 ~ 41.1 N•m
CAUTION
• Install the change shift adjustor between two sides
of return spring.
(b) Tighten the change shift adjustor to the end.

(c) Then loosen the change shift adjustor until it can operate
the change shifter adjustor.
(d) Tighten the luck nut.
NOTE
Do not loosen the change shift adjustor over 2 rounds when
adjusting the change shift adjustor.
69. INSTALL UNDER COVER SUB-ASSY.

(a) Apply grease to both side of under cover gasket and
install the under cover gasket.
CAUTION
Install a new gasket to ensure great sealability.
Sealant: Mitsubishi genuine sealant NO.997740 or
equivalent.
(b) Install under cover and 12 bolts.

70. INSTALL ODOMETER DRIVEN GEAR.

(a) Install the odometer driven gear bracket, spring pin,
odometer driven gear and O-sealing ring.
CAUTION 41A
• Align the marks.
• Make sure that slit dose not face gear shaft and
install the spring pin.
(b) Install sleeve clamp and lock nut.
71. INSTALL EXTENSION HOUSING.

41A
(a) Make the identification mark barkward and install the
vent plug.
NOTE
Regularly clean up the vent plug to keep the vent plug
unblocked.
(b) Apply grease to both sides of extension housing gasket

and install the extension housing gasket.
CAUTION
Install a new gasket to ensure great sealability.
Sealant: Mitsubishi genuine sealant NO.997740 or
equivalent.
(c) Install extension housing and 8 bolts.

Torque: 14.7 ~ 21.5 N•m
(d) Install extension housing dust-proof cover and oil seal

NOTE
Apply grease to oil seal.
CAUTION
Install a new oil seal to ensure great sealability.
TRANSMISSION (R5M21-Z-GBA5) - OUTPUT SHAFT 41A-53
OUTPUT SHAFT
COMPONENTS
41A
41A
41A-54 TRANSMISSION (R5M21-Z-GBA5) - OUTPUT SHAFT
1 Needle Roller Bearing 9 2nd Speed Gear Sub-assy
2 Snap Ring 10 Bearing Sleeve
3 Synchronizer Ring 11 1st Speed Gear
4 Synchronizer Spring 12 Adjusting Washer
5 Synchronizer Hub 13 Output Shaft Middle Bearing
6 Synchronizer Sleeve 14 Reverse Gear Sub-assy
7 3rd Speed Gear Sub-assy 15 Overdrive Gear Sub-assy
8 Output Shaft 16 Output Shaft Lock Nut

OVERHAUL
1. REMOVE 3RD-4TH SPEED SYNCHRONIZER ASSY.
(a) Remove 3rd-4th speed synchronizer snap ring with snap 41A
ring pliers.
(b) Remove 3rd-4th speed synchronizer assy from output

shaft.
41A
(c) Remove synchronizer sleeve, synchronizer hub,

(d) Remove 3rd synchronizer ring.
2. REMOVE OUTPUT SHAFT 3RD SPEED GEAR SUB-

ASSY.
(a) Remove 3rd speed gear sub-assy and 3rd speed gear
needle roller bearing.
3. REMOVE OUTPUT 1ST SPEED GEAR.

(a) Remove adjusting washer.
(b) Remove 1st speed gear.

(c) Remove needle roller bearing of 1st speed gear.
41A
(d) Remove 1st speed gear sleeve.
4. REMOVE 1ST-2ND SPEED SYNCHRONIZER ASSY.

41A
(a) Remove 1st synchronizer ring.
(b) Remove 1st-2nd speed synchronizer assy from output

shaft.

(d) Remove 2nd synchronizer ring.
5. REMOVE OUTPUT SHAFT 2ND SPEED GEAR SUB-

ASSY.
(a) Remove output 2nd speed gear sub-assy.
(b) Remove needle roller bearing of 2nd speed gear sub-

assy.
6. INSPECT OUTPUT SHAFT.

(a) Measure the output shaft runout.
(b) Measure the outer diameter of the output shaft journal

surface.
Part Diameter
41A
A 34.975 ~ 34.991 mm
B 37.975 ~ 37.991 mm
C 30.385 ~ 30.4 mm
D 30.585 ~ 30.6 mm
7. INSTALL OUTPUT SHAFT 2ND SPEED GEAR SUB-

ASSY.
(a) Install needle roller bearing of 2nd speed gear sub-assy.
CAUTION
• Check the needle roller bearing should not be higher 41A
NOTE
(b) Install output shaft 2nd speed gear sub-assy.
8. INSTALL 1ST-2ND SPEED SYNCHRONIZER ASSY.

(a) Inspect the 2nd synchronizer ring for wear and damage.
(b) Turn the 2nd synchronizer ring in one direction while
(c) Inspect axial clearance between 2nd synchronizer ring

and 2nd speed gear.
CAUTION
(d) Inspect radial clearance between 2nd synchronizer ring

and 2nd speed gear.
CAUTION
(e) Install 2nd synchronizer ring.

NOTE
(f) Inspect the sliding condition between synchronizer

(g) Inspect the clearance between synchronizer sleeve and

gearshift fork.
CAUTION 41A
Replace the synchronizer sleeve or (and) gearshift fork if
necessary.
(h) Install synchronizer sleeve, synchronizer hub, synchronizer

ring and synchronizer key.
NOTE
key but not on the same one. 41A
(i) Install 1st-2nd speed synchronizer assy to output shaft.
(j) Inspect the 1st synchronizer ring for wear and damage.
(k) Turn the 1st synchronizer ring in one direction while
(l) Inspect axial clearance between 1st synchronizer ring

and 1st speed gear.
(m) Inspect radial clearance between 1st synchronizer ring

and 1st speed gear.
CAUTION
(n) Install 1st synchronizer ring.

NOTE
9. INSTALL OUTPUT 1ST SPEED GEAR.

(a) Install 1st speed gear sleeve.
(b) Install needle roller bearing of 1st speed gear.

CAUTION
NOTE
(c) Install 1st speed gear.
41A
(d) Install adjusting washer.
10. INSTALL OUTPUT SHAFT 3RD SPEED GEAR SUB- 41A

ASSY.
(a) Install 3rd speed gear needle roller bearing and 3rd
speed gear sub-assy.
CAUTION
NOTE
11. INSTALL 3RD-4TH SPEED SYNCHRONIZER ASSY.

(a) Inspect the 3rd synchronizer ring for wear and damage.
(b) Turn the 3rd synchronizer ring in one direction while
(c) Inspect axial clearance between 3rd synchronizer ring

and 3rd speed gear.
Ultimate: 0.5 mm
CAUTION
(d) Inspect radial clearance between 3rd synchronizer ring

and 3rd speed gear.
Ultimate: 0.5 mm
CAUTION
(a) Inspect the sliding condition between synchronizer

(b) Inspect the clearance between synchronizer sleeve and

gearshift fork.
CAUTION
Replace the synchronizer sleeve or (and) gearshift fork if
necessary.
(c) Install synchronizer sleeve, synchronizer hub,

NOTE
When installing the synchronizer ring, make sure that the 41A
(d) Install 3rd-4th speed synchronizer assy to output shaft.

NOTE
Be careful for the installation direction when installing 3rd-
4th speed synchronizer assy.
(e) Install 3rd-4th speed synchronizer snap ring with snap

41A
ring pliers.
CAUTION
• Select and install a proper snap ring in order to
ensure the axial clearance within specification.
41A-66 TRANSMISSION (R5M21-Z-GBA5) - COUNTER SHAFT
COUNTER SHAFT
COMPONENTS
1 Tapered Roller Bearing 5 Counter Shaft Overdrive Gear
2 Counter Shaft 6 Counter Shaft Rear Bearing
3 Washer 7 Counter Shaft Luck Nut
4 Counter Shaft Idler Gear

TRANSMISSION (R5M21-Z-GBA5) - COUNTER SHAFT 41A-67
REPLACEMENT
1. USE THE PRESS MACHINE TO REMOVE COUNTER
SHAFT FRONT TAPERED ROLLER BEARING. 41A
2. USE THE PRESS MACHINE TO REMOVE COUNTER

SHAFT REAR TAPERED ROLLER BEARING.
41A
3. REMOVE COUNTER SHAFT.
4. USE THE PRESS MACHINE TO INSTALL COUNTER

SHAFT FRONT TAPERED ROLLER BEARING.
CAUTION
Check the bearing for wear or damage. Replace with a new
part if necesaary.
NOTE
Apply grease to bearing to prevent dry friction. Replace
41A-68 TRANSMISSION (R5M21-Z-GBA5) - COUNTER SHAFT
5. USE THE PRESS MACHINE TO INSTALL COUNTER

SHAFT REAR TAPERED ROLLER BEARING.
CAUTION
Check the bearing for wear or damage. Replace with a new
part if necesaary.
NOTE
Apply grease to bearing to prevent dry friction. Replace
TRANSMISSION (R5M21-Z-GBA5) - INPUT SHAFT AND REVERSE IDLER GEAR SHAFT 41A-69
INPUT SHAFT AND REVERSE IDLER GEAR SHAFT

COMPONENTS
41A
41A
1 Input Shaft Snap Ring 7 Needle Roller Bearing
2 Input Shaft Bearing Snap Ring 8 Reverse Idler Gear
3 Input Shaft Bearing 9 Washer
4 Input Shaft 10 Slotted Nut
5 Reverse Idler Gear Shaft 11 Cotter Pin
6 Nut
41A-70 TRANSMISSION (R5M21-Z-GBA5) - INPUT SHAFT AND REVERSE IDLER GEAR SHAFT
REPLACEMENT
Refer to “Chapter 41A transmission (R5M21-Z-GBA5) - transmission assy, overhaul”
TRANSMISSION
41B
TRANSMISSION OPERATION MECHANISM ASSY ...................... 41B-1
COMPONENTS ......................................................................... 41B-1
REPLACEMENT ........................................................................ 41B-2
TRANSMISSION ASSY.................................................................... 41B-6 41B
COMPONENTS ......................................................................... 41B-8
REPLACEMENT ...................................................................... 41B-10
OVERHAUL ............................................................................. 41B-16 41B
OUTPUT SHAFT ASSY ................................................................. 41B-48
COMPONENTS ....................................................................... 41B-48
OVERHAUL ............................................................................. 41B-49
COUNTER SHAFT ASSY .............................................................. 41B-62
COMPONENTS ....................................................................... 41B-62
REPLACEMENT ...................................................................... 41B-63
INPUT SHAFT AND REVERSE IDLER GEAR SHAFT ................. 41B-64
COMPONENTS ....................................................................... 41B-64
REPLACEMENT ...................................................................... 41B-65
41B
TRANSMISSION (ZM001AJ2) - TRANSMISSION OPERATION MECHANISM ASSY 41B-1
TRANSMISSION OPERATION MECHANISM ASSY

TRANSMISSION (ZM001AJ2)
COMPONENTS
41B
41B
Transmission Operation Mechanism 8 Gear Selector Connecting Rod Assy

1
Handle Assy
9 Nut
2 Dust Boot
10 Bolt
3 Transmission Operation Mechanism Assy
11 Fixing Rod Bracket Assy
4 Bolt
12 Fixing Rod Assy
5 Return Spring
13 Washer
6 Gearshift Connecting Rod Assy
14 Spring Washer
7 Nut
15 Nut
41B-2 TRANSMISSION (ZM001AJ2) - TRANSMISSION OPERATION MECHANISM ASSY
REPLACEMENT
1. PARK VEHICLE ON LEVELGROUND WITH PARKING BRAKE AND STOP THE ENGINE.
2. REMOVE NUT AND DISCONNECT FIXING ROD ASSY

ASSY.

WARNING
return spring when removing it.
4. DISCONNECT GEAR SELECTOR CONNECTING ROD

ASSY.
(a) Remove the nut and disconnect the gear selector
connecting rod assy from gear selector vertical arm.
NOTE
removing it.
(b) Remove the nut and disconnect the gearshift connecting

rod assy from gearshift vertical arm.
NOTE
Tape the gearshift connecting rod and put it aside after 41B
removing it.
5. REMOVE MIDDLE PLATFORM. (Refer to “Chapter 83 instrument panel - middle platform)
6. REMOVE TRANSMISSION OPERATION MECHANISM

ASSY.
(a) Remove 4 bolts and spring washers.
(b) Remove transmission operation mechanism assy. 41B
7. INSTALL TRANSMISSION OPERATION MECHANISM

ASSY.
(a) Install a new transmission operation mechanism assy.
(b) Install 4 bolts and spring washers.
41B-4 TRANSMISSION (ZM001AJ2) - TRANSMISSION OPERATION MECHANISM ASSY
8. CONNECT GEAR SELECTOR CONNECTING ROD

TO TRANSMISSION OPERATION MECHANISM ASSY.
(a) Connect the gear selector connecting rod assy to gear
selector vertical arm and install the nut.
NOTE
• Make sure that the transmission operation mechanism is
in neutral position before connecting the gear selector
connecting rod to it.
(b) Connect the gearshift connecting rod assy to gearshift

vertical arm and install the nut.
NOTE
• Make sure that the transmission operation mechanism is
in neutral position before connecting the gearshift
connecting rod to it.

WARNING
return spring when install it.
10. CONNECT FIXING ROD ASSY TO TRANSMISSION

OPERATION MECHANISM ASSY AND INSTALL NUT.
41B
11. INSPECT TRANSMISSION OPERATION MECHANIZM ASSY FOR SMOOTH SHIFTING.

12. INSTALL MIDDLE PLATFORM. (Refer to “Chapter 83 instrument panel - middle platform)
41B
41B-6 TRANSMISSION (ZM001AJ2) - TRANSMISSION ASSY
TRANSMISSION ASSY
Use the table below to help you find the cause of the problem. The numbers indicate the priority of
the likely cause of the problem. Check each part in order. If necessary, replace these parts..
1. Transmission fluid (Low -

viscosity)
2. Transmission fluid (Level low) -
Chapter 41B transmission (ZM001AJ2) -


4. Gearshift fork and synchronizer transmission assy, overhaul
Noisy sleeve (Improper engagement) Chapter 41B transmission (ZM001AJ2) - output

5. Synchronizer (Worn or transmission assy, overhaul
damaged) Chapter 41B transmission (ZM001AJ2) - output

6. Gear tooth (Damaged) transmission assy, overhaul
1. Transmission fluid (High -

viscosity)
Chapter 42 clutch - clutch pedal, adjustment

2. Clutch (Does not disengage) Chapter 42 clutch - clutch sub - assy, overhaul


Hard to shift or does transmission assy, overhaul
not shift 4. Synchronizer (Damaged) Chapter 41B transmission (ZM001AJ2) - output
5. Gearshift fork (Warping or Chapter 41B transmission (ZM001AJ2) -


6. Gearshift (Warping or damaged) transmission assy, overhaul

TRANSMISSION (ZM001AJ2) - TRANSMISSION ASSY 41B-7
1. Gear (Excessive radial Chapter 41B transmission (ZM001AJ2) -

clearance) transmission assy, overhaul
41B
2. Engage side (Worn) transmission assy, overhaul

transmission assy, overhaul
3. Synchronizer (Damaged) Chapter 41B transmission (ZM001AJ2) - output
Jump out of gear Chapter 41B transmission (ZM001AJ2) -
4. Bearing （Axial moving） transmission assy, overhaul
5. Gearshift fork (Warping or Chapter 41B transmission (ZM001AJ2) -

6. Locating spring (Failure or Chapter 41B transmission (ZM001AJ2) -



Erratic shifting 1. Inter-lock pin (Worn) transmission assy, overhaul 41B
1. Transmission fluid (Excess) -
2. Sealing parts (Failure or -

damaged)
Oil leakage -
3. Fastener (Loose)
5. Sealant (uneven) -
COMPONENTS
1 Clutch Housing 7 Shift Mechanism
2 Limit Control Mechanism Assy 8 Input Shaft Assy
3 Front Bearing Retainer 9 Output Shaft Assy 41B
4 Transmission Case 10 Counter Shaft Assy
5 Extension Housing Sub-assy 11 Counter Shaft Assy
6 Gear Shift And Gear Selector
41B
REPLACEMENT
1. STOP THE ENGINE. PARK VEHICLE ON LEVELGROUND WITH PARKING BRAKE AND SHIFT IN
NEUTRAL POSITION.
3. REMOVE DRAIN PLUG BY DOWNSIDE AND DRAIN

TRANSMISSION FLUID COMPLETELY. TIGHTEN
DRAIN PLUG.
NOTE
• Keep vent plug unblocked and loosen the filler plug
before draining fluid. In order to drain transmission
fluid completely, drain the fluid when it is hot.
• Use container for transmission fluid when draining.
4. DISCONNECT TRANSMISSION ASSY FROM OTHER

PARTS.
(a) Disconnect gear selector connecting rod from transmission
assy.
NOTE
removing it.
(b) Disconnect gearshift connecting rod from transmission

assy.
NOTE
Tape the gearshift connecting rod and put it aside after
removing it.
(c) Remove clutch slave cylinder assy. (Refer to “Chapter 42

(d) Remove back-up lamp switch.
41B
(e) Remove odometer sensor.
41B
(f) Remove propeller shaft assy. (Refer to “Chapter 34 axle

(g) Remove 4 nuts and disconnect the transmission from

lifting lug.
WARNING
Use jack to support transmission assy and adopt protective
measures to prevent from injuring before operation.
(h) Remove 2 bolts and disconnect the exhaust pipe from

transmission assy.
WARNING
Be careful not to be scalded by exhaust pipe.
(i) Remove 8 nuts and disconnect transmission assy from

engine. Remove the transmission assy.
5. CONNECT OTHER PARTS TO TRANSMISSION ASSY.

(a) Support the transmission assy by jack and shift in one of
forward gears. Rotate the input shaft and align with the
spline of clutch disk at the same time. Then insert the
input shaft completely and shift in neutral position.
WARNING
supporting by jack.
(b) Install 8 bolts by hand.
(c) Support the transmission assy by jack and connect the

transmission assy to lifting lug. Install 4 bolts by hand.
WARNING
supporting by jack.
(d) Tighten 4 nuts of lifting lug.
(e) Connect transmission assy to engine and tighten 8 bolts.
NOTE
Diagonally tighten all bolts in order to combined closely.
(f) Connect the exhaust pipe to the transmission assy and

tighten 2 bolts.
41B
(g) Install propeller shaft assy. (Refer to “Chapter 34 axle

(h) Install odometer sensor.
41B
(i) Install back-up lamp switch.
(j) Install clutch slave cylinder assy. (Refer to “Chapter 42

(k) Connect gearshift connecting rod to transmission assy.

(l) Connect gear selector connecting rod to transmission

assy.
6. FILL TRANSMISSION FLUID AND TIGNTEN FILLER

PLUG.
CAUTION
• According to demand to fill transmission fluid GL-5 75W/
90, GL-5 80w/90 or GL-5 85W/90 for 2.0 L.
• Do not to mix different kind of transmission fluid.
• Parking the vehicle on the levelground when checking
fluid level. The fluid level must be with in 5 mm from the
lowest position of the filler plug.
7. TRANSMISSION RUNNING-IN TEST.

(a) Keep the rotate speed around 1500 r/min; keep the fluid temperature upper 15 centidegree; without
load; keep transmission run more than 15 min in neutral position; keep transmission run more than 15
min in other positions. 41B
(b) Inspect transmission for smooth shifting.
(c) Check there is no fricative and clash during running-in test.
(d) Check there is no leakage around trasmission.
(e) Drain out transmission fluid and clean inside of transmission after running-in test. Fill transmission fluid
according to specification.
41B
OVERHAUL
1. REMOVE CLUTCH RELEASE BEARING AND
(a) Remove clutch release bearing hub clip.
(b) Remove clutch release bearing.
(c) Remove clutch release fork.
2. REMOVE CLUTCH HOUSING.

(a) Remove 9 nuts and clutch housing.
3. REMOVE INPUT SHAFT FRONT BEARING RETAINER.

(a) Remove 8 bolts and input shaft front bearing retainer.
41B
(b) Remove oil seal from front bearing retainer.
4. REMOVE INPUT SHAFT ASSY.

41B
(a) Remove input shaft snap ring with snap ring pliers.
(b) Remove input shaft bearing snap ring with snap ring
pliers.
(c) Remove input shaft assy.
(d) Remove input shaft bearing.
(e) Remove 4th synchronizer ring.
5. REMOVE COUNTER SHAFT FRONT BEARING.

(a) Remove counter shaft front bearing snap ring with snap
ring pliers.
(b) Remove counter shaft front bearing.
41B
6. REMOVE EXTENSION HOUSING SUB-ASSY.

(a) Remove 8 bolts and extension housing sub-assy.
41B
(b) Remove extension housing dust-proof cover and oil seal

(c) Remove odometer driven gear oil seal, odometer driven

gear bracket, odometer driven gear, O-sealing ring and
snap ring from extension housing.
7. REMOVE 3RD-4TH SPEED GEARSHIFT SNAP RING

WITH SNAP RING PLIERS.
8. REMOVE COUNTER SHAFT OVERDRIVE CONNECTING

GEAR.
(a) Remove counter shaft overdrive connecting gear snap
ring with snap ring pliers.
(b) Remove counter shaft overdrive connecting gear.

9. REMOVE OVERDRIVE GEARSHIFT FORK PIN.
41B
10. REMOVE OVERDRIVE GEARSHIFT FORK AND

OVERDRIVE SYNCHRONIZER SLEEVE.
(a) Remove overdrive synchronizer ring.
(b) Remove overdrive gearshift fork and overdrive
synchronizer sleeve.
NOTE 41B
Be careful not to lose synchronizer key and synchronizer
spring.
11. REMOVE COUNTER SHAFT OVERDRIVE GEAR.

(a) Remove counter shaft overdrive gear.
(b) Remove the needle roller bearing of counter shaft

overdrive gear.
(c) Remove thrust washer of counter shaft overdrive gear.
12. REMOVE ODOMETER DRIVING GEAR.

(a) Remove the odometer driving gear upper snap ring with
snap ring pliers.
(b) Remove the odometer driving gear.

CAUTION
Be careful not to lose steel ball.
(c) Remove the odometer driving gear lower snap ring with
snap ring pliers.
41B
13. REMOVE OUTPUT SHAFT OVERDRIVE GEAR.

(a) Remove output shaft overdrive gear snap ring with snap
ring pliers.
41B
(b) Remove output shaft overdrive gear.

14. REMOVE OUTPUT SHAFT REAR BEARING BAFFLE.

(a) Remove 4 bolts and output shaft rear bearing baffle.
15. REMOVE OUTPUT REAR BEARING.

(a) Remove output shaft rear bearing snap ring with snap
ring pliers.
(b) Remove output shaft rear bearing.

16. REMOVE COUNTER SHAFT REAR BEARING.

(a) Remove counter shaft rear bearing snap ring with snap
ring pliers.
41B
(b) Remove counter shaft rear bearing.
41B
17. REMOVE CONTROL COVER.

(a) Remove 6 bolts and control cover.
CAUTION
Be careful not to lose torsion spring and spring cover.
18. REMOVE LIMIT MECHANISM SUB-ASSY.
19. REMOVE CONTROL LEVER SUB-ASSY, CHANGE

SHIFTER AND RESERVE SHIFTER.
(a) Remove 2 pins and disconnect control lever sub-assy
from change shifter and reserve shifter.
(b) Remove control lever sub-assy.

(c) Remove change shifter and reserve shifter.
41B
20. REMOVE REVERSE IDLER GEAR SHAFT PRESSURE

PLATE.
(a) Remove the bolt and reverse idler gear shaft pressure
plate.
41B
21. REMOVE INTERMEDIATE PLATE SUB-ASSY.

22. REMOVE 4 SETS OF LOCATING SPRING PLUG,

FORK LOCATING SPRING AND STEEL BALL.
23. INSPECT GEAR AND GEAR PAIRS FOR WEAR.

(a) Make red marks on each of gear pair. Check that engaging position occupies more than 60% of each
gear end-face. Replace with a new part if necessary.
(b) Check that the wear of each gear end-face is less than 15%. Replace with a new part if necessary.
24. REMOVE COUNTER SHAFT ASSY.
25. REMOVE REVERSE IDLER GEAR SHAFT.

(a) Remove reverse idler gear sub-assy.
(b) Remove reverse idler gear shaft.
41B
26. REMOVE OUTPUT SHAFT ASSY.
41B
27. REMOVE OD-R SPEED GEARSHIFT SNAP RING AND

3RD-4TH SPEED GEARSHIFT SNAP RING.
28. REMOVE 1ST-2ND SPEED GEARSHIFT FORK PIN

AND BOLTS.
29. REMOVE 3RD-4TH SPEED GEARSHIFT BLOCK AND

REVERSE SPEED ROCKER ARM PIN.
30. REMOVE AII GEARSHIFTS, GEARSHIFT FORKS,

GEARSHIFT BLOCKS, GEARSHIFT KEYS, INTER-
LOCK PINS AND REVERSE ROCKER ARM
BRACKET SUB-ASSY.
CAUTION
Be careful not to lose any iner-lock pins.
31. INSTALL AII GEARSHIFTS, GEARSHIFT FORKS,

GEARSHIFT BLOCKS, GEARSHIFT KEYS, INTER-
LOCK PINS AND REVERSE ROCKER ARM
BRACKET SUB-ASSY. 41B
CAUTION
• Inspect each gearshift for wear and warping. Replace
• Inspect each inter-lock pin for wear and warping.
• Inspect reverse rocker arm bracket sub-assy for
wear and warping. Replace with a new part if
necessary.
32. INSTALL 3RD-4TH SPEED GEARSHIFT BLOCK AND

REVERSE SPEED ROCKER ARM PIN.
41B
33. INSTALL 1ST-2ND SPEED GEARSHIFT FORK PIN

AND BOLTS.
34. INSTALL OD-R SPEED GEARSHIFT SNAP RING AND

3RD-4TH SPEED GEARSHIFT SNAP RING.
35. INSTALL OUTPUT SHAFT ASSY.
36. INSTALL REVERSE IDLER GEAR SHAFT.

(a) Install reverse idler gear shaft.
(b) Install reverse idler gear sub-assy.
41B
37. INSTALL COUNTER SHAFT ASSY.

CAUTION
Check the counter shaft gear tooth for wear. Replace with a
41B
38. INSTALL 4 SETS OF LOCATING SPRING PLUG,

FORK LOCATING SPRING AND STEEL BALL.
39. APPLY GREASE TO THE INTERFACE BETWEEN

INTERMEDIATE PLATE SUB-ASSY AND TRANSMISSION
CASE. THEN INSTALL INTERMEDIATE PLATE SUB-
ASSY.
NOTE
Align the pin with location hole when installing.
Grease: Mitsubishi genuine grease Part NO:997740
or equivalent.
40. INSTALL REVERSE IDLER GEAR SHAFT PRESSURE

PLATE.
(a) Install the bolt and reverse idler gear shaft pressure
plate.
Torque: 17 ~ 22 mm
41. INSTALL CONTROL LEVER SUB-ASSY, CHANGE

SHIFTER AND RESERVE SHIFTER.
(a) Install change shifter and reserve shifter.
(b) Install control lever sub-assy.
41B
(c) Connect control lever sub-assy to change shifter and

reserve shifter and then install 2 pins.
41B
42. INSTALL LIMIT MECHANISM SUB-ASSY.

NOTE
Be careful not to lose the return spring when installing.
43. INSTALL CONTROL COVER.

(a) Install 6 bolts and control cover.
Torque: 17 ~ 22 mm
CAUTION
• Be careful not to lose torsion spring and spring
cover.
• Apply grease to control cover before installing.
44. INSTALL COUNTER SHAFT REAR BEARING.

(a) Install counter shaft rear bearing.
CAUTION
Check the bearing for wear or damaged. Replace with a new
part if necessary.
NOTE
Apply grease to the bearing to prevent dry friction.
(b) Install counter shaft rear bearing snap ring with snap ring
pliers.
CAUTION
45. INSTALL OUTPUT REAR BEARING.

(a) Install output rear bearing.
CAUTION
41B
(b) Install output shaft rear bearing snap ring with snap ring
pliers.
CAUTION
41B
46. INSTALL OUTPUT SHAFT REAR BEARING BAFFLE.

(a) Install output shaft rear bearing baffle and 4 bolts. Apply
sealant to 4 bolts before installing.
Torque: 17 ~ 22 mm
47. INSTALL OUTPUT SHAFT OVERDRIVE GEAR.

(a) Install output shaft overdrive gear.
(b) Install output shaft overdrive gear snap ring with snap
ring pliers.
CAUTION
48. INSTALL ODOMETER DRIVING GEAR.

(a) Install the odometer driving gear lower snap ring with
snap ring pliers.
CAUTION
(b) Install the odometer driving gear.

CAUTION
Do not forget to install steel ball.
41B
(c) Install the odometer driving gear upper snap ring with
snap ring pliers.
CAUTION
41B
49. INSTALL COUNTER SHAFT OVERDRIVE GEAR.

(a) Install thrust washer of counter shaft overdrive gear.
NOTE
Apply grease to thrust washer to prevent dry friction.
(b) Install the needle roller bearing of counter shaft overdrive

gear.
CAUTION
NOTE
(c) Install counter shaft overdrive gear.
50. INSTALL OVERDRIVE GEARSHIFT FORK AND

OVERDRIVE SYNCHRONIZER SLEEVE.
(a) Install overdrive gearshift fork and overdrive
synchronizer sleeve.
CAUTION
Do not forget to install the synchronizer key and
synchronizer ring.
(b) Inspect the od-r synchronizer ring for wear and damage.
(c) Turn the od-r synchronizer ring in one direction while
(d) Inspect axial clearance between od-r synchronizer ring

and overdrive connecting gear.
Ultimate value: 0.8 mm 41B
CAUTION
(e) Inspect radial clearance between od-r synchronizer ring

and overdrive connecting gear.
CAUTION
(f) Install overdrive synchronizer ring.
NOTE
41B
51. INSTALL OVERDRIVE GEARSHIFT FORK PIN.
52. INSTALL COUNTER SHAFT OVERDRIVE CONNECTING

GEAR.
(a) Install counter shaft overdrive connecting gear.
(b) Install counter shaft overdrive connecting gear snap ring

with snap ring pliers.
CAUTION
53. INSTALL 3RD-4TH SPEED GEARSHIFT SNAP RING

WITH SNAP RING PLIERS.
54. INSTALL EXTENSION HOUSING SUB-ASSY.

(a) Install odometer driven gear oil seal, odometer driven
gear bracket, odometer driven gear, O-sealing ring and
snap ring to extension housing. 41B
CAUTION
Install a new O-seal to ensure great sealability.
(b) Install extension housing dust-proof cover and oil seal

CAUTION
Install a new O-seal to ensure great sealability.
(c) Install 8 bolts and extension housing sub-assy.

41B
CAUTION
Apply sealant to extension housing before installing.
55. INSTALL COUNTER SHAFT FRONT BEARING.

(a) Install counter shaft front bearing snap ring with snap
ring pliers.
CAUTION
Check the bearing for wear or damaged. Replace with a new
part if necessary.
NOTE
Apply grease to the bearing to prevent dry friction.
(b) Install counter shaft front bearing snap ring with snap
ring pliers.
CAUTION
56. INSTALL INPUT SHAFT ASSY.

(a) Inspect the 4th synchronizer ring for wear and damage.
(b) Turn the 4th synchronizer ring in one direction while
(c) Inspect axial clearance between 4th synchronizer ring

and 4th speed gear.
CAUTION

and 4th speed gear.
CAUTION
(e) Install 4th synchronizer ring.

NOTE
41B
(f) Install input shaft bearing.

CAUTION
NOTE
(g) Install input shaft assy to transmission case.

41B
(h) Install input shaft bearing snap ring with snap ring pliers.
CAUTION
(i) Install input shaft snap ring with snap ring pliers.
CAUTION
NOTE
Select and install an appropriate snap ring in order to
ensure the axial clearance be within specification.
57. INSTALL INPUT SHAFT FRONT BEARING RETAINER.

(a) Install oil seal to front bearing retainer.
CAUTION
• Apply grease to oil seal before installing.
or equivalent.
(b) Apply grease to input shaft front bearing retainer and

install it to transmission case. Tighten 8 bolts.
or equivalent.
58. INSTALL CLUTCH HOUSING.

(a) Install clutch housing and 9 nuts.
59. INSTALL CLUTCH RELEASE BEARING AND CLUTCH

RELEASE FORK.
(a) Install clutch release fork.
CAUTION 41B
Fasten the clutch release fork to the release fork support.
(b) Install clutch release bearing.
(c) Install clutch release bearing hub clip.

41B
41B-48 TRANSMISSION (ZM001AJ2) - OUTPUT SHAFT ASSY
OUTPUT SHAFT ASSY

COMPONENTS
1 Snap Ring 10 Output Shaft
2 Synchronizer Spring 11 2nd Speed Gear Sub-assy
3 Synchronizer Key 12 1st Speed Gear
4 Synchronizer Hub 13 1st Speed Gear Sleeve
5 Synchronizer Sleeve 14 Output Shaft Rear Bearing
6 Synchronizer Ring 15 Output Shaft Rear Bearing Snap Ring
7 3rd Speed Gear Sub-assy 16 Overdrive Gear
8 Needle Roller Bearing 17 Odometer Driving Gear
9 Steel Ball
TRANSMISSION (ZM001AJ2) - OUTPUT SHAFT ASSY 41B-49
OVERHAUL
1. REMOVE 3RD-4TH SPEED SYNCHRONIZER ASSY.
(a) Remove 3rd-4th speed synchronizer snap ring with snap 41B
ring pliers.
(b) Remove 3rd-4th speed synchronizer assy from output

shaft.
41B

(d) Remove 3rd synchronizer ring.
2. REMOVE OUTPUT SHAFT 3RD SPEED GEAR SUB-

ASSY.
(a) Remove 3rd speed gear sub-assy.
(b) Remove needle roller bearing of 3rd speed gear sub-

assy.
3. REMOVE OUTPUT 1ST SPEED GEAR.

(a) Remove 1st speed gear sleeve.
41B
(b) Remove 1st speed gear.
41B
(c) Remove 2 needle roller bearings of 1st speed gear.

4. REMOVE 1ST-2ND SPEED SYNCHRONIZER ASSY.

(a) Remove 1st synchronizer ring.
(b) Remove 1st-2nd speed synchronizer assy from output

shaft.

(d) Remove 2nd synchronizer ring.
41B
5. REMOVE OUTPUT SHAFT 2ND SPEED GEAR SUB-

ASSY.
(a) Remove output 2nd speed gear sub-assy.
41B
(b) Remove needle roller bearing of 2nd speed gear sub-

assy.
6. INSPECT OUTPUT SHAFT.

(a) Measure the output shaft runout.
(b) Measure the outer diameter of the output shaft journal

surface.
Part Diameter
A 34.975 ~ 34.991 mm
B 37.975 ~ 37.991 mm
C 30.385 ~ 30.4 mm
D 30.585 ~ 30.6 mm
7. INSTALL OUTPUT SHAFT 2ND SPEED GEAR SUB-

ASSY.
(a) Install needle roller bearing of 2nd speed gear sub-assy.
CAUTION
NOTE
(b) Install output shaft 2nd speed gear sub-assy.
8. INSTALL 1ST-2ND SPEED SYNCHRONIZER ASSY.

(a) Inspect the 2nd synchronizer ring for wear and damage.
(b) Turn the 2nd synchronizer ring in one direction while
(c) Inspect axial clearance between 2nd synchronizer ring

and 2nd speed gear.
CAUTION

and 2th speed gear.
CAUTION
(e) Install 2nd synchronizer ring.

41B
NOTE


gearshift fork.
(h) Install synchronizer sleeve, synchronizer hub,

NOTE
(i) Install 1st-2nd speed synchronizer assy to output shaft.
(j) Inspect the 1st synchronizer ring for wear and damage.
(k) Turn the 1st synchronizer ring in one direction while
(l) Inspect axial clearance between 1st synchronizer ring

and 1st speed gear.
CAUTION
(m) Inspect radial clearance between 1st synchronizer ring

and 1st speed gear.
CAUTION
(n) Install 1st synchronizer ring.

41B
NOTE
9. INSTALL OUTPUT 1ST SPEED GEAR.

(a) Install 2 needle roller bearings of 1st speed gear.
CAUTION
NOTE
(b) Install 1st speed gear.
(c) Install 1st speed gear sleeve.
10. INSTALL OUTPUT SHAFT 3RD SPEED GEAR SUB-

ASSY.
(a) Install needle roller bearing of 3rd speed gear sub-assy.
CAUTION
NOTE
(b) Install 3rd speed gear sub-assy.
41B
11. INSTALL 3RD-4TH SPEED SYNCHRONIZER ASSY.

(a) Inspect the 3rd synchronizer ring for wear and damage.
(b) Turn the 3rd synchronizer ring in one direction while
apply a small amount of the fine lapping compound 41B
(c) Inspect axial clearance between 3rd synchronizer ring

and 3rd speed gear.
CAUTION
(d) Inspect radial clearance between 3rd synchronizer ring

and 3rd speed gear.
CAUTION
(e) Install 3rd synchronizer ring.

NOTE


gearshift fork.
(h) Install synchronizer sleeve, synchronizer hub,

NOTE
(i) Install 3rd-4th speed synchronizer assy to output shaft.

CAUTION
Be careful the installation direction when installing 3rd-4th 41B
speed synchronizer assy.
(j) Install 3rd-4th speed synchronizer snap ring with snap

ring pliers.
CAUTION
41B
41B-62 TRANSMISSION (ZM001AJ2) - COUNTER SHAFT ASSY
COUNTER SHAFT ASSY

COMPONENTS
1 Snap Ring 8 Synchronizer Key
2 Counter Shaft Bearing Snap Ring 9 Counter Shaft Overdrive Gear
3 Counter Shaft Bearing 10 Snap Ring
4 Counter Shaft 11 Synchronizer Spring
5 Steel Ball 12 Synchronizer Sleeve
6 Overdrive Gear Thrust Washer 13 Synchronizer Ring
7 Needle Roller Bearing 14 Counter Shaft Overdrive Connecting Gear

TRANSMISSION (ZM001AJ2) - COUNTER SHAFT ASSY 41B-63
REPLACEMENT
Refer to “Chapter 41B transmission (ZM001AJ2) - transmission assy, overhaul”
41B
41B
41B-64 TRANSMISSION (ZM001AJ2) - INPUT SHAFT AND REVERSE IDLER GEAR SHAFT
INPUT SHAFT AND REVERSE IDLER GEAR SHAFT

COMPONENTS
1 Input Shaft Snap Ring 6 Reverse Idler Gear Shaft
2 Input Shaft Bearing Snap Ring 7 Reverse Idler Gear Sub-assy
3 Input Shaft Bearing 8 Reverse Idler Gear Shaft Pressure Plate
4 Input Shaft Assy 9 Bolt
5 Output Shaft Needle Roller Bearing

TRANSMISSION (ZM001AJ2) - INPUT SHAFT AND REVERSE IDLER GEAR SHAFT 41B-65
REPLACEMENT
Refer to “Chapter 41B transmission (ZM001AJ2) - transmission assy, overhaul”
41B
41B
MEMO
INDEX 1
（ORGNIZED ALPHABETICALLY）
A E 1
ACCELEARTOR PEDAL POSITION SENSOR ....................... 11B-31 ENGINE ACCESSORY BELT .................................... 15A-20, 15B-21
ADJUSTMENT(FRONT WHEEL ALIGNMENT) ...........................31-8 ENGINE ASSY ............................................................... 15A-4, 15B-5
1
ADJUSTMENT(REAR WHEEL ALIGNMENT) ..............................32-6 ENGINE BLOCK .......................................................................15B-57
AIR FILTER ASSY ..........................................................14A-7, 14B-5 ENGINE CONTROL MODULE?ECM? ....................... 11A-15, 11B-16 1
ENGINE CONTROL SYSTEM ....................................... 11A-1, 11B-1
B ENGINE COOLANT TEMPERATURE SENSOR ....... 11A-20, 11B-23
ENGINE MECHANICAL PART ....................................... 15A-1, 15B-1 1
BASIC IDLE SPEED ADJUSTMENT(THROTTLE BODY) ...... 11A-25 ENGINE OIL ...............................................................................18A-4
BASIC PRINCIPLE(ENGINE CONTROL SYSTEM) .......11A-8, 11B-9 ENGINE TIMING BELT .............................................. 15A-26, 15B-31
BATTERY ....................................................................20A-22, 20B-20 ENGINE TIMING BELT COVER ................................ 15A-23, 15B-28
1
C EXHAUST GAS RECIRCULATION VALVE (EGR VALVE) .......13B-2
EXHAUST MANIFOLD ................................................... 16A-7, 16B-6 1
EXHAUST PIPE ............................................................. 16A-1, 16B-1
CAMSHAFT ................................................................15A-53, 15B-54
CAMSHAFT POSITION SENSOR ........................................... 11B-27 F 1
CANISTER SOLENOID VALVE ............................................... 11A-55
CHARCOAL CANISTER ............................................................ 13A-2 FRONT SHOCK ABSORBER .................................................... 31-11
CHARCOAL CANISTER SOLENOID VALVE ............................ 13A-4 FRONT STABILIZER BAR ......................................................... 31-20 1
CKP SENSOR .............................................................11A-44, 11B-41 FRONT SUSPENSION ................................................................. 31-1
COMMON RAIL PRESSURE SENSOR .................................. 11B-48 FRONT WHEEL ALIGNMENT ..................................................... 31-8
COMPONENTS 1
FUEL FILLING DOOR ................................................ 12A-18, 12B-30
(CRANKSHAFT/ENGINE BLOCK/FLYWHEEL) ...................... 15A-72 FUEL FILTER ASSY ................................................................12A-10
COMPONENTS(CYLINDER HEAD AND VALVE) ................... 15B-41 FUEL INJECTOR ASSY ............................................. 12A-13, 12B-26 1
COMPONENTS(CYLINDER HEAD/VALVE) ........................... 15A-55 FUEL LEVEL SENSOR ASSY ................................... 12A-11, 12B-18
COMPONENTS(ENGINE BLOCK) .......................................... 15B-57 FUEL PUMP ASSY ..................................................................12A-12
COMPONENTS(ENGINE TIMING BELT) ...................15A-26, 15B-31 FUEL SYSTEM ............................................................... 12A-1, 12B-1 1
COMPONENTS(EXHAUST GAS RECIRCULATION VALVE FUEL TANK ASSY ......................................................... 12A-5, 12B-8
(EGR VALVE)) ........................................................................... 13B-2 FUEL TANK CAP ........................................................... 13A-1, 13B-1
COMPONENTS(EXHAUST PIPE) ..................................16A-1, 16B-1 1
COMPONENTS(FRONT SUSPENSION) .....................................31-5 G
COMPONENTS(FUEL SYSTEM) .............................................. 12A-4 1
COMPONENTS(GENERATOR) ................................................ 20A-4 GENERATOR ................................................................. 20A-4, 20B-3
COMPONENTS(IGNITION SYSTEM) ....................................... 19A-1 GENERATOR OVERHAUL(ENGINE ACCESSORY BELT) ....15B-25
COMPONENTS(INTAKE AIR SYSTEM) ........................14A-2, 14B-2 1
COMPONENTS(LUBRICATION SYSTEM) ............................... 18A-2 H
COMPONENTS(PISTON AND CONNECTING ROD ASSY) .. 15B-66
COMPONENTS(PISTON AND CONNECTING RODS) .......... 15A-63 HIGH-PRESSURE COMMON RAIL .........................................12B-24 1
COMPONENTS(RADIATOR) .........................................17A-8, 17B-7 HIGH-PRESSURE FUEL PUMP ASSY ...................................12B-20
COMPONENTS(REAR SUSPENSION) .......................................32-3 J 1
COMPONENTS(ROCKER ARM/ROCKER SHAFT/HYDRAULIC
ADJUSTER) ............................................................................. 15A-41 IDLE AIR CONTROL MOTOR ..................................................11A-28
COMPONENTS(STARTER) .......................................20A-12, 20B-11 IGNITION COIL/SPARK PLUG WIRE/SPARK PLUG OVERHAUL 1
COMPONENTS(TURBOCHARGER ASSY) .............................. 14B-8 (IGNITION SYSTEM) .................................................................19A-2
COMPOSITION(BATTERY) ..................................................... 20A-22 IGNITION CONTROL MODULE ...............................................11A-65
COOLANT .......................................................................17A-5, 17B-4 1
IGNITION SYSTEM ....................................................................19A-1
COOLANT PUMP .......................................................17A-19, 17B-18 INSPECTION ON VEHICLE
COOLING FAN ...........................................................17A-14, 17B-13 (ACCELEARTOR PEDAL POSITION SENSOR) .....................11B-32 1
COOLING SYSTEM ........................................................17A-1, 17B-1 INSPECTION(BATTERY) ........................................... 20A-25, 20B-23
CRANKSHAFT/ENGINE BLOCK/FLYWHEEL ........................ 15A-72 INSPECTION(FUEL TANK CAP) ................................... 13A-1, 13B-1
CYLINDER HEAD AND VALVE ............................................... 15B-41 INTAKE AIR HOSE ........................................................ 14A-3, 14B-3
CYLINDER HEAD/VALVE ....................................................... 15A-55 INTAKE AIR SYSTEM .................................................... 14A-1, 14B-1
D INTAKE CONNECTION PIPE ..................................................14B-15
INTAKE MANIFOLD ................................................... 14A-12, 14B-18
DIESEL FUEL FILTER ASSY .................................................. 12B-13 INTAKE MANIFOLD
DIESEL FUEL SYSTEM COMPONENTS AND PRINCIPLE PRESSURETEMPERATURE SENSOR ..................................11A-35
(FUEL SYSTEM) ........................................................................ 12B-3 INTAKE RESONATOR ASSY ..................................................14A-10
DOWNSTREAM OXYGEN SENSOR ...................................... 11A-51 INTRODUCTION TO SYSTEM FUNCTION
(ENGINE CONTROL SYSTEM) .................................................11A-6
K OVERHAUL(OIL PUMP) .......................................................... 18A-11
OVERHAUL(OVERHAUL) ....................................................... 15A-64
KNOCK SENSOR .....................................................................11A-40 OVERHAUL(PISTON AND CONNECTING ROD ASSY) ........ 15B-68
OVERHAUL(POSITIVE CRANKCASE VENTILATION VALVE
L (PCV VALVE)) ........................................................................... 13A-7
OVERHAUL(REAR COIL SPRING) ............................................32-10
LOWER CONTROL ARM ........................................................... 31-18 OVERHAUL(REAR SHOCK ABSORBER) ...................................32-7
LUBRICATION SYSTEM ............................................................18A-1 OVERHAUL(ROCKER ARM/ROCKER SHAFT/HYDRAULIC
ADJUSTER) ............................................................................. 15A-43
M OVERHAUL(STARTER) .............................................20A-13, 20B-12
OVERHAUL(THERMOSTAT) .....................................17A-16, 17B-15
MAF SENSOR ..........................................................................11B-38
OVERHAUL(THROTTLE BODY) ............................................. 11A-26
MAIN COMPNNENT(ENGINE CONTROL SYSTEM) ..............11B-14
OVERHAUL(THROTTLE POSITION SENSOR (TPS)) ........... 11A-34
MAIN COMPONENT(ENGINE CONTROL SYSTEM) ..............11A-13
OVERHAUL(TURBOCHARGER ASSY) .................................. 14B-10
MAINTENANCE OF TURBOCHARGER
OVERHAUL(VACUUM REGULATOR) ...................................... 13B-5
(TURBOCHARGER ASSY) ........................................................14B-9
P
O
PISTON AND CONNECTING ROD ASSY .............................. 15B-66
ODOMETER SENSOR ............................................... 11A-61, 11B-44 PISTON AND CONNECTING RODS ...................................... 15A-63
OIL FILTER ................................................................................18A-6
POSITIVE CRANKCASE VENTILATION VALVE
OIL PAN .....................................................................................18A-9
(PCV VALVE) ............................................................................. 13A-7
OIL PUMP ................................................................................18A-11 POWER STEERING PUMP AND A/C COMPRESSOR BELT
ON VEHICLE INSPECTIO
OVERHAUL(ENGINE ACCESSORY BELT) ........................... 15B-21
N(CAMSHAFT POSITION SENSOR) ......................................11B-28
PRECAUTION(COOLING SYSTEM) ..............................17A-1, 17B-1
ON VEHICLE INSPECTION PRECAUTION(ENGINE CONTROL SYSTEM) ..............11A-1, 11B-1
(CANISTER SOLENOID VALVE) .............................................11A-56
PRECAUTION(ENGINE MECHANICAL PART) .............15A-1, 15B-1
ON VEHICLE INSPECTION
PRECAUTION(FRONT SUSPENSION) .......................................31-1
(DOWNSTREAM OXYGEN SENSOR) ....................................11A-52 PRECAUTION(FUEL SYSTEM) .....................................12A-1, 12B-1
PRECAUTION(INTAKE AIR SYSTEM) ..........................14A-1, 14B-1
(IDLE AIR CONTROL MOTOR) ...............................................11A-29
PRECAUTION(LUBRICATION SYSTEM) ................................. 18A-1
PRECAUTION(REAR SUSPENSION) .........................................32-1
(INTAKE MANIFOLD PRECAUTION
PRESSURE/TEMPERATURE SENSOR) ................................11A-36
(STARTING AND CHARGING SYSTEM) .......................20A-1, 20B-1
ON VEHICLE INSPECTION(KNOCK SENSOR) .....................11A-41
PRINCIPLE
ON VEHICLE INSPECTION (ACCELEARTOR PEDAL POSITION SENSOR) .................... 11B-31
(ODOMETER SENSOR) ............................................ 11A-62, 11B-45
PRINCIPLE(CAMSHAFT POSITION SENSOR) ..................... 11B-27
PRINCIPLE(CANISTER SOLENOID VALVE) ......................... 11A-55
(THROTTLE POSITION SENSOR (TPS)) ...............................11A-33 PRINCIPLE(CKP SENSOR) .......................................11A-44, 11B-41
PRINCIPLE(COMMON RAIL PRESSURE SENSOR) ............. 11B-48
(UPSTREAM OXYGEN SENSOR) ...........................................11A-48
PRINCIPLE(DOWNSTREAM OXYGEN SENSOR) ................. 11A-51
ON VEHICLE INSPECT(COOLING SYSTEM) .............. 17A-3, 17B-3 PRINCIPLE
ON-VEHICLE INSPECTION(FRONT SUSPENSION) ................. 31-7
(ENGINE CONTROL MODULE?ECM?) .....................11A-15, 11B-16
ON-VEHICLE INSPECTION(REAR SUSPENSION) .................... 32-5
PRINCIPLE
OPERATION(BATTERY) .........................................................20B-20 (ENGINE COOLANT TEMPERATURE SENSOR) .....11A-20, 11B-23
OVERHAUL(CAMSHAFT POSITION SENSOR) .....................11B-29
PRINCIPLE(IDLE AIR CONTROL MOTOR) ............................ 11A-28
OVERHAUL(CAMSHAFT) .......................................... 15A-53, 15B-54
PRINCIPLE(IGNITION CONTROL MODULE) ......................... 11A-65
OVERHAUL(CANISTER SOLENOID VALVE) .........................11A-57 PRINCIPLE(INTAKE MANIFOLD
OVERHAUL(CHARCOAL CANISTER SOLENOID VALVE) ......13A-4
PRESSUREEMPERATURE SENSOR) ................................... 11A-35
OVERHAUL(CHARCOAL CANISTER) ......................................13A-2
PRINCIPLE(KNOCK SENSOR) ............................................... 11A-40
OVERHAUL(CKP SENSOR) ...................................... 11A-45, 11B-42 PRINCIPLE(MAF SENSOR) .................................................... 11B-38
OVERHAUL(COOLANT PUMP) ................................. 17A-19, 17B-18
PRINCIPLE(ODOMETER SENSOR) ..........................11A-61, 11B-44
OVERHAUL(CRANKSHAFT/ENGINE BLOCK/FLYWHEEL) ...15A-74
PRINCIPLE(THROTTLE POSITION SENSOR (TPS)) ............ 11A-32
OVERHAUL(CYLINDER HEAD AND VALVE) .........................15B-42 PRINCIPLE(UPSTREAM OXYGEN SENSOR) ....................... 11A-47
OVERHAUL(DOWNSTREAM OXYGEN SENSOR) ................11A-53
PROBLEM SYMPTOMS TABLE(COOLING SYSTEM) ............. 17A-2
OVERHAUL(ENGINE ACCESSORY BELT) ............................15A-20
OVERHAUL(ENGINE BLOCK) ................................................15B-59 (ENGINE MECHANICAL PART) .....................................15A-3, 15B-2
OVERHAUL
PROBLEM SYMPTOMS TABLE(FRONT SUSPENSION) ...........31-2
(ENGINE COOLANT TEMPERATURE SENSOR) ...................11B-24
PROBLEM SYMPTOMS TABLE(FUEL SYSTEM) .........12A-3, 12B-4
OVERHAUL(ENGINE TIMING BELT) ........................ 15A-27, 15B-32 PROBLEM SYMPTOMS TABLE(REAR SUSPENSION) .............32-2
OVERHAUL(FRONT SHOCK ABSORBER) .............................. 31-11
OVERHAUL(FUEL INJECTOR ASSY) ....................... 12A-13, 12B-26
(STARTING AND CHARGING SYSTEM) .......................20A-2, 20B-2
OVERHAUL(FUEL PUMP ASSY) ............................................12A-12
OVERHAUL(GENERATOR) ........................................... 20A-5, 20B-3 R
OVERHAUL(IDLE AIR CONTROL MOTOR) ...........................11A-30
OVERHAUL(INTAKE MANIFOLD RADIATOR .....................................................................17A-8, 17B-7
PRESSURE/TEMPERATURE SENSOR) ................................11A-37 REAR COIL SPRING ..................................................................32-10
OVERHAUL(KNOCK SENSOR) ..............................................11A-42 REAR SHOCK ABSORBER .........................................................32-7
OVERHAUL(MAF SENSOR) ....................................................11B-39 REAR STABILIZER BAR ............................................................32-16
OVERHAUL(ODOMETER SENSOR) ........................ 11A-63, 11B-46 REAR SUSPENSION ...................................................................32-1
REAR TRANSVERSE ARM ........................................................32-13 REPLACEMENT(UPPER CONTROL ARM) .............................. 31-16
REAR WHEEL ALIGNMENT ........................................................32-6 REPLACENEMT(ENGINE TIMING BELT COVER) .................15A-23
REPLACEMENT(ACCELEARTOR PEDAL POSITION REPLACMENT(FUEL FILTER ASSY) .....................................12A-10
SENSOR) ................................................................................. 11B-33 REPLACMENT(FUEL LEVEL SENSOR ASSY) ......................12A-11
REPLACEMENT(AIR FILTER ASSY) .............................14A-7, 14B-5 ROAD TEST(FRONT SUSPENSION) .......................................... 31-4 1
REPLACEMENT(BATTERY) ......................................20A-27, 20B-25 ROCKER ARM/ROCKER SHAFT/HYDRAULIC ADJUSTER ..15A-41
REPLACEMENT(COMMON RAIL PRESSURE SENSOR) ..... 11B-49
REPLACEMENT(COOLANT) .........................................17A-5, 17B-4 S 1
REPLACEMENT(COOLING FAN) ..............................17A-14, 17B-13
REPLACEMENT(DIESEL FUEL FILTER ASSY) ..................... 12B-13 STARTER ................................................................... 20A-12, 20B-11
REPLACEMENT(ENGINE ASSY) ..................................15A-4, 15B-5 STARTING AND CHARGING STARTING AND 1
REPLACEMENT CHARGING SYSTEM ...............................................................20A-1
(ENGINE CONTROL MODULE （ECM） ) ................11A-16, 11B-17 STARTING AND CHARGING SYSTEM ......................... 20A-1, 20B-1
STRUT ROD ............................................................................... 31-23
1
REPLACEMENT(ENGINE OIL) ................................................. 18A-4
REPLACEMENT(ENGINE TIMING BELT COVER) ................. 15B-28 SYSTEM FUNCTION INTRODUCTION(ENGINE
REPLACEMENT(EXHAUST GAS RECIRCULATION VALVE CONTROL SYSTEM) .................................................................11B-7 1
(EGR VALVE)) .......................................................................... 13B-3 SYSTEM OVERVIEW
REPLACEMENT(EXHAUST MANIFOLD) ......................16A-7, 16B-6 (ENGINE CONTROL SYSTEM) ..................................... 11A-2, 11B-2
1
REPLACEMENT(EXHAUST PIPE) .................................16A-2, 16B-2 T
REPLACEMENT(FRONT STABILIZER BAR) ............................31-20
REPLACEMENT(FUEL FILLING DOOR) ...................12A-18, 12B-30 THE FIXED SPEED ADJUSTING SCREW 1
REPLACEMENT(FUEL LEVEL SENSOR ASSY) .................... 12B-18 (SAS) ADJUSTMENT(THROTTLE BODY) ..............................11A-24
REPLACEMENT(FUEL TANK ASSY) ............................12A-5, 12B-8 THERMOSTAT ........................................................... 17A-16, 17B-15
REPLACEMENT(HIGH-PRESSURE COMMON RAIL) ........... 12B-24 1
THROTTLE BODY ...................................................................11A-23
REPLACEMENT(HIGH-PRESSURE FUEL PUMP ASSY) ...... 12B-20 THROTTLE BODY CLEANING(THROTTLE BODY) ...............11A-23
REPLACEMENT(INTAKE AIR HOSE) ............................14A-3, 14B-3 THROTTLE POSITION SENSOR (TPS) ..................................11A-32
REPLACEMENT(INTAKE CONNECTION PIPE) .................... 14B-15
1
TORSION BAR SPRING ............................................................ 31-14
REPLACEMENT(INTAKE MANIFOLD) ......................14A-12, 14B-18 TURBOCHARGER ASSY ..........................................................14B-8
REPLACEMENT(INTAKE RESONATOR ASSY) .................... 14A-10 1
REPLACEMENT(LOWER CONTROL ARM) ..............................31-18 W
REPLACEMENT(OIL FILTER) ................................................... 18A-6
REPLACEMENT(OIL PAN) ........................................................ 18A-9 VACUUM REGULATOR .............................................................13B-5 1
REPLACEMENT(RADIATOR) ........................................17A-9, 17B-8 VALVE OVERHAUL(CYLINDER HEAD/VALVE) .....................15A-59
REPLACEMENT(REAR STABILIZER BAR) ...............................32-16 UPPER CONTROL ARM ............................................................ 31-16
REPLACEMENT(REAR TRANSVERSE ARM) ..........................32-13
1
UPSTREAM OXYGEN SENSOR .............................................11A-47
REPLACEMENT(STRUT ROD) ..................................................31-23 USE AND MAINTENANCE(BATTERY) ..................... 20A-23, 20B-21
REPLACEMENT(TORSION BAR SPRING) ...............................31-14 1

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Edition: September 2010 VOLUME 1

Printing: October 2010 INTRODUCTION 01

ENGINE CONTROL SYSTEM

• Over voltage protection

• Fuel pump control

• Canister solenoid valve control

• Idle air control motor control

• A/C, coolant water box fan control

• Intake pressure speed-density method air measurement

• Trouble self diagnosis function

3. ECM CONTROL STRUCTURE.

4. ENGINE CONTROL SYSTEM DIRGRAM.

1 Intake 10 MAP/IAT Sensor

2 Air Filter 11 From Fuel Pump

3 Idle Air Control Motor 12 Injector

4 Throttle Position Sensor (TPS) 13 ECT Sensor

5 Canister Solenoid Valve 14 CKP Sensor

6 Canister 15 Upstream Oxygen Sensor

7 Fuel Pressure Regulation 16 Downstream Oxygen Sensor

8 To Fuel Box 17 Three-Way Catalyst (TWC)

Positive Crankshift Ventilation (PCV)

5. ENGINE CONTROLSYSTEM MAIN COMPONENTS DISTRIBUTION GRAPH.

1 Injector 8 Vehicle Speed Sensor

2 Throttle Body Manifold Absolute Pressure/Intake Air Tem-

INTRODUCTION TO SYSTEM FUNCTION

8. A/C COMPRESSOR CONTROL.

Signal Input ECM Control Output

Closed loop feedback modify

Intake manifold absolute pressure

Air charging temperature

Air charging efficiency

Decelerate fuel reduction

Decelerate fuel cut

CONTROL SIGNAL DESCRIPTION

Modified Item Content

• Start air/fuel ratio. 11A

• When the system detects the vehicle is under deceleration status, it

(e) Modification for the engine mixture:

Signal Modify ECM Output Control

Decelerate fuel reduction modify

Accelerate deepen modify

(b) Calculate the target idle speed.

Input ECM Output Control

Vehicle speed compensation

Fan compensation Calculate target idle speed Target idle speed

(b) Knock control conditions:

Component Summary Quantity Function

ECM 16 bit CPU 1 • ECM optimization control system

Upstream oxygen sensor With heated 1 • Check oxygen concentration in

• ECM judge whether the TWC is

Component Summary Quantity Function

Injector 4 hole type 4 • Inject fuel depending on the sensor

Carbon solenoid valve Electromagnetic type 1 • Control the exhaust depending on

3- lines type carbon film

ECT sensor NTC thermal resistance type 1 • Check ECT.

IAT sensor NTC thermal resistance type 1 • Check IAT.

Odometer sensor Hall effect type 1 • Check vehicle speed.

Ignition coil Electromagnetic coil type 1 • Ignite mixed gas.

ENGINE CONTROL MODULE (ECM)

2. DISCONNECT BATTERY NEGATIVE CABLE.

3. REMOVE STEERING COLUMN LOWER COVER.

(c) Pull out the engine hood control handle.

(e) Remove 3 retaining screws of the steering column lower

(f) Remove the steering column lower cover.