2011

BENNI MINI SERVICE MANUAL

This service manual consists of BENNI MINI repair information

2011 Changan Automotive Co., Ltd.

Copyright ©
Information up to Nov 2011.

Without written permission, any form of duplicate, storage or distribution (including, but not limited to, electronic copying, photocopying,
scanning and recording) of any part of this manual is not allowed. This statement applies to all texts, figures and tables.
Maintenance Manual of BENNI-MINI
100-00-1 Overview
100-00-1

Section 100-00 Overview

Contents Page
Instruction and Operation

About the Manual ............................................................................................................................................ 100-00-3

Brief Introduction ............................................................................................................................................ 100-00-4
Spare Parts Substitution ................................................................................................................................... 100-00-3
Special Tools ................................................................................................................................................... 100-00-3
Important safety instruction ............................................................................................................................. 100-00-3
Warning, Caution and Prompting .................................................................................................................... 100-00-4
How to Use the Manual ................................................................................................................................... 100-00-3
Examples ......................................................................................................................................................... 100-00-4
Precautions of Health and of Safety................................................................................................................. 100-00-5
Brief Introduction ............................................................................................................................................ 100-00-5
Acid and Alkali Metals .................................................................................................................................... 100-00-5
Safety Air Bag ................................................................................................................................................. 100-00-5
Air-conditioning Cooling Agent ...................................................................................................................... 100-00-6
Sealing Agent and Adhesive Agent ................................................................................................................. 100-00-6
Anti-freezing Fluid .......................................................................................................................................... 100-00-6
Electrolyte........................................................................................................................................................ 100-00-7
Clutch Plate and Brake Shoe ........................................................................................................................... 100-00-7
Braking Fluid ................................................................................................................................................... 100-00-7
Braze Welding ................................................................................................................................................. 100-00-7
Chemical Substance......................................................................................................................................... 100-00-7
Clutch Oil ........................................................................................................................................................ 100-00-8
Clutch Friction Disc and Friction Lining......................................................................................................... 100-00-8
Corrosion Preventing Material......................................................................................................................... 100-00-8
Cutting ............................................................................................................................................................. 100-00-8
Paraffin Removal ............................................................................................................................................. 100-00-8
Dust.................................................................................................................................................................. 100-00-8
Electric Shock.................................................................................................................................................. 100-00-8
Engine Oil........................................................................................................................................................ 100-00-8
Exhaust Gas ..................................................................................................................................................... 100-00-8
Acoustic Insulation Fiber................................................................................................................................. 100-00-8
Fire Prevention................................................................................................................................................. 100-00-9
First Aid ........................................................................................................................................................... 100-00-9
Foam-polyurethane .......................................................................................................................................... 100-00-9
Cooling Agent.................................................................................................................................................. 100-00-9
Fuel .................................................................................................................................................................. 100-00-9
High Pressure Cylinder.................................................................................................................................... 100-00-9
Gas ................................................................................................................................................................... 100-00-9
General Purpose Maintenance Tool / Device .................................................................................................. 100-00-10
Testing Device for High Pressure Air, Lubricating Oil and Oil Fluid ............................................................. 100-00-10
Legal Affairs.................................................................................................................................................... 100-00-10
Lubricating Oil and Lubricating Grease .......................................................................................................... 100-00-10
Noises............................................................................................................................................................... 100-00-10
Acoustic Insulation Material ............................................................................................................................ 100-00-10
Paints .............................................................................................................................................................. 100-00-10
Pressure Device ................................................................................................................................................ 100-00-11
Solder ............................................................................................................................................................... 100-00-11
Solvent.............................................................................................................................................................. 100-00-11
Suspended Load ............................................................................................................................................... 100-00-11
100-00-2 Overview
100-00-2

Sealing on Vehicle Base................................................................................................................................... 100-00-11

Soldering .......................................................................................................................................................... 100-00-11
Warning Signs on Vehicle................................................................................................................................ 100-00-12
Petroleum Solvent Oil ...................................................................................................................................... 100-00-13
Standard Workshop Operating Manual ............................................................................................................. 100-00-14
Vehicle in the Maintenance Workshop ............................................................................................................ 100-00-14
Vehicle Traction............................................................................................................................................... 100-00-14
Connect the Auxiliary Battery with the Jumper Wire ...................................................................................... 100-00-14
Component Cleaning........................................................................................................................................ 100-00-15
Calibration of the Important Measuring Equipment......................................................................................... 100-00-15
Solvent, Sealing Agent and Adhesive Agent.................................................................................................... 100-00-16
Brief Introduction ............................................................................................................................................. 100-00-16
General Specifications...................................................................................................................................... 100-00-16
Test of Road or Rolling Testing Platform........................................................................................................ 100-00-17
Check before Testing........................................................................................................................................ 100-00-17
Engine Starting................................................................................................................................................. 100-00-17
Test of Road or Rolling Testing Platform ........................................................................................................ 100-00-17
Braking Test ..................................................................................................................................................... 100-00-18
100-00-3
100-00-3
Instruction and Operation
DESCRIPTION AND OPERATION
About the Manual
Brief Introduction
The compiling format of this manual aims to satisfy
the requirements of the maintenance skill men, and
this manual provides the general instructions for
completing the service and maintenance. The
reliability of the work can be enhanced according to
the maintenance specified in the manual.
Spare Parts Substitution
The maintenance fittings of Chang’an Automobile
Company Limited are manufactured according to
the original factory standard. Thus, when the
maintenance service is performed, only the original
maintenance fittings manufactured by Chang’an
Automobile Company Limited can be used.
Special Tools
All the special tools required by the maintenance
every time are provided in the Special Tool List
before every procedure. Moreover, when necessary,
illustrations are additionally provided for the
identification of these special tools.
The special tools can be ordered from Chang’an
Automobile Company Limited.
Important Safety Instruction
Suitable maintenance methods and correct
maintenance procedures are vital for the operation
reliability of all vehicles and the safety of the
maintenance personnel.
This manual can not foresee all circumstances and
provide the relevant warning and suggestions.
Anyone who does not follow the instructions in this
manual must identify that the selected maintenance
method, tool and parts can not endanger the
personnel safety and the automobile integrity.
Warning, Caution and Prompting in the Manual
Warning: used for indicating the possible
personnel injury if the Manual is not
observed.
Caution: used for indicating that the
vehicle and the applied maintenance
device can be damaged if the operation is
not carried out according to the
appropriate procedures.
Prompting: used for providing other information
for the complete and satisfied maintenance service.
When reading this manual, you may encounter the
signs of “Warning”, “Cautious” and “Prompting”.
The signs of “Warning”, “Caution” and
“Prompting” are provided at the beginning of each
step.
How to Use the Manual
The descriptions in this manual are given in the
form of sections, and the sections of the specific
system are gathered in the relevant chapters.
Overview
Each chapter gives a brief description of a specific
part of automobile. This manual is divided into five
chapters: Overview, Chassis, Power Steering
System, Electricity, Vehicle Body and Coating.
Page numbers of all the chapters and sections are
provided in the first page of this manual. Each
chapter includes the contents of Overview,
Introduction and Operation and Maintenance
Adjustment and Check.
If the parts need to be dismounted or disassembled
according to instruction or sequence, the splitting
procedures with the corresponding diagrammatic
drawing and description are provided and are noted
in sequence. (Please see Example.)
The left and right sides of vehicle are determined
by looking forward form the driver seat position.
The left and right sides of the engine are
determined by looking towards the front end belt of
camshaft from the flywheel.
Inspection and Identification
This chapter comprises the Visual Inspection Table,
Failure Phenomenon Table, other information table
(such as Diagnosis Procedures) and Supplemental
Testing Procedures and Technical Standards or
Specific Testing Procedures which guides the
mechanic how to perform.
Failure Phenomenon Table
This table is used for indicating the failure
phenomenon, causes and diagnosis procedures
under some certain circumstances.
Fixed Point Test
As for the electric failure, the causes of the failure
should be gradually identified according to the
logical procedures by referring to the Fixed Point
Test Table. The Fixed Point Test Table comprises
two columns: Inspection Items and Concrete
Procedures/ Results/ Measures.
Many diagrams and icons (with or without titles)
are shown in the column Inspection Items. The
explanatory notes concerning the test procedures or
the special handling measures are provided in the
Concrete Procedures/ Results/ Measures.
The number marks are used for indicating the serial
numbers of inspection items.
Component Testing
When some step is over complicated and therefore
can not be arranged in the signal page fixed point
test or a plurality of fixed point tests require to
measure one identical component, the component
testing should be performed.
100-00-4 Overview
100-00-3

Instruction and Operation

Illustration Indication
The testing diagram shows the required
measurement or test in some certain testing
procedure.

The typical test diagram is suitable for the use of a

voltage gauge and an ampere meter.
When a signal diagram shows the multi-step test,
the solid line draws the conducting wire until the
multi-step measured conducting wire branch points,
and the conducting wire of multi-step measuring
points after the branch point should adopt the dotted
line.
The double circle testing pin is used for indicating
the disaster box type instrument. The testing pin
should be labeled with pin number.

Examples
When the special tool is required, its figure and use
method will be provided, or the tool number will be
listed. The preset torque value will be given at the
corresponding position in the procedures.
100-00-5 Overview
100-00-3
Instruction and Operation
Precautions of Health and of Safety
Brief Introduction
Many operations in connection with the service and
maintenance of the vehicle will threaten and
endanger the human health. Plenty of dangerous
operations and its relevant dangerous articles and
equipment are listed below in the alphabetical
(English) order. Please pay special attention to the
following dangerous articles.
Listed contents are not always complete, therefore
the safety and health should be always considered
first during the practical operation.
Before the use of any product, the safety
specification table of the material supplied by the
manufacturer or the supplier of the products should
be firstly consulted.
Acid and Alkali Metals
See Section Electrolyte.
Such as corrosive soda ash or sulfuric acid.
Electrolyte and cleaning material.
Irritable and corrosive substances to skins, eyes,
noses, throats and clothes, inflammable articles and
substances which can damage the normal protection
clothes.
These substances should be avoided from splitting
on skin, eyes and clothes. Suitable protective
overall, gloves and glasses should be worn. Never
inspire the acid fume.
Eye washing bottles, water taps and soaps are
positioned nearby for the use at ay time when
unexpected accident happens.
Signs of Harmful to Eyes shall be placed.
Safety Air Bag
See Section Inflammable Chemical Substance.
Inflammable and Explosive Substance--observance
of the non-smoking regulation.
The safety air bag is installed on the instrument
panel before the steering wheel and passenger(s) for
protecting the life safety of driver and passengers.
Highly explosive substance is contained in the
safety air bag, and when the substance is ignited,
gases of high temperature and high pressure
(2500°C) will be generated.
The gas generating agent used for the air bag is
sodium azide. The sodium azide is sealed in a
module and can be fully released when the air bag
is extended. Never try to open the air bag by
yourself, or the sodium azide will be exploded. If
the gas generator is broken, the complete protective
working clothes must be worn during the treatment.
After the air bag is normally extended, the
protective gloves and glasses must be worn on site
during the treatment.
The used safety air bag should be packed by
using the plastic bags according to the local
regulations strictly and then discarded at the
designated disposal site for chemical waste.
If directly contact with the generated gas, please:
– Use water to thoroughly clean the site
(affected area).
– Seek medical assistance if necessary.
Air Bag--operations which shall be performed
– Position the air bag vertically.
– Keep the air bag dry.
– The unsealed face shall be toward the human
body when the air bag is carried.
– The sealed side of the air bag should be placed
upwards.
– Carefully inspect whether the air bag is
damaged.
– Stand at the side face when the air bag is
connected.
– Identify that all the testing devices have been
correctly calibrated and maintained.
– Clean both hands when the expanded air bag is
carried away.
Air Bag--operations which shall be forbidden
– It is forbidden to place the inflammable
substance or gas generator together with the air
bag.
– The storage temperature of gas generator can
not be more than 80°C.
– The air bag can not be inversed.
– It is forbidden to open the housing of gas
generator.
– It is forbidden to place the gas generator near
open fire or heat source.
– It is forbidden to position any object on the air
bag.
– It is forbidden to use the damaged air bag.
– It is forbidden to contact the air bag and the gas
generator after they are burnt in ten minutes.
– It is forbidden to use the electricity meter probe
on the air bag circuit.
100-00-6
Description and Operation (Continued)
Air-conditioning Cooling Agent
See Section Chemical Substance.
Inflammable substance—observance of the
non-smoking regulation
Frostbite can be caused when the cooling agent is
contacted with skin.
The manufacturer’s guidance must be strictly
observed. The protective gloves and glasses can
avoid the strong light exposure.
If the cooling agent is inadvertently contacted with
skins or eyes, please wash with water immediately.
The suitable cleaning agent should be used to wash
if the cooling agent is split into the eyes, never rub
your eyes. Seek medical assistance if necessary
Air-conditioning Cooling Agent—forbidden
items
– It is forbidden to expose the air-conditioning
cooling agent under sunshine or heat the
air-conditioning cooling agent.
– When the cooling agent is filled, never position
the filling bottle vertically, and the filling
opening should be positioned downwards.
– Prevent the frostiness on the air-conditioning
cooling agent bottle.
– Prevent the dropping of the air-conditioning
cooling agent bottle.
– It is forbidden to vent the air-conditioning
cooling agent under any circumstances.
– It is forbidden to use the cooling agent in a
mixing way, such as fluorine R12 and R134a.
Sealing Agent and Adhesive Agent
See Chapter Inflammable Chemical Substance.
Inflammable Substance--observance of the
non-smoking regulation.
In general, the sealing agent and the adhesive agent
should be placed in the non-smoking area and must
be preserved cleanly, for example, put the sealing
agent and the adhesive agent on the storage rack
covered by disposable paper towel, it is advisable
that the sealing agent and the adhesive agent are
taken out of the package boxes to position them
separately; the package boxes include subpackage
boxes on which corresponding labels should be
applied.
Overview 100-00-6
For melting and sealing agents and adhesive
agent, see Section Melting Agent
Follow the instruction book of the manufacturer.
Water Soluble Sealing Agent and Adhesive
Agent
The water soluble viscose glue based on
macromolecule emulsion and latex may contain
small amount of volatile toxic substances and
chemicals harmful for human body. Avoid making
the substances contact with eyes and skins, please
make sure good ventilation when the water soluble
viscose glue is used.
Hot Melt Viscose
The solid hot melt viscose is safe. Under the molten
state, the hot melt viscose can be burnt and will
release harmful gases, therefore being harmful to
health.
Wear suitable protective working overalls, use a
constant temperature heater with self-deenergizing
function, and enough air drafting equipments
should be provided.
Resin Sealing Agent and Adhesive Agent, such
as Epoxide and Formaldehyde Resin
The adhesive agent should be mixed in the places
of good ventilation because harmful or toxic
volatile substances will be released during mixing.
Dermatitis can be caused when the skin contacts
with the tacky resin and hardening agent, some
harmful and toxic chemical substances will be
absorbed by skin.
The spatters can injure eyes.
Keep good ventilation and avoid contacting with
skins and eyes.
Anaerobic Cyan Acrylate Adhesive and Acrylic
Acid Adhesive
Most of the adhesive has irritation, causes the
irritability or the damage to the skin and the
respiratory tract. Some of them have strong
irritation to eyes.
Avoid such substances contacting skin and eyes and
follow the instruction book of the manufacturer.
Forbid the cyan acrylate adhesive to contact
with skin and eyes. If contact for carelessness,
please put the clean and wet cloth immediately
100-00-7
Description and Operation (Continued)
or go to hospital. Forbid to touch the wound
position by hands. Select the places of well
ventilation because the steam will stimulate
eyes and nose.
Isocyanate (Polyurethane) Sealing Agent and
Adhesive Agent
See Resin Adhesive.
Any person suffering asthma and other
respiratory system diseases can not touch or
close to such substances.
Excessively exposing such substances will
stimulate eyes and the respiratory system. If the
concentration is over high, the substances will
stimulate the nervous system, and will make
the person lose consciousness in the severe
situation. Touching such substance for a long
time will influence the good health.
Touching with the skin for a long time will
stimulate skin, and will cause the dermatitis
when the situation is severe. If entering into
eyes, the eyes will be hurt.
Any sprinkling action must be performed in the
places of well ventilation, and the steam and
the sprinkled grains shall be far away from the
respiratory area.
Wear the proper the gloves, the glasses and the
respirator.
Anti-Freezing Fluid
See Section Combustibles and Melting Agent.
The anti-freezing fluid includes isopropanol,
ethylene glycol and methanol.
High inflammable, inflammable and combustible.
Solutions used in the automobile cooling system
and the water spraying system of wipers.
The anti-freezing fluid will generate the steam
when being heated. Avoid inhale such gas.
The anti-freezing fluid or other harmful materials
may enter into the human body through the skin. If
the anti-freezing fluid is drunk for carelessness, it
may cause the deadliness, and the person must go to
hospital immediately.
Forbid to use any of such substances in the cooling
or industrial water use system related to the food
manufacturing or drinking system.
Overview 100-00-7
Electrolyte
Please see Section Acid and Alkali Metal
simultaneously.
When the battery cell is charged, the released gas
will cause explosion. Forbid to use the open fire or
the mars when the battery cell is charged.
Ensure good ventilation.
Braking Fluid
Please see Section Fire Prevention.
If the braking fluid is splashed on skin and eyes,
there will have slight stimulus. Possibly avoid the
braking fluid touching skin and eyes. Because the
steam pressure is lower, the harmful steam can not
be inhaled at normal temperature.
Braze Welding
See Section Welding.
Chemical Substances
See the contents of the laws and regulations.
The chemical substance includes melting agent,
sealing agent, adhesive, paint, resin foam,
electrolyte, anti-freezing agent, braking fluid, fuel,
oil and grease. Be careful when use and store the
substance. They may be noxious, harmful, and has
corrosive irritability and are inflammable and will
cause generate some harmful gas and dust.
If the chemical substance is exposed for a long time,
the human health will be influenced to different
extents.
Chemical Substance--operations which shall be
performed:
– The labels on the dangerous articale vessel and
the corresponding promotion information and
instruction book shall be carefully read to
obtain the relevant safety information. The
safety and health data table of the substance
can be obtained from the manufacturer.
– If being polluted by the chemical substance,
the skin and clothes shall be cleaned in time.
Replace the severely polluted clothes and
clean them.
– The operation regulation shall be compiled, and
wear the protective clothes to avoid the
substance polluting skin and eyes, avoid
inhaling the harmful gas, acid mist, dust and
100-00-8
Description and Operation (Continued)
smog, etc. and avoid the combustion and
explosion caused by such substance.
– Clean hands immediately after touching the
substance.
– The working area shall be kept clean and tidy
without leakage.
– The chemical substance shall be managed and
stored strictly in accordance to the national
and local regulation.
– Avoid the children touching.
Chemical Substance--Forbidden Operations:
– Forbid to mix the chemical substance arbitrarily
without following the manufacturer’s guiding.
Mixing some chemical substances will
generate the harmful substance; the noxious
and harmful gas will be released or the
explosion occurs.
– Forbid to spray the chemical substance in the
narrow space, such as in the automobile with
persons, especially to spray the melting agent
chemicals.
– Forbid to heat or burn the chemical substances
arbitrarily without following the
manufacturer’s guide, some chemical
substances are combustible, and some
substance will release the noxious or harmful
gas when burnt.
– Do not openly put the vessel, the gas emitted
in the vessel will cause the poison to the
human body or cause the explosion. Some
gases lighter than air will accumulate in the
small section.
– Do not transport the chemical substances with
the vessel without being labeled.
– Forbid to wash hands or clothes with the
chemical substances. The chemical substances,
especially the melting agent and fuel will
make the skin dry, and also stimulate the skin
to catch dermatitis, or the hands or clothes
will absorb some noxious and harmful gas
through the skin.
– Forbid to store other articles with the empty
tank which once used to store the chemical
substance without the special treatment.
– Do not smell the chemical substance. The
sudden gases of high concentration will cause
the poisoning or cause the injury.
Clutch Oil
See Section Braking Fluid.
Overview 100-00-8
Corrosion Preventing Material
Please see Sections Melting Agent and Fire
Prevention simultaneously.
Because the corrosion preventing material belongs
to the inflammable substance, please follow the
regulation of No Open Flames.
Because the substance has various types, please
follow the instruction book of the manufacturer.
The melting agent, the resin or the product oil may
be contained in the substance. The substance shall
be avoided touching skin and eyes. The substance
can not be sprayed in the enclosed space and only
can be sprayed in the conditions of well ventilation.
Cutting
Please see Section Wielding.
Wax Removal
See Section Melting Agent And Fuel (Kerosene).
Dust
The dust may be poisonous and stimulate the
human skin. Avoid inhaling the ash of the powder
chemical substance or other ashes. Wear the
respirator when the air is not smoothly circulated.
The extra fine dust of the inflammable material will
cause the explosion. The explosive threshold and
ignition source shall be avoided.
Electric Shock
Incorrectly using or using the electrical equipment
with defects will cause the electric shock.
The electrical equipment shall be regularly detected
and the equipment shall be ensured to be perfect.
The equipment with defects shall have the clear
label and be removed from the working area.
Ensure that the conducting wire, the cable, the
plug and the socket have no abrasion, knotting,
cutting, cracking or other damages.
Do not make the electrical equipment and the
electric wire contact with water.
Ensure that the electrical equipment is
protected by the fuse.
Correctly use the electrical equipment and do
not use the device with problems, and violation of
this operation will cause the fatal danger.
100-00-9
Description and Operation (Continued)
The electric wire of electric appliance shall be
ensured not to be intercepted or damaged when the
automobile is hoisted.
Ensure that the electrician be trained in first aid.
If electrically shocked:
– Cut off the power source before touching the
electric shocker.
– If the power source can not be cut off, use the
dry and non conducting materials to push away
the sufferer or draw the sufferer away the
power source.
– Perform the cardio-pulmonary resuscitation
immediately.
– Seek the medical help.
Engine Oil
Please see Section Lubricating Oil and Grease.
Waste Gas
The waste gas includes the noxious, harmful
and smothering chemical materials, such as
carbon monoxide, nitrogen monoxide,
acetaldehyde, aromatic hydrocarbon and lead
containing gas, etc. The engine can only be
started after the waste gas is discharged or in
the places of air circulation.
Gasoline Engine
The gasoline engine has no symptom before
generating the noxious and harmful gas. The harm
of the noxious and harmful gas can be immediate
and also can be latent.
Acoustic Insulation Fiber
See Section Dust.
The acoustic insulation fiber is used for insulating
the sound and the noise.
The cellulose and the cutting scrap will cause the
skin stimulation. This is often the physical effect
but not the chemical reaction.
The working practice guide must be complied, and
the gloves must be worn to avoid the substance
contacting with the skin for a long time.
Overview 100-00-9
Fire Prevention
See Welding, Foam and Legal Affairs.
Most of the substances related to the automobile
maintenance are the inflammable substances. The
noxious or harmful gas can be released when some
of them are burnt.
When the inflammable substances or the melting
agents are stored or used, especially when welding
or being close to the electrical equipment, the fire
safety shall be strictly noted.
Before using the welding device or the heating
device is used, ensure that there are no
combustibles around, and place the extinguisher
nearby.
First Aid
Besides meeting the legal requirements, the
maintenance workshop must be equipped with the
personnel who have been trained for first aid.
After any substance is sprayed in eyes, the eyes
must be washed for at least ten minutes with clean
water.
After polluted by the chemical substance, the skin
shall be washed with water and the toilet soap.
Wash and cool with cold water immediately after
burnt by some substances.
If inhale the dust, go to the places with fresh air
immediately. If this method does not take effect,
please send to the hospital immediately.
If drink some liquid for carelessness, please go to
hospital immediately and say the name and
composition of the liquid. Do not try to vomit
unless there has special instruction on the label.
Foam - polyurethane
See Section Fire Prevention.
The foam is used for isolating the sound and the
noise. There are also foams in the seat and the
shock absorber.
Operate by strictly following the instruction book
of the manufacturer.
The unreacted components have irritability and will
cause damage to skin and eyes. Please wear gloves
and the protective glasses.
The person suffering from the chronical respiratory
system diseases, asthma and bronchitis or person
100-00-10
Description and Operation (Continued)
with allergic history is not allowed to operate in the
unvulcanized material place or nearby.
Some components, steam or spray will have
irritability and may have damage.
Do not inhale the steam and the spray. These
substances must be used in the places of well
ventilation and well take the measures of protecting
the respiratory system. After spraying, do not take
off the respirator until the spray is completely
dispersed.
Burning the unslaked components and the slaking
foam will generate the noxious and harmful gas.
Forbid to smoke and use the open fire or the electric
tool in treating the foam. Any operation for heating
and cutting the foam must be performed in the
places of air circulation. Please see Vehicle Body
and Maintenance Manual.
Cooling Agent
Please see Air-Conditioning Cooling Agent.
Fuel
See Fire, Legal Affairs and Melting Agent.
Avoid the fuel contacting with the skin as best as
one can. If touch for carelessness, wash with the
clean water and the toilet soap.
Gasoline
Inflammable substance--the regulation on no
smoking must be followed.
Swallowing the gasoline for carelessness will
stimulate mouth and throat, if the gasoline is
absorbed by the stomach, it will cause sleepiness
and unconsciousness. A small quantity of gasoline
will cause the death of the child. When the inhaled
fluid reaches the lung, the severe damage will be
caused.
Contacting the gasoline for a long time will make
the person’s skin dry and have the strong irritability.
The gasoline entering in eyes will cause blindness.
A great amount of benzene is contained in the
gasoline, inhaling the benzene will make person
poison. The gasoline concentration must be very
low, the excessively high concentration will
stimulate person’s eyes, nose and throat and make
person vomit, dizziness and dyspnea chest
discomfort, even make person lose consciousness.
Overview 100-00-10
The gasoline shall be transported or used in the
places of air circulation. The damage to human
respiratory system due to the gasoline leakage must
be strictly avoided.
For the cleaning and maintenance of gasoline
storage, there must have special preventive
measures. The gasoline can not be used as the
cleaning agent and also can not be siphoned with
mouth.
Kerosene (Paraffin)
The kerosene can be taken as the heating fuel, the
melting agent and the cleaning agent at the same
time.
The kerosene belongs to the inflammable
articles--the regulation on no smoking must be
followed.
Swallowing the kerosene for carelessness will
stimulate mouth and throat.
Contacting with such substance for a long time will
make the person’s skin dry and have the irritability.
The kerosene sprayed in eyes will have the slight
irritating sensation.
Generally, the harmful team can not be generated
due to a small quantity of volatilization. The
volatilization due to the high temperature shall be
avoided (the acid mist will be generated in the
dewaxing process). Avoid touching the skin and
eyes as best as one can and ensure the air
circulation.
High pressure cylinder
See Section Fire Prevention.
The oxygen, acetylene, argon and propane with air
pressure of 138 bar (2000 pa) are generally
contained in the high pressure cylinder. Be
extremely careful when treating such high pressure
gas bottle, the mechanical damage of the high
pressure cylinder or the high pressure cylinder
switch device shall be avoided. The gases in each
high pressure cyclinder shall be clearly marked.
The high pressure cylinder shall be stored in the
places of well ventilation and avoid the rain and
snow or direct solarization. The acetylene and
propane gas bottles shall not be put near the oxygen
bottle.
The leakage of the high pressure cylinder shall be
strictly avoided and the fire sources shall be
avoided.
100-00-11
Description and Operation (Continued)
Gas
See Section High Pressure Cylinder.
General Purpose Maintenance Tool / Device
All tools and devices shall be kept in the intact state,
and the appropriate safe device shall be used if
necessary.
The use of the maintenance tool / device does not
exceed the designing scope. The maintenance
device, such as the lifting device and the jack can
not be overloaded for use. Because the damage to
the device caused by the overload generally is not
significant, the fatal damage may occur when being
used for the next time.
Forbid to use the damaged or defective tool / device,
especially the high speed running device, such as
the grinding wheel. The damaged grinding wheel
will be fragmented in the conditions without any
signs and make person severely injured.
The eye protection tool shall be worn when the
grinding wheel, the chisel or the sand blasting
device is used.
The appropriate protective mask shall be worn
when the sand blasting device, the substance
containing asbestos or the mist spraying device is
used.
Confirm that there are places of well ventilation to
control the dust, acid mist and smoke.
High Pressure Air, Lubricating Oil and Oil
Testing Device
See Section Lubricating Oil and Lubricating
Grease.
Regularly check the high pressure device,
especially the connector and keep the device good.
Forbid to face the high pressure pipe orifice, such
as the diesel oil filling mouth to the human skin
because the oil will penetrate the human
subcutaneous tissue and cause the severe disease.
Legal Affairs
The material use and disposal in the
maintenance workshop shall conform to the legal
articles with regard to safety and health.
To create a safe working environment and avoid the
environmental pollution, the personnel in the
maintenance workshop must be familiar with the
national legal articles with regard to safety and
health.
Overview 100-00-11
Lubricating Oil and Lubricating Grease
Avoid touching the mineral oil for a long time. All
the lubricating oil and lubricating grease have
irritability to eyes and skin.
Used oil
Touching the mineral oil for a long time will make
the person’s skin dry and have the irritability to the
person to catch dermatitis. In addition, if one uses
the mineral oil containing the toxic and harmful
substance, he will suffer from the skin cancer. The
appropriate devices for protecting and cleaning skin
must be provided.
Forbid to use the used oil as the lubricating oil or in
any device which can contact with the skin.
Health Precautions:
– Avoid touching the oil, especially the engine oil
for a long time.
– Wear the protective clothes, including the
gloves.
– Please do not put the wiping cloth with oil
stains in the pocket.
– Avoid the oil polluting the clothes.
– Please do not wear the clothes and shoes
seriously stained with oil. The protective
clothes shall be regularly cleaned.
– If injured for carelessness, perform the first aid
immediately.
– Protect hands with the protective cream before
working.
– Please wash with the toilet soap and the clear
water.
– Forbid to wash the skin with gasoline, diesel oil,
kerosene, diluents and melting agent.
– If the skin is abnormal, please go to hospital
immediately.
– Please degrease the oil first if possible.
– If the oil will cause damage to eyes, wear the
protective goggles.
Environmental Protection
The depleted engine oil only can be burnt in
the approved places. If the places can not be
confirmed, please confirm with the local authority.
The depleted engine oil must be treated by the
approved waste disposal contractor or the waste oil
100-00-12
Description and Operation (Continued)
recycling dealer in the designated site. Consult with
the local authority if have doubts.
Directly dumping the depleted engine oil to the
ground, the sewer, the drainage ditch or the water
sources is illegal.
Noise
The high noise generated by some operation
may damage the hearing, and the ear defender shall
be worn at this time.
Acoustic Insulation Material
See Section Foam, Insulation Fiber.
Coating
See Sections Oil and Chemical Substance at the
same time.
The paint belongs to the inflammable substances,
and the regulation on no smoking must be followed.
Monocomponent
Some toxic and harmful pigment, drying agent and
other melting agent may be contained. The coating
only can be performed in the places of well
ventilation.
Multi-component
Some toxic and harmful and unreacted resin and
resin firming agent may be contained. The
manufacturer’s guide must be followed, please see
Section Resin Adhesive Agent.
The coating must be performed in the places of well
ventilation and far away from the crowded. The
operation personnel shall wear the protective
respirator.
Pressure device
See Sections High Pressure Gas, Lubricating Oil
and Oil Testing Device.
Solder
The solder is the polymetal mixture, and the
melting point of the mixture is lower than the
composed metal (generally the lead and tin).
Generally, the harmful gases containing lead can
Overview 100-00-12
not be generated during the welding process. The
oxygen bearing acetylene flame can not be used
because the leady smog will be generated due to the
high temperature of the oxygen bearing acetylene
flame.
Some smog may be generated when the flame
is sprayed on the surface with grease, and the smog
is avoided inhaling.
Remove the surplus solder with extreme care,
and ensure that the fine lead dust is not generated,
for example, the lead dust will injure the human
body when the human body inhales. The gas mask
must be worn.
The leaking material and filings of solder must
be collected uniformly and treated rapidly to avoid
air being polluted by the lead.
Avoid uptaking the lead or inhaling the dust of
solder.
Solvent
Refer to Sections Chemical Materials, Fuels and
Fire Prevention.
The common solvent includes: propanone,
petroleum solvent oil, methylbenzene, dimethyl
benzene, chloroform and the like.
Use the clean dewaxed substance, paint, plastics,
resin and diluting agent. Some substances are
inflammable articles. The long-term contact with
the substances will make the skin dry and have
irritability. Some toxical and harmful substances
will be absorbed through skin.
If carelessly splashed into the eyes by accident, it
will have strong irritability and even lead to
blindness.
The steam or smog produced by the solvent of high
concentration which is exposed in the air will
irritate eyes and throats of people, and make people
dizzy and headachy. People will lose consciousness
when the circumstances are serious.
The steam or smog produced by the solvent of low
concentration which is exposed excessively in the
air for a long term will produce severe poison
because it is without obvious symptom.
In order to prevent the substances from spattering
onto the eyes, skins and clothing, the protective
work clothes, the protective gloves and the
protective glasses should be worn.
When using the substances, ensure that the
ventilation conditions of the field are good, try to
prevent the inhalation of the smog, steam and spray,
and keep the container sealed. It is prohibited to use
in the narrow space.
100-00-13
Description and Operation (Continued)
When spraying the substances with the solvent,
such as oil paint, adhesive agent, ensure that the
ventilation conditions of the field are good, if the
air ventilation is poor, use the gas mask.
The heating and combustion operation are
performed only under the manufacturer’s special
guide.
Suspended Load
Warning: it is prohibited to piece together
the hoisting device temporarily.
When the heavy article is raised or suspended, there
is dangerous. Never operate under the objects
without being supported, suspended or raised, such
as the suspended engine.
Ensure the equipment such as the hoisting devices
of hoisting jack, lifter, axle stand and assist strap to
be intact, and regularly inspect them.
Sealing on Vehicle Base
Refer to the Section Corrosion Preventing Material.
Welding
Refer to Fire Prevention, Electric Shock and High
Pressure Cylinder.
The welding procedures include (resistance welding)
spot welding, arc welding and gas welding.
Resistance Welding
The spot welding will release plentiful high speed
melting metal grains, so pay attention to protect
skins and eyes.
Arc Welding
During the arc welding, there has a great amount of
ultraviolet radiation, and the ultraviolet radiation
will damage the skins and eyes of the operators and
the nearby staff. The gas shielded welding is
extremely dangerous, so the personal protective
clothes should be wore, and the protective screen
should be used to protect other people.
The contact glasses wearer is suggested to wear
the normal glasses when using the arc welding.
The arc light will release microwave which will
make the space between the cornea and the
glasses of the contact glasses wearer dry, even
lead to blindness.
Overview 100-00-13
There will be metal splashing during the use of the
arc welding, so the correct protection measures for
the eye and the skin should be taken.
When the welding core or its protective layer is
polluted, the heat quantity of welding arc light will
enable the metal melting pond to produce smog and
gases during the welding, the gases may have
poison, thus avoiding inhaling the gases. The toxic
gases within working area muste be eliminated,
especially when the air circulation is poor and the
large quantity of welding is known in advance. The
oxygen mask should be worn while welding is
performed under the special cases or in the small
section.
Gas Welding (Gas Cutting)
The oxuacetylene furnace will be used for cutting
during welding and cutting, be cautious to the
leakage of the gases, and carelessness will lead to
combustion and explosion.
When the gas welding is adopted, the metal
splashes will be produced, thus the proper
protective measures for the skins and the eyes must
be taken.
The welding flame is much glared, so the eyes must
be protected. As the ultraviolet light produced by
the gas welding is less than that produced by the arc
welding, the protective glasses can be used.
When the gas welding is adopted, some harmful
gases may be produced, but the harmful gases are
produced by the welding coating, especially the
cutting damaged parts. Avoid inhaling the gases.
During the braze welding, the metal in the braze
welding bars will produce harmful gases, and it is
extremely dangerous if the braze welding bars have
cadmium. Be extremely cautious to avoid inhaling
the harmful gases when the circumstances happen,
and ask for help from specialists.
The special preventive measures should be taken
before any welding or cutting in the automobile
with inflammable materials (such as the fuel which
is volatilized or boiled away from the oil tank).
Warning Signs on Vehicle
The warning signs will be seen on the various
automobile components.
It is prohibited to move these signs. The owner of
the vehicle or the maintenance staff should pay
attention to the warning signs.
The marks of most commonly seen warnings are as
follows and are attached with notes.
100-00-14
Description and Operation (Continued)
1. The above figure shows that the relevant parts of
the special instruction manual should be referred
while contacting or trying to adjust and maintain
any components.
2. The above figure indicates that the internal high
voltage should be watched out. It is prohibited to
touch the engine or ignition device which is running.
Refer to the Section Electric Shock.
3. This mark shows that the corrosive materials in
the components should be watched out. Please refer
to Section Acid and Alkali Metals.
Overview 100-00-14
4. The mark shows that there are inflammable and
explosive fluids or steam nearby. It is prohibited
to use open fire. Refer to Section Fire Prevention.
5. The mark (usually connected with the above 5
warning signs) shows that there are objects which
will explode nearby.
6. The mark shows that kids are not allowed to
enter the place without management.
Petroleum Solvent Oil
Refer to the Section Solvent.
100-00-15 General Introduction
Instruction and Operation
Standard Workshop Operating Manual
Automobile in Maintenance Workshop
When the automobile in the maintenance workshop
is maintained, the following items shall be ensured:
– Apply parking brake or fix the wheel in order to
avoid the automobile moving forward and
backward.
– Take off the ignition key during the front
operation of the automobile.
– If the automobile engine will be started, ensure
that the field ventilation is good, or exhaust the
waste gas with the waste gas centralized
exhausting pipe.
– Enough space should be needed to hoist the
automobile for replacing the tyres if necessary.
– The fender flap pad should be provided during
the maintenance in the engine compartment.
– Firstly cut off the power source of battery when
the engine is maintained or the maintenance or
automobile hoisting is performed at the vehicle
base.
Warning: firstly cut off the generator
wiring harness when the arc welding of the
automobile are performed in order to avoid
possible and excessively strong current which
may damage the generator internal
components.
If the welding device is used in the automobile,
the extinguisher should be placed nearby.
Traction Automobile
Warnings: During the traction process of
the automobile, the ignition switch of automobile
must at the position II. (Open the steering lock
and start the indicating lamp), and thus the
steering lamp, the loudspeaker and the brake
lamp can operate normally; otherwise, the
personal injury can be caused.
Notes: The movable towing hook is provided with
a left rotating thread, and the left rotating thread
must be screwed completely before the traction
automobile. When the traction automobile is
required, the traction hook shall be adopted. The
hook must be fastened firmly through the traction
rope, and the traction rope must be connected on
the other automobile, to avoid the vehicle body
entangled with the rope.
100-00-15
When the automatic speed-changing automobile is
dragged, the gear position must be at the N position.
The pulling speed of the automatic speed-changing
automobile can not exceed 50 km/h or the trailer
car distance can not exceed 50 km. If the distance
of the traction automobile must be ultra-long, the
driving wheels must lift off completely.
The automobile can be transported through the
trailer car with the low boarding or the traction
automobile.
Connect the auxiliary battery through the
jumper wire
Warnings: If the auxiliary battery has been
charged and processed with gas, during
connecting with the jumper wire, the upper
ventilator of the plug or the wet clothing cover
shall be adopted, thus the explosive hazard
caused by the ignition of the electrical arc is
reduced during connecting with the jumper wire.
If the operation is not achieved according to the
procedures, the personal injury can be caused.
Warnings: The battery can be discharged
due to the current short circuit, and if the
electric discharge phenomenon exists, the
energized circuit still exists in the automobile
after the normal circuit is cut off. When the
jumper wire is connected, the casing of the
battery can be distorted.
Warnings: When the vehicle is not
required to jump and start, it can be
considered as the only feasible method to start
the vehicle if necessary. On this condition, the
discharged battery must be charged
immediately again after jumping and starting,
to avoid the permanent damage.
– Check whether the jumper wire can bear load,
and use the heavy-load conducting wire.
– Ensure that the auxiliary battery shall have the
identical voltage with the vehicle battery. Two
batteries must be connected.
– Before the jumper wire is connected, check
whether the circuit of available switch control is
cut off. Thus, when the final connection is
performed, the danger of electrical arc generated
can be reduced.
100-00-16 General Introduction
Instruction and Operation (Continued)
Warnings: When the conducting wire is
connected onto the battery, check whether the
terminals of jumper wire are not contacted
mutually or connected with the ground through
the vehicle body. If the battery charged
completely can charge by over 1000 A current
and generate strong electrical arc during the
short circuit through the jumper wire. The fast
heating of jumper wire and binding post even
can make the battery explode. If the operator
does not conform to the rules, the personal
injury can be caused.
Connect the jumper wire according to the following
sequence:
– Firstly connect the anode of the auxiliary battery,
and then connect the anode of the automobile
battery.
– Connect the cathode of the auxiliary battery, and
then the other end is connected at the ground
terminal at least 12 inches (300 mm) away from the
automobile battery terminal, such as on the engine
hoisting ear.
Before the jumper wire is disconnected, the engine
speed shall be reduced.
Before the jumper wire is removed from the
automobile of the battery without being fully
charged, open the air heater or the wind blower of
the rear bumper glass, to reduce the high voltage
generated during disconnecting the jumper wire.
Disconnect the jumper wire according to the
sequence opposite to the connection and the short
circuit can be avoided by all means at the rear end
of the jumper wire.
The electric quantity of battery can be restored by
the engine, because if the engine is used to charge,
the engine must work continuously for over 8 hours
when the battery is without any other loads.
100-00-16
Component Cleaning
In order to avoid dirtying the entry, the dirt
accumulation, grease, the decomposing component
or the assembly shall be eliminated before
disconnecting the jumper wire.
During the reassembly, the components shall be
cleaned carefully and then checked and assembled.
Cleaning Method:
– Dry cleaning
– Eliminate accumulated dirt with the soft brush.
– Raze dirt with the sheet metal or the batten.
– Wipe with the cleaning cloth.
Warnings: The water content of
compressed air is high sometimes, so pay more
attention when the compressed air is
particularly used in the hydraulic system.
– Clean dirt with the compressed air. (When being
in this method, a pair of protective glasses shall
be worn.)
– Clean dry dust with the cleaner. The method is
usually used to clean dust of the friction disc.
– Steam cleaning method.
Warnings: Most of melting agents are
harmful for the human body, thus the
processing shall be performed cautiously. See
“Safety and Health Precautions” and Safety
Protection Instructions of the Manufacturer. If
the operation is performed without conforming
to the specification, the injury will be brought
for the human body.
There is abundant melting agent suitable for
cleaning the components. Some components are
listed such as the braking hydraulic pressure
element, the electric assembly, etc, and the
cleaning is performed with the electric assembly.
Please see “Melting Agent, Sealing Agent and
Adhesive Agent” and relevant manuals.
Calibration of the important measuring equipment
Warnings: If the operation is performed
without conforming to the following suggestion,
the personal injury or the damage of the
components can be caused.
Some important equipment are important properly,
such as the torque spanner, the universal meter,
the waste gas analyzer and the check line, etc, and
the equipment must be calibrated regularly
according to the guiding of the manufacturer.
100-00-17 General Introduction
Instruction and Operation (Continued)
Melting Agent, Sealing agent, Sealing
Agent, Adhesive Agent and Adhesive
Agent
Brief Introduction
Warnings: The operator shall be cautious
fairly when all the melting agents, the sealing
agent and the adhesive agent are adopted. Some
chemicals or volatile gas spray are harmful to
the human health. Please follow the
manufacturer’s instructions strictly, and strictly
prohibit to use any material with question of
safety!
100-00-17
Warnings: If the applicability of any
melting agent or sealing agent for the special
purpose is with question, please contact with the
manufacturer for the storage, processing and
operating of the material.
“Safety and Health Precautions” introduces some
generally used chemicals and dangerous articles
and the operation method and the corresponding
safety measures shall be taken section by section.
100-00-18 General Introduction
Instruction and Operation
Road Test or Rolling Testing Platform
Test
In many cases, the road test or rolling testing
platform test is required to for the automobile. The
detailed instructions of checking procedures before
relevant test are illustrated as follows, from the
engine starting and stopping, the check before
driving, the check during the test to the final check
after testing.
After only when the tests of all performances are
completed, the road test of the automobile can be
performed. However, the selective testing is
performed for the checked items in connection with
the system.
Check before Testing
Warnings: If the pressure of the braking
system is lower, the stroke of the braking pedal
is too large or the leakage exists in the hydraulic
system, the road test is prohibited. After the
problems are found and rectified, the road test
can be performed.
It is suggested that before the road test is performed,
the test be performed at first before the inspection.
The functional test is performed for those
influencing the automobile safety driving
system/circuit, such as the brake, the vehicle lamp
and steering, etc.
– The fluid level of engine oil.
– The fluid level of engine coolant.
– Check whether the tyre air pressure is qualified,
the mode and the pattern are applicable and the
abrasion limitation is exceeded.
– Check whether the sufficient fuel used for road
testing exists in the fuel tank.
– Check whether the oil leakage (the engine oil,
hydraulic oil and fuel) and water leakage exist
around the engine and the transmission gear and at
the bottom of the vehicle. Write down the possible
leakage positions and the vicinal area is wiped
cleanly, and thus the leaking degree can be easily
checked after the test is finished.
100-00-18
Start the engine
Notes: Within the time of the initial starting of the
cold engine or the initial 1.5 km, before the
automobile driving speed reaches 25 km/h, the
accelerator pedal does not exceed half of the stroke.
Do not operate the engine at the high speed during
the refrigerator car, or the accelerator pedal is
stepped to the last.
Close the ignition system and Check:
– Apply the parking braking.
– Check whether the transmission lever is at the
neutral position
– Check whether the pointers of all the
instruments (except the fuel gauge) point to
Zero.
Turn on the ignition switch and confirm:
– Confirm whether the indicating lamp of the
ignition switch is bright.
– Confirm whether the engine temperature
pointer has the correct reading.
– Confirm whether the reading of the fuel
pointer conforms to the fluid level of the fuel
tank.
– Display the manual brake caution lamp and
the fluid level caution lamp.
– During the Road Test or the Rolling
Testing Platform, inspect:
Warnings: During the road test, the
braking system shall be checked when the
driving speed of the automobile is slow. If
the brake derivation or other problems
exist, please find out the problems and
modify them, and before the problems are
solved, prohibit the vehicle to be started.
– Step on the clutch pedal easily.
– The low gear meshing and the clutch
connection are stable.
– The manual brake operation is flexible, and
the releasing of the manual brake is rapid and
thorough.
100-00-19 General Introduction 100-00-19

Instruction and Operation

If the running is steady during loosening the Warnings: The braking test including the
clutch, the automobile will not skid or tremble. heavy-trodden braking shall not be
– The transmission shift is steady, thus the performed on the new brake shoe
abnormal noise or the vibration does not occur plate/brake disc or the friction disc/brake
in the gear box. drum, unless the components have been
– The output power of the engine is normal, the worn in, because the new braking friction
components can not exert the efficiency
production output is normal, the acceleration is
completely before being worn in.
steady, the accelerator pedal operation is
flexible and the engine idle-speed is restored to Test the brake for the slightly step or heavily
the normal state. step on the braking pedal under the condition of
– The no excessive or abnormal smog is various vehicle speeds of normal operation at
discharged from the engine in the normal each gear position.
driving, over loading or over driving. Slide the vehicle and pay attention to the
– The steering operation includes whether the tendency of vehicle derivation or the
power steering is normal, steady and accurate, phenomenon of viscous braking.
and whether the steering wheel is too heavy or
After the vehicle (stop of non-emergency
too light and the direction of the automobile
braking) is stopped, check the braking
waggles. The steering wheel returns to the
temperature carefully. If the brake disc is
original position after turning.
extremely hot or the brake disc is hotter than the
– The pointer reading of the odometer, the other brake discs, it is shown that the
caution lamp with oil pressure, the coolant phenomenon of viscous braking exists.
temperature pointer and the tachometer are
correct or they work normally.
– The switch and the controlling system work
normally, the caution lamp (indicating lamp)
works normally and the engine extinguishes
automatically after the steering wheel returns to
the original position.
– The heating and ventilation system works
normally.
– The braking system works normally.

Baking Test
Warnings: During checking the brake, the smog
released by hot braking can be avoided. See
“Safety and Health Precautions”.
The check of the brake can be avoided on the
road with abundant vehicles, which may cause
inconvenience or danger for others.
100-00-20 General Introduction 100-00-20

Instruction and Operation

Braking Test
Warnings: During checking the brake, the
smog released by hot braking can be avoided.
See Safety and Health Precautions.
Avoid the check of the brake on the road with many
vehicles, as that may cause inconvenience or danger
for others.
Warnings: The braking test including the
heavy-trodden braking shall be not performed
on new brake shoe plate/brake disc or the
friction disc/brake drum, unless the components
have been worn in, because the new braking
friction components can not perform the
complete functions before being worn in.
Slightly step or heavily step on the braking pedal
under the condition of various vehicle speeds of
normal operation at each gear position, so as to
check the brake.
Slide the vehicle and pay attention to the tendency
of vehicle derivation or the phenomenon of viscous
braking.
After the vehicle (stop of non-emergency braking)
is stopped, check the braking temperature carefully.
If the brake disc is extremely hot or the brake disc
is hotter than other brake discs, it is indicated that
the phenomenon of viscous braking exists.

After the test is finished, check:

– Check whether the leakage of engine oil,
coolant, hydraulic pressure, air and fuel exists.
– The abnormal high temperature of any
rotating components or assemblies, such as
wheel hubs, speed change gear, axle, etc. may
show excessively tight assembly or deficient
lubrication.
100-01-1 Lifting 100-01-1

Chapter 100-01 Lifting

Vehicle applied: Changan·Benni MINI

Contents Page
Description and operation

Support.................................................................................................................................... 100-01-2
Lifting.................................................................................................................................... 100-01-3

Changan·Benni MINI
100-01-2
Description and operation
Support
Warning: Be sure that the vehicle is
parked on the hard ground. If the vehicle is on
soft ground, things should be put under the
jack in order to detract power. Be sure to put
blocks in front of the wheel diagonally
opposite direction. Failure to follow these
instructions may cause personal injury.
Lifting 100-01-2
When the jack is needed during the
maintenance of vehicles, the comprehensive
understanding of the following guidelines is
essential. Must confirm the right support and
the support points should usually on an open
area between the front and rear wheels.
When using the jack, the application of a
protective liner is necessary to prove the paint
from being damaged.
长安·奔奔MINI
100-01-3 Lifting 100-01-3

Description and operation

Lifting

Note: When using the two-column lift to lift

vehicle, pads must be used at the location

Use the correct lifting and support position is very important

Changan·Benni MINI
201-00-1 Suspension System - General

Section 201-00 Suspension System - General

Applicable Vehicle Model： Benni Mini

Contents Pages
Specification

Specification 201-00-2

Instruction and Operation

Suspension System 201-00-2

Inspection and Confirmation 201-00-4
Failure Table 201-00-6
Fixed Point Inspection 201-00-9

Common Procedures

Toe-in Adjustment 201-00-21

Inspection of the Wheel Bearing 201-00-219

Benni Mini
201-00-2 Suspension System - General

Specification

Front Wheel Alignment (Kerb Mass) - Kingpin Caster Angle and Camber Angle
Kingpin Caster Kingpin Caster
Model Angle Angle Camber Angle Camber Angle
Vehicle Model Standard Value Tolerance Scope Standard Value Tolerance Scope
2.8° or 2°48’ 2.3° to 3.3° or 2°06’ 0.5° or 0°30’ 0° to 1°
to 4°06’

Front Wheel Alignment (Kerb Mass) - Total Toe-in

Vehicle Model Tolerance Scope Adjust If Necessary
0° to 0.34° 0.17°±0.17°
0°00’ to 0°20’ 0°10’ ±0°10’
0 mm to 6.2mm 3.1mm±3.1 mm

Rear Wheel Alignment (Kerb Mass) - Camber Angle

Vehicle Model Standard Value Tolerance Scope
4 doors 0° -0°33' to 0.33° or -0.20° to 20°
Maximum variation value – Right and left - Camber angle 1°15' (1.25°)

Rear Wheel Alignment (Kerb Mass) - Total Toe-in

Vehicle Model Standard Value Tolerance Scope
4 doors 0.33° -0°33' (positive toe-in) to 0°33' (negative
toe-in)
4 doors 0° -0.20° to 0.20°
4 doors 0mm -6.2mm (positive toe-in) to 6.2 mm
(negative toe-in)

Torque Specification
Specification Nm lb-ft lb-in
Locking nuts of the tie rod 43 -
Wheel nuts
DIAGNOSIS AND TESTING
65 -
Suspension System
Warning: Before and after the inspection, make sure the tyre air pressure is accurate.
Excessive wear of the tyre, sunken tyre or unbalanced tyre can result in automobile vibration, shaking or steady
running.
Uneven or fluctuant road can also result in the above-mentioned circumstances. If such circumstances occur when
the automobile is on this type of road, please try different types of road to confirm the cause.
When finding the cause of automobile vibration, do not immediately doubt the tyre, for the following
circumstances can also lead to automobile vibration:

Benni Mini
201-00-3

201-00-3 Suspension System - General

Diagnosis and Test (Continued)
– Loosened or worn front wheel bearings.
– Loosened or worn suspension or steering components.
– Excessive run-out of the front brake disc.
– Loosened engine or driving axle bracket.
– Engine accessories.
This section covers vibration related to suspension, tyre, etc.
Excessive automobile noise is generally the noise generated through friction between the abraded position of the
tyre and the ground. The sound of varoom made by the tyre is different from that made by the driving axle, since
the sound of the latter can vary with different load or speed. However, the tyre noise remains the same within a
certain speed scope.
In order to confirm that noise generated from tyres is not related to automobile vibration, tyres can be excessively
aerated to inspect whether the abnormal sound of tyres is variable. The bumpy degree of the automobile and noise
can change with the tyre air pressure.
Inspect vibration of other types. See Section 100-01 for relevant information.

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201-00-3 Suspension System
Diagnosis and Test (Continued)
Inspection and Confirmation
Vibration diagnosis procedures usually begin with
road test. The road test and the interview with clients
(if possible) can provide a great deal of information
for confirming failure cause.
During the road test, the automobile should be running
on a smooth road without slopes. If obvious fluttering
occurs, please record the following contents:
– The speed when the automobile flutters.
– The type of automobile vibration occurring within
a certain speed scope.
– The impact on vibration when the engine torque,
the automobile speed and the engine rotating
speed change.
– The type of vibration sensitivity - torque
sensitivity, automobile speed sensitivity or
sensitivity of the engine rotating speed.
If the road test shows that the automobile vibration is
related to the automobile tyre, please use tyre wear
status table to inspect the failure cause at a fixed point.
If the road test indicates that abnormal sound of the
tyre occurs but the automobile is vibrationless;
abnormal sound of the tyre is caused by contact of the
tyre and the ground.
Utilize the following contents to find out the vibration
cause:
Torque Sensitivity
This indicates that noise can be weakened or
increasingly vibrate with speedup, slowdown,
skidding or keeping uniform speed of the vehicle.
Automobile Speed Sensitivity
This indicates that automobile speed sensitivity
always occurs within a fixed vehicle speed scope, and
cannot be affected by the automobile torque, the
engine rotating speed or the transmission case.
Sensitivity of the Engine Rotating Speed
This indicates that fluttering can be caused when
different gears of the transmission case are chosen, the
engine rotating speed is constant, and the automobile
is at different speeds. Fluttering can also be caused by
speeding up or slowing down when the transmission
case of the automobile is at the position of neutral gear
or the four wheels hang up and the neutral gear is put
into. If the situation is related to the engine rotating
speed, the vibration cause has nothing to do with tyres.
Ball Head of the Tie Rod
Note: Before the inspection or positioning of the front
suspension, inspect the ball head of the tie rod for
abrasion at first.
1. Inspect air pressure of four tyres.
2. Hoist the automobile. See Section 100-02 for
relevant information. Inspect whether the ball
head and the bracket of the front suspension are
loose, abraded or damaged. See the section of
Ball Head of the Lower Cross Arm for relevant
information. Tighten all the loose nuts according
to torque specifications. When parts are required
to be replaced, see Section 201-01.
3. Inspect whether connection between the steering
mechanism and the tie rod is loose. Tighten them
according to the torque specifications. If the ball
head of the tie rod is abraded or broken, replace it.
See Section 211-02 for relevant information.
4. Disassemble the front tyres. Inspect run-out amount
of the tyre and single-edge abrasion. Perform
dynamic balancing of the tyre.
5. Inspect the suspension device and the working
situation of the accessories. See the section of
Inspection of the Suspension Assembly. Jamming
of the suspension assembly would cause that the
automobile cannot achieve the normal position,
and thereby would impact on front wheel
alignment.
Inspection of the Ball Head of the Lower Cross
Arm
1. Hoist the automobile. See Section 100-01 for
relevant information.
2. Tightly grip the outer end of the lower cross arm,
and try to move vertically to observe if there is
movement. Free movement is generally followed
by the sound of click, which shows that the ball
head of the lower cross arm has been damaged.
3. If free movement occurs, replace the ball head.
See Section 201-01 for relevant information.
4. After the ball head is replaced, front wheel
alignment shall be performed. See the section of
Common Procedures for relevant information.
Inspection of the Suspension Device
All the automobiles are equipped with low pressure
gas-hydraulic suspension devices which can not be
adjusted or refilled.
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201-00-3 Suspension System
Diagnosis and Test (Continued)
1. Oil leakage. A layer of oil film is allowed to be
(exuded) attached on front and rear shock
absorbing devices, which is normal. Oil
penetration refers to a situation that a layer of
thick oil film accumulates outside the shock
absorbing housing, and generally is easy to be
noted owing to a mass of absorbed dust. The
phenomenon of oil penetration during shock
absorption is a manifestation of the normal
function of the automobile, thus the shock
absorber is not required to be replaced. Leaking
phenomenon refers to a situation that the
suspension of the whole shock absorbing device
is covered with the leaked oil, and simultaneously
the oil fluid can drop off onto the ground from the
suspension.
If case of such circumstances:
– Check that the observed oil film is just from the
shock absorbing device.
– If worn or damaged, the shock absorbing device
should be replaced.
2. Decline of the vehicle body: The problem of
automobile decline is solved commonly through
replacing front and rear damping springs, because
the designed shock absorbing device belongs to a
hydraulic type damping device. Unlike a
suspension spring, the designed shock absorbing
device can not be used for loading and bearing
weight. Therefore, the problem of automobile
decline cannot be solved through the method of
replacing the suspension device.
3. Note: When a suspension device is damaged, pair
replacement is not needed.
Replace a pair of new shock absorber. In the past, we
would recommend that if a shock absorber is damaged,
a pair of shock absorber can be replaced. Now that
new technology and enhancing management are
adopted during manufacture and the sealing
technology is improved, the working reliability of the
shock absorber is remarkably improved.
Automobile Inspection
1. Inspect air pressure of all tyres.
2. Inspect tyres to confirm positioning of the ball
head of the tie rod, dynamic balancing of the tyre
and whether tyres are cracked or abnormally
bulged.
3. Inspect optional suspension equipment of the
automobile, such as suspension of the heavy-duty
towing trailer. The suspension is firmer than the
standard suspension in the running process.
4. Inspect whether the automobile is overloaded or
not. Inspect whether the luggage carrier contains
heavy object.
5. After the above procedures are finished, perform
road test to confirm the failure mentioned by
clients.
Inspection through Automobile Hoisting
1. Noise: Loosening of the suspension or accessories
of the suspension assembly would cause noise.
Inspect and tighten the suspension assembly and the
accessories thereof. If the lining sleeve of the lower
bracket is damaged, replace it. Inspect whether front
and rear suspension assemblies are externally
damaged or not.
2. Bottom / rebound: Inspect the travel for the
rubber shock absorbing sleeve. If damaged or lost,
install a new shock absorbing sleeve. Inspect
whether the shock absorbing sleeve is overloaded
or not. If the shock absorbing sleeve is overloaded,
replace it.
3. If abrasion of the shock absorber is found, only
the damaged shock absorber is to be replaced.
Working Rack Test
The inner part of the shock absorber is fully filled with
compressed gas, and the shock absorber should be
completely stretched when there is not limit. If the
shock absorber is found not to be completely stretched,
this means that it has been damaged. Replace a new
shock absorber. Inspect the total length of the shock
absorbing device, if the shock absorbing device does
not meet the requirements of the total length, which
means that a certain part among parts does not meet
the requirements, replace the shock absorbing device.
When the suspension device is at the vertical position,
compress the suspension assembly and allow it to
stretch three times, through which the intake gas
through the pressure chamber in the treatment process
is cleared.
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201-00-3 Suspension System

Diagnosis and Test (Continued)

Warning：When disassembling the dust shield

/ limit block, over pushdown of the pushing
rod of the shock absorber should be avoided
in the compression process, so as not to cause
damage of internal components.
The shock absorber should be vertically placed on a
vice. Use a possibly-quick large travel compression
shock absorber. The compression motion of each time
must be steady and consistent. The phenomenon that
extending resistance is greater than compression
resistance is normal.
The following situations are abnormal:
– If lagging or skipping occurs during return after
the shock absorber is installed in place and in the
installation process.
– Locked.
– Apart from the slight sound of swish, noise, such
as the sound of click occurring during quick
return.
– Leakage.
– The pushing rod of the shock absorber is
completely stretched, and the piston rod of the
shock absorber swings corresponding to the
housing of the shock absorber.
If the shock absorber is still unstable after air
purification, please replace a new shock absorber. See
Section 201-01 (Front Shock Absorbing Devices) and
Section 201-02 (Rear Shock Absorber).

Rear Shock Absorber

Conduct the following inspections periodically to the
rear shock absorber:
1. Inspect whether the rear shock absorber has oil
leakage. (A layer of oil film is allowed, provided
that the leakage is not from other positions).
2. Inspect the working state of the rear shock
absorber.
3. Inspect the working state of the upper and the
lower axle linings.

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201-00-15 Suspension System-General Information

Diagnosis and Testing

Failure Table
Phenomena Possible Reasons Measures
•Swing / Derivation / Excursion • Excessive difference of the kingpin • Perform tyre positioning. See the
caster angle or camber angle of the section of Common Procedures for
left and right wheels relevant information.
• Toe-in value exceeds the regulated • Perform tyre positioning. See the
scope. section of Common Procedures for
relevant information.
• Abnormal automobile running • Inspect overload, loosened shock
height (Front or rear, high or low) absorbing spring or non-standard
spring.
• The steering mechanism or the ball • Inspect the steering system. See
head of the tie rod is abraded. Section 204-00 for relevant
information.
• Tyres are abraded or defective. • Inspect the tyres. See Section
201-03 for relevant information.
• Heavy steering • Excessive kingpin caster angle • Perform tyre positioning. See the
section of Common Procedures for
relevant information.
• Incorrect vehicle height (Front or • Inspect overload, loosened shock
rear, high or low) absorbing spring or non-standard
spring.
• The steering mechanism or the ball • Inspect the steering system. See
head of the tie rod is abraded. Section 204-00 for relevant
information.
• The ball head of the lower cross • See the section of Maintenance
arm is abraded. Procedures for relevant
information.
• Tyres are abraded or unblanced • Inspect tyres. See Section 201-03
for relevant information.
• Lacking power steering force • Inspect the steering system. See
Section 204-01 for relevant
information.
• Braking lagging • Different tyre pressure • Fill gas into tyres at the precise
pressure. See Section 201-04 for
relevant information.

• Braking system failure • Check the brake. See Section

• Automobile Fluttering
203-00 for relevant information.
• Unbalance and excessive wear of • Check the tyres. See Section
the tyres 201-03 for relevant information.
• Abrasion of the driving axle of the • Check the driving axle of the front
front wheels wheels. See Section 202-01 for
relevant information.
•Abrasion of the steering system •Check the steering system. See
Section 204-00 for relevant
information.

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201-00-16 Suspension System-General Information

Diagnosis and Testing (Continued)

•Loosening and abrasion of the •Check the suspension device

suspension device assembly assembly. See this section for
relevant information.
• Loosening of the bracket for the •Fasten according to the torque
suspension device assembly requirements. See Sections 201-01
(former) and 201-02 (latter) for
relevant information.
• Abrasion of the ball head of the • Replace the ball head of the front
lower cross arm lower cross arm. See Section
201-01 for relevant information.
• Abrasion and loosening of the bush •Replace the axle bushing of the
of the lower cross arm of the front lower cross arm of the front
suspension suspension. See Section 201-01 for
relevant information.
• Abrasion of the axle bushing of the •Replace the axle bushing or
direction stabilizing rod (if connecting rod of the direction
equipped) stabilizing rod. See sections 201-01
(former) and 201-02 (latter) for
relevant information.
• Abrasion or loosening of the rear • Replace the rear suspension and the
suspension and the axle bushing axle bushing if necessary. (Section
201-02)
• Abrasion of the wheel bearing • Replace the wheel bearing. See
Sections 203-01 (former) and
203-02 (latter) for relevant
information.
• Derivation •Damage of the rear suspension •Repair or replace the parts of the
rear suspension if necessary. See
Section 201-02 for relevant
information.
•The kingpin caster angle is not in • Perform tyre positioning. See this
the regulated scope. section for relevant information.
Impact Derivation • Loosening or abrasion of the • Repair or replace the installation
installation supporting frame and bracket and the axle bushing if
the bearings of the steering necessary. See Section 204-02 for
mechanism relevant information.
• Loosening and abrasion of the front •Repair or replace the front
suspension assembly suspension assembly if necessary.
See Section 201-01 for relevant
information.
•Noise of the Front and Rear • Loosening or abrasion of the •Repair or replace the bracket if
Suspension suspension assembly bracket necessary. See Sections 201-01
(former) and 201-02 (latter) for
relevant information.
• Abrasion of the wheel bearing • Check the wheel bearing. See
Sections 203-01 (former) and
203-02 (latter) for relevant
information.

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201-00-16
Diagnosis and Testing (Continued)
• Swaying of the Vehicle Body
•Incline of the Vehicle Body
• Poor Running Comfort
• Unsteady Direction
Suspension System-General Information
• Abrasion of the connecting rod or • Replace the connecting rod or axle
bearing of the front direction bushing of the front direction
stabilizing rod (if equipped) stabilizing rod. See Section 201-01
for relevant information.
• Loosening or abrasion of the lower • Repair or replace the axle bushing
cross arm of the front suspension of the lower cross arm of the front
suspension. See Section 201-01 for
relevant information.
• Loosening or abrasion of the • Check the suspension assembly.
suspension assembly See Sections 201-01 (former) and
201-02 (latter) for relevant
information.
•Softening or damage of the front or • Check the shock absorbing springs.
rear damping springs See Sections 201-01 (former) and
201-02 (latter) for relevant
information.
• Inappropriate tyre air pressure • Adjust the tyre air pressure.
•Softening of the front or rear • Check the shock absorbing springs.
damping springs See Sections 201-01 (former) and
201-02 (latter) for relevant
information.
• Abrasion of the front or rear • Check the suspension assembly.
suspension assembly See Sections 201-01 (former) and
201-02 (latter) for relevant
information.
• Unbalance and damage or • Check the tyres. See Section
excessive run-out amount of the 201-03 for relevant information.
tyres
• The front toe-in value is out of the • Perform the wheel alignment. See
regulated scope. this section for relevant
information.
• Abrasion of the steering system • Check the steering system. See
Section 204-00 for relevant
information.
• Damage of the ball head of the • Replace the ball head of the lower
lower cross arm of the front cross arm of the front suspension.
suspension See Section 201-01 for relevant
information.
•Softening of the front or rear • Check the shock absorbing springs.
damping springs See sections 201-01 (former) and
201-02 (latter) for relevant
information.
• Abrasion of the front or rear • Check the suspension assembly.
suspension assembly See sections 201-01 (former) and
201-02 (latter) for relevant
information.
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201-00-16 Suspension System-General Information

Diagnosis and Testing (Continued)

• Loosening and abrasion of the rear • Check the rear suspension. See
suspension, axle bushing or bolts. Section 201-02 for relevant
information.
• Abrasion of the axle bushing or • Replace the axle bushing or
connecting rod of the direction connecting rod of the direction
stabilizing rod stabilizing rod. See Section 201-01
for relevant information.
• Abnormal Return of the Steering • Abnormal wheel alignment • Perform the wheel alignment. See
Wheel this section for relevant
information.
• Abrasion of the steering system • Check the steering system. See
Section 204-00 for relevant
information.
• Abrasion of the ball head of the • Replace the ball head of the lower
lower cross arm of the front cross arm of the front suspension.
suspension See Section 201-01 for relevant
information.
• The Derivation to One Side of the • Unbalance and damage or • Check the tyres. See Section
Steering Wheel excessive run-out amount of the 201-03 for relevant information.
tyres
•Abrasion of the braking system • Check the braking system. See
Section 203-00 for relevant
information.
• Abrasion of the steering system • Check the steering system. See
Section 204-00 for relevant
information.
•Incorrect wheel alignment • Perform the wheel alignment. See
this section for relevant
information.
• Damage or jamming of the ball • Replace the ball head of the lower
head of the lower cross arm of the cross arm of the front suspension.
front suspension. See Section 201-01 for relevant
information.
•Softening of the front shock • Check the front shock absorbing
absorbing spring spring. See Section 201-01 for
relevant information.
• Damage or loosening of the axle • Repair or replace the axle bushing
bushing of the lower cross arm of of the lower cross arm of the front
the front suspension suspension. See Section 201-01 for
relevant information.
• Abnormal Noise of the Suspension •Damage or jamming of the ball • Replace the ball head of the lower
System head of the lower cross arm of the cross arm of the front suspension.
front suspension. See Section 201-01 for relevant
information.
• The loosening and abrasion of the • Repair or replace the direction
front direction stabilizing rod (if stabilizing rod. See Section 201-01
equipped) for relevant information.

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201-00-16 Suspension System-General Information

Diagnosis and Testing (Continued)

• Loosening of the front or rear • Repair or replace the suspension

suspension components components. See Section 201-01
for relevant information.
• Loosening or abrasion of the axle • Repair or replace the axle bushing
bushing of the lower cross arm of of the lower cross arm of the front
the front suspension suspension. See Section 201-01 for
relevant information.
• Loosening or abrasion of the • Check the suspension assembly.
suspension assembly See sections 201-01 (former) and
201-02 (latter) for relevant
information.

Fixed Point Inspection

Fixed Point Inspection A: Left and Right Derivation
Phenomena Concrete Procedures/Results/Measures
A1: Check the left and right derivation

Warning: In order to avoid the bodily injuries caused by uncontrolled operation, inspection shall be
carried out by two operators to maintain safe driving status. The appropriate control to the steering wheel
shall be maintained. Failing to comply with these instructions may cause bodily injuries.
Notes: Following conditions must be met when automobiles are evaluated.
1 Check the tyre air pressure
- Drive the automobile at the speed of 88 km/h (55
mph) on smooth road.
- Confirm that there is no crosswind or gale
when driving
- Run back and forth for two times.
- If the trace of the automobile deviates 12 feet
within 7 seconds, the automobile deviates.
• Does the automobile deviate?
　Yes
Switch to A2
　No
Switch to fixed point inspection B.
A2: Check the steering connection rod
1 Hoist the automobile. See Section 100-01 for
relevant information.
- Check whether the steering connection rod is
excessively worn.
• Is the steering connection rod excessively worn?
　Yes
Replace or repair the damaged component. Test
and operate the system to determine whether it is
in the normal condition.
　No
Switch to A3
A3: Check the wheel alignment
1 Check the wheel alignment

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201-00-16 Suspension System-General Information

Diagnosis and Testing (Continued)

Phenomena Concrete Procedures/Results/Measures

• Is the steering wheel in central position and the

wheel alignment data in regulated scope?
　Yes
Switch to A4
　No
Perform the wheel alignment if necessary. Test
and operate the system to determine whether it is
in the normal condition.
A4: Check the tyres
1 Check the excessive wear of the tyres
• Are the tyres excessively worn?
　Yes
Replace the tyres. Test and operate the system to
determine whether it is in the normal condition.
　No
Switch to A5
A5: Rotate wheels
1 Hoist the automobile. See Section 100-01 for
relevant information.
- Rotate wheels in a cross way.
• Does the automobile deviate?
Yes
Check the abrasion of the suspension parts.
Replace or repair the damaged parts if necessary.
See Section 201-01 for relevant information.
Test and operate the system to determine
whether it is in the normal condition.
　No
Replace the tyres. Test and operate the system to
determine whether it is in the normal condition.
Fixed Point Inspection B: the steering wheel deviates from the central position
Phenomena Concrete Procedures/Results/Measures
B1: Check the steering components
1 Hoist the automobile. See Section 100-01 for
relevant information.
- Check whether the steering components are
excessively worn.
• Are the steering components excessively worn?
　Yes
Replace or repair the abraded components. See
Section 204-00 for relevant information.
　No
Switch to B2
B2: Check the wheel alignment
1 Check the wheel alignment.
• Is the steering wheel in the central position and the
wheel alignment data in regulated scope?
　Yes

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201-00-16 Suspension System-General Information

Diagnosis and Testing (Continued)

Phenomena Concrete Procedures/Results/Measures

Switch to fixed point inspection C.
　No
Perform the Wheel alignment if necessary. Test
and operate the system to determine whether it is
in the normal condition.
Fixed Point Inspection C: Abnormal Running Trace
Phenomena Concrete Procedures/Results/Measures
C1: Check the kingpin caster angle
1 Check the kingpin caster angle.
• Is the kingpin caster angle in regulated scope?
　Yes
Switch to C2
　No
Check the wear of the suspension components.
Replace or repair the abraded components if
necessary. See Sections 201-01 (former) and
201-02 (latter) for relevant information. Test and
operate the system to determine whether it is in
the normal condition.
C2: Check the rear suspension
1 Measure the distance between the left and right
wheels of the automobile
- Compare the measured value
• Are the data the same?
　Yes
Switch to fixed point inspection D.
　No
Check the wear of the rear suspension parts.
Replace or repair the abraded components if
necessary. See Section 201-02 for relevant
information. Test and operate the system to
determine whether it is in the normal condition.
Fixed Point Inspection D: Poor Running Comfort
Phenomenon Concrete Procedures/Results/Measures
D1: Check the suspension assembly
1 Check the tyre air pressure.
- Automobile hoisting. See Section 100-01 for
relevant information.
- Check the leaked or damaged suspension
components.
• Are the suspension components leaked or
damaged?
　Yes
Replace the suspension components if
necessary. See Sections 201-01 (former) and
201-02 (latter) for relevant information. Test
and operate the system to determine whether it
is in the normal condition.
　No
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201-00-16 Suspension System-General Information

Diagnosis and Testing (Continued)

Phenomenon Concrete Procedures/Results/Measures

Confirm the failures described by the customer.
Fixed Point Inspection E: Excessive Noises
Phenomena Concrete Procedures/Results/Measures
E1: Check the suspension
1 Hoist the automobile . See Section 100-01 for
relevant information.
- Check the installation bolts of the suspension
components
• Are the bolts loose or broken?
　Yes
Tightly fix or change the bolts. See sections
201-01 (former) and 201-02 (latter) for relevant
information. Test and operate the system to see
whether it is in normal condition.
　No
Switch to E2

E2: Check shock absorbing spring

1 Check if the shock absorbing spring is damaged.
• Is the shock absorbing spring damaged?
　 Yes
Replace the shock absorbing spring. See Section
201-01 (former) and Section 201-02 (latter) for
relevant information. Test and run the system to
determine if it is normal.
　 No
Switch to E3
E3: Check the lower cross arm of the front suspension
1 Check excessive wear or damage of the axle
bushing of the lower cross arm of the front
suspension.
• Is the bush of the lower cross arm of the front
suspension abraded?
Yes
Replace the axle bushing of the lower cross
arm of the front suspension. See Section
201-01 for relevant information. Test and run the
system to determine if it is normal.
No
Switch to E4
E4: Check the ball head
1 Hoist the automobile. See Section 100-01 for
relevant information.
- Firmly hold the outer end of the lower cross
arm of the front suspension and move up and
down, in order to check if there has free
movement. Note that the free movement is not
allowed.

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201-00-16 Suspension System-General Information

Diagnosis and Testing (Continued)

• Does there have free movement?

Yes
Replace the ball head. See Section 201-01 for
relevant information. Test and run the system to
determine if it works normally.
No
Switch to E5
E5: Check the front wheel bearings
1 Check the front wheel bearings
- Hold the bottom and top of wheel and sway
forcefully. Check if bearings excessively loosen.
- Rotate the front wheel, and check the working
status.
• Does bearing loosen or have sound?
Yes
If necessary, replace the front wheel bearings.
See Section 203-02 for relevant information.
Test and run the system to determine if it is
normal.
No
Switch to E6
E6: Check the tyre
EE

1 Check the wear unevenness of the tyre.

• Is tyre wear uneven?

Yes
Replace the tyre. Perform wheel alignment. Test
and run the system to determine if it is normal.
No
Confirm the failure customer described.

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201-00-16 Suspension System-General Information

Diagnosis and Testing (Continued)

Fixed Point Inspection F: Check Tyre Wire

Phenomena Concrete Procedures/Results/Measures

F1: Check tyres

1 Hoist the automobile. See Section 100-02 for
relevant information.
- Check the unbalanced abrasion of inner
edge and outer edge abrasion of the tyre or
sawtooth abrasion.

Does tyre have unbalanced abrasion?

Yes
Replace the excessively abraded tyre.
Check wheel alignment. Test and run the
system to determine if it is normal.

No
Switch to F2
F2: Check sunken tyres
1 Check the sunken tyres.
• Is tyre sunken?
Yes

Replace the tyre. The tyre is dynamically

balanced See Section 201-03 for relevant
information. Test and run the system to
determine if it is normal.
No
Confirm the failure customer described.

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201-00-16 Suspension System-General Information

Diagnosis and Testing (Continued)

Fixed Point Inspection G: Vibration

Phenomena Concrete Procedures/Results/Measures

G1: Check the tyre

1 Hoist the automobile. See Section 100-02 for
relevant information.
- Check the damage or excessive wear of
the tyre.

Is the tyre damaged or excessively worn?

Yes
Replace tyre. Test and run the system to
determine if it is normal.

No

Switch to G2
G2: Check front wheel bearings
1 Check the front wheel bearings.
- Hold the bottom and top of wheel and
sway forcefully. Check if bearings excessively
loosen.
- Rotate the front wheels. Check the
working status of the front wheels.
Do bearings loosen or have sound?
Yes
Switch to G3
No
Switch to G4
G3: Measure the axial clearance of the front wheel bearing
1 Disassemble the wheels, the brake calipers and
the brake disc.
- Install the dial gauge with the installing
bracket, and ensure it to abut against wheel
hub of the front wheel.
- Axially push and pull the wheel hub, and
check the axial clearance of the wheel hub and
the front wheel bearing.
• Is axial clearance of the front wheel bearing in
the specification value?
Yes

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201-00-16 Suspension System-General Information

Diagnosis and Testing (Continued)

Phenomena Concrete Procedures/Results/Measures

See component test part in this Section.

Check the ball head. Switch to G4

No
If necessary, replace the wheel hub and
bearings assembly. Test and run the system
to determine if it is normal.
G4: Check the rear wheel bearing
1 Check the rear wheel bearing.
- Hold the bottom and top of the wheel and
sway forcefully. Check if bearings excessively
loosen.
- Rotate the rear wheel. Check working status
of the rear wheel.
Does bearing loosen or have sound?
Yes
Switch to G5
No
Switch to G6
G5: Measure the axial clearance of the rear wheel bearing
1 Disassemble the rear wheel
- Install the dial gauge with the installing
bracket, and ensure it to abut against the rear
brake drum.
- Axially push and pull the wheel hub, and
check the axial clearance of the rear wheel
bearing.
Is axial clearance maintained in the specification
value?
Yes
Switch to G6
No
If necessary, replace the rear wheel bearing.
See Section 201-02 for relevant information.
Test and run the system to determine if it is
normal.
G6: Check the wheel/tyre run-out value in the automobile

1 Use the radial run-out table and measure radial

run-out of the wheel and the tyre in the
automobile, and the transverse and radial
run-out amount of the assembly is smaller than
1.14 mm.
• The measured value is in regulated scope.
Yes
Switch to G12
No
Switch to G7

Benni Mini
201-00-16 Suspension System-General Information

Diagnosis and Testing (Continued)

G7: Measure the wheel/tyre run-out value under the automobile

1 Measure the wheel that the radial run-out
or the transverse run-out exceeds 1.14 mm. The
positions of the tyre bolts and the relevant bolt
holes should be marked before the wheel is
disassembled so that the wheel can be installed
at the original position. Disassemble the wheel
and install the wheel on the tyre balancing
apparatus, and measure the run-out value. The
radial and transverse run-out of the wheel and
tyre assembly must be less than 1.14 mm.
• The measured value is in the regulated scope.
　 Yes.
Switch to G7
　 No
Switch to G8
G8: Match the installation position
1 Mark the highest run-out positions of the
tyre and the wheel. Blow off the air in the tyre
and rotate the tyre by 180 degrees. Aerate the
tyre and measure the run-out value of the tyre.
• Are the run-out positions of the wheel and the
tyre coincident?
Yes

Perform dynamic balancing of the tyre. Reinstall

the tyre on the automobile. Test and run the
system to determine whether it is normal.

　No
If the highest points during the two tests are
beyond 101.6 mm, replace the tyre. If the highest
points are within 101.6 mm, switch to G9.
G9: Measure wheel run-out
1 Dismount the tyre casing of the wheel, and install
the wheel on the tyre balancing machine. Measure
the run-out of the inner and outer edges of the
wheel. The radial and transverse run-out should be
less than 1.14 mm.
• Is the run-out normal?
　Yes
Find and mark the lowest point of the run-out of
the wheel. Install the tyre, to be matched with
the highest point of the run-out of the wheel.
Balance the tyre. Test and run the system to
determine whether it is normal.
　No

Benni Mini
201-00-16 Suspension System-General Information

Diagnosis and Testing (Continued)

Replace the tyre. Checke the run-out of the new

wheel. If the new wheel is in the regulated
scope, search and mark the lowest point of the
wheel run-out. Install the wheels, to make the
highest point of the wheel run-out coordinate
with the lowest point of the wheel run-out. Make
them balanced. Test and run the system to
determine if it is normal.
G10: Radial run-out of the rear wheel hub and the wheel bolts
1 Measure the run-out of the flange surface of the
wheel hub (larger than 0.254 mm) and the
circumferential run-out of the wheel bolt (larger
than 0.08 mm)
• Is the measured value in the normal range?
Yes
Switch to G11
No
Replace the rear wheel hub. See Section 204-2
for relevant information. Test and run the system
to determine if it is normal.
G11:Circumferential run-out of the front wheel hubs and the tyre bolts
1 Dismount the front wheels.
- Dismount the brake disc.
- Measure the circumferential radial run-out of
the tyre bolts (larger than 0.06mm)
• Is measured value in the normal scope?
Yes
Check the run-out of the brake disc. See Section
203-00 for relevant information. Test and run the
system to determine if it is normal.
No
Replace the wheel hub. See Section 201-01 for
relevant information. Test and run the system to
determine if it is normal.
G12: Wheel balancing
1 Perform the wheel balancing. Perform the road
test.
• Can automobile vibration be felt?
Yes
See Section 100-04 for relevant information.
No
Confirm the failure customer described.

Benni Mini
204-00-17 Suspension System-General Information

GENERAL PROCEDURES

Toe-in adjustment (14 117 0)

GENERAL PROCEDURES

2. Loosen the locking nuts of the ball head of the tie

rod.
General Tool
Wheel Alignment Ruler

Inspection
1. Operate toe-in adjustment with a wheel
alignment ruler on a flat ground according to
the instruction.
• Check suspension and steering
components, to confirm that there is no wear.
• Check and adjust the tyre air pressure if
necessary. 3. Rotate the locking nuts of the ball head of the
• Ensure that the automobile is in the kerb tie rod clockwise or counterclockwise to adjust
mass. The standby tyre, the lifting jack and the the toe-in.
driver's tool are all in the right place. Get out
other tools or goods.
• Press the automobile up and down, to make
the vehicle suspension system in the normal
position.

Adjustment
1. Turn the steering wheel to the central position
and lock it.

4. Lock the locking nuts of the ball head of the tie

rod.
Locking
锁死

5. Check the toe-in.

Benni Mini
Inspection of the Wheel Bearing 5. Install an appropriate fixer of the dial gauge or
similar devices on the wheel hub and then
Special Tool push and pull the wheel hub. Measure the
axial clearance between the wheel hub and the
wheel bearing assembly. There should not
Fixing Supporting Seat of the have any axial clearance, if there has any axial
Dial Gauge clearance, replace the front wheel bearings.
205-044 (15-008)

General Tool
Dial Gauge

Inspection
1. Notes ：Do not confuse the loosening of the lower cross
arm ball head with the loosening of the bearing.
Hoist the fore part of the automobile. See Section
100-01 for relevant information. 6. Install the front brake calipers. See Section
2. Shake the wheels. Check if the front wheel bearings is 203-01 for relevant information
loosened.

3. Fast rotate the wheels, to confirm that the wheels

rotate smoothly and quietly.
4. Dismount the front brake calipers and the supporting
plate. See Section 203-01 for relevant information.
201-01-1 Front Suspension

Item Ⅰ Section 201-01 Front Suspension

Applicable Vehicle Model: Benni Mini

Contents Pages
Specification

Specification 201-01-2

Instruction and Operation

Front Suspension 201-01-2

Diagnosis and Test

Front Suspension 201-01-3

Disassembly and Installation

Front oscillating arm 201-01-4

Front supporting column 201-01-7
Front stabilizing rod 201-01-09

Disintegration and Assembly

Shock Absorbing Supporting Column and Absorbing Supporting Spring Assembly 201-01-11

Benni Mini
201-01-2 Front Suspension

Instruction and Operation

(ⅰ) Torque Specification

Description Nm lb-ft lb-in
Locking nuts between the ball head of the tie rod 30-55 -
Connecting bolts between the bracket of the front 89-95 -
stabilizing rod and the front oscillating arm
Connecting nuts between the low bracket of the
front longibeam and the low crossbeam of radiator
65-79
Connecting bolts and nuts between the low bracket 65-79
of the front longibeam and the low plate of the front -
cabin
Connecting bolts between the ball head pin of the 45-55
front oscillating arm and the steering knuckle
Connecting bolts between the front oscillating arm 65-79 -
and the front oscillating arm mounting plate
Wheel nuts 75-95 -
Fixing nuts of the wheel hub 250-300
Connecting nuts between the front supporting 33-40
column and the vehicle body
Connecting bolts and nuts between the front 80-95 -
supporting column and the steering knuckle
-

节 1.01 DESCRIPTION AND OPERATION

Front Suspension

The front suspension is composed of accessories of two
front supporting column assemblies (including shock
absorbing springs), an oscillating arm, transverse
stabilizing rod, etc.
The oscillating arm is formed through welding after a
steel plate is stamped. Each piece is connected through
a way that one bolt and the oscillating arm mounting
plate. The transverse stabilizing rod penetrate through
the piece and tighten by a bolt.
The oscillating arm is connected with the steering
knuckle through a ball head.
The wheel steering knuckle is connected with the
suspension assembly and the ball head of the tie rod.
The suspension device is supported at the upper
installing position by using the gum cover installed on
the supporting seat of the top of the supporting column.
The spiral spring is installed between two springs of the
suspension device. The piston rod is provided with a
dust shield, to prevent dirt or influent water. In order to
protect the suspension device at the full compression
state, an anti-impact rubber cushion is also installed.

Benni Mini
204-01-3 Front Suspension 204-01-3

Disassembly and Installation

(a) Front Suspension

See Section 201-00.
Front oscillating arm
Disassembly
1. Unscrew the tyre nuts.
2. Hoist the automobile. See Section 100-01 for
relevant information.
3. Disassemble the wheel.
4. Disassemble the connecting nuts and bolts
between the low bracket of the front longibeam and
the low plate of the front cabin. 6. Disassemble the locking nuts and locking pin of
the tie rod

5. Disassemble the Connecting nuts between the

low bracket of the front longibeam and the low
crossbeam of radiator

Benni Mini
201-01-4 Front Suspension

Disassembly and Installation (Continued)

7. Disassemble the tie rod 10. Disassemble front oscillating arm

8. Disassemble the connecting bolts between the Installation

ball head pin of the front oscillating arm and the
Reverse the disassembly process for
steering knuckle
installation.
1. Install the bolts of the front oscillating arm and
the front oscillating arm mounting plate.

Warning: Use cotton cloth to protect the ball

head from being damaged.
2.Install the connecting bolts between the ball
9. Disassemble the bolts of the front oscillating arm head pin of the front oscillating arm and the
and the front oscillating arm mounting plate. steering knuckle

Benni Mini
201-01-5 Front Suspension

3. Install the connecting nuts and bolts between the

low bracket of the front longibeam and the low
plate of the front cabin.

4. Install the Connecting nuts between the low

bracket of the front longibeam and the low
crossbeam of radiator

5. Install the locking nuts and locking pin of the tie

rod

Benni Mini
204-01-6 Front Suspension 204-01-6

Disassembly and Installation

节 1.02 DIAGNOSIS AND TESTING

(b) Front supporting column assembly

Disassembly
1. Loosen the tyre bolts.
2. Hoist the automobile. See Section 100-02 for
relevant information.
3. Disassemble the wheel.
4. Remove the rotating speed sensors of the front
wheels and brake fuel pipe from the front
supporting column.

Installation

1.Install the front supporting column and the fixed

nuts

5. Disassemble the bolts of the front supporting

column and the steering knuckle.

2. Install the bolts of the front supporting column

and the steering knuckle.

6. Release the fixed nuts on the front supporting

column and remove the front supporting column
assembly.

Benni Mini
201-01-7 Front Suspension

Disassembly and Installation (Continued)

3. Install the rotating speed sensors of the front

wheels and brake fuel pipe to the front
supporting column.

Benni Mini
201-01-8 Front Suspension

Disintegration and Assembly

(d) Shock absorbing supporting column and

absorbing supporting spring assembly (14 783 4)

13. Disassemble the absorbing assembly

Disintegration
1. Disassemble the suspension assembly. See this
section for relevant information.
2. Warning: Always be careful to avoid injury
as the spiral spring is at the extreme
strained state.
Compress the spiral spring partially.

Assembly

1. Note: Place the end of the spring on the spring seat

correctly.
Reverse the disassembly process for installation.

3. Disintegrate the front shock absorbing devices

and the spiral springs.

1. Disassemble the nuts
2. Disassemble the washers
3. Disassemble the elastic washers
4. Disassemble the sub assembly of the inner
connecting sleeve.
5. Disassemble the sub assembly of the outer
connecting sleeve.
6. Disassemble the washers
7. Disassemble the bearing pad.
8. Disassemble the bearings.
9. Disassemble the mounting
10. Disassemble the cushion of the spring.
11. Disassemble the spiral spring.
12. Disassemble the collision mat.

Benni Mini
201-02-1 Rear Suspension 201-02-1

Section 204-02 Rear Suspension

Applicable Vehicle Model: Benni Mini

Contents Pages
Specification 201-02-2

Specification

Instruction and Operation 201-02-3

Rear Suspension

Diagnosis and Test 201-02-4

Rear Suspension

Disassembly and Installation 201-02-5

The connecting rubber cushion of the tie rod

The tie rod
The upper seat of the spiral spring
The collision mat
The rear spiral spring

Shock Absorbing Supporting Column and Absorbing Supporting Spring Assembly

The longibeam oscillating arm

The rear axle

Benni Mini
201-02-2 Rear Suspension 201-02-2

Specification

Torque Specification
Instructions Nm lb-ft lb-in
Connecting bolts between rear shock absorber and the 80~95 -
vehicle body
Connecting bolts between the rear shock absorber and 80~95 -
the rear axle
Connecting bolts between the rear axle and the vehicle 80~95 -
body
Connector of the barking hose 16±2 -
Wheel nuts 85±10 -
Fixing bolts of the wheel axle 170~220 -

Connecting bolts between the longibeam oscillating arm 80~95

and rear axle

Connecting bolts between the longibeam oscillating arm 80~95

and the vehicle body
Connecting bolts between the tie rod and the vehicle 80~95
body
Connecting bolts between the tie rod and the rear axle 40~50

Connecting bolts between the rear brake assembly and 40~45

the rear axle
The head of rear rotating speed sensor (ABS)and the 8~10
rear axle flange

Connecting bolts M10 of braking fuel pipe 14~18

Connecting bolts M12 of braking fuel pipe 16~20

Benni Mini
201-02-3 Rear Suspension 201-02-3

Instruction and Operation

DESCRIPTION AND OPERATION

Rear Suspension

Serial Parts Number Name

Number
1 2916012-K01 The connecting rubber cushion of the tie rod

2 2916010-K01 the tie rod

3 2912002-C01 The upper seat of the spiral spring

4 2912012-K01 The collision mat

5 2912011-K01 The rear spiral spring

6 2915010-K01 The rear Shock absorber assembly

7 2917010-K01 The longibeam oscillating arm

8 3300100-K01 The rear axle

9 2502200-K01 Wheel hub and brake drum assembly

The rear suspension is composed of a rear axle assembly, spiral springs and a shock absorber assembly. The wheels
are connected to the rear suspension through the brakes.

Benni Mini
201-02-4 Rear Suspension 201-02-4

Diagnosis and Test

DIAGNOSIS AND TESTING

Rear Suspension

See this section for relevant information.

Benni Mini
201-02-5 Rear Suspension 201-02-5

Disassembly and Installation

The tie rod and the connecting rubber cushion

Disassembly 2. Install the tie rod to the vehicle body.

1. Hoist the vehicle. See the section 100-01 for
relevant information
2. Loosen the fixing nuts and bolts of the tie rod.
1. Loosen the bolts and nuts between the tie rod
and the vehicle body.
2. Disassemble the fixing nuts and washers
between the tie rod and the rear axle
.
3. Lower the vehicle.
4. Tighten the two nuts on the tie rod according to
the stated torque.
The spareparts of the rear suspension must
be last fastening when the vehicle is lowered
completely and unloaded.

3. Remove the outer connecting rubber cushion of

the tie rod

4．Remove the tie rod and the connecting rubber

cushion and washers of the fixing pin

Installation
1. As the following picture shows, to install the
washer, the connecting rubber cushion, the tie
rod , the connecting rubber cushion and the
washer.
The fixing pin of the
tie rod

.Don’t fastening the nuts.

Benni Mini
201-02-6 Rear Suspension 201-02-6

Disassembly and Installation

Rear shock absorber assembly

Disassembly
1. Hoist the automobile. See section 100-01 for
relevant information.
2. Use a jack to support the rear axle.
2. Remove the jack from the rear axle.
3. Lower the vehicle.
4. Tighten the nuts and the lower bolts on the rear
shock absorber assembly to the stated torque.
The spareparts of the rear suspension must
be last fastening when the vehicle is lowered
completely and unloaded.

3. Disassembly the fixing bolts of the rear shock

absorber assembly.
1.Diassembly the lower nuts
2.Diassembly the upper nuts.

4. Remove the rear shock absorber

assembly.

Installation
1. Install it according to the procedures adverse to
the disassembly sequence.
Don’t fastening the nuts and the bolts.

Benni Mini
201-02-7 Rear Suspension 201-02-7

Disassembly and Installation

The rear spiral spring and the upper and

the lower seats of the rear spiral spring and
shock absorber cushion
.
Disassembly
1. Hoist the automobile. See this section for relevant
information.
2. Use a jack to support the rear axle.
3. Disassemble the nuts and bolts between the tie
rod and the vehicle body.
4. Disassemble the lower bolts of the rear shock
absorber assembly.
5. Disassembly of the rear spiral spring, as well as
the upper and the lower seats of the rear spiral
spring and the shock absorber cushion.
.
Shock absorber
cushion

Installation
1. Install it according to procedures adverse to the
disassembly sequence.
Don’t tighten the nuts and the bolts.
2. Remove the jack from the rear axle.
3. Lower the vehicle.
4. Tighten the nuts and the lower bolts on the rear
shock absorber assembly to the stated torque.
The spareparts of the rear suspension must
be last fastening when the vehicle is lowered
completely and unloaded.

Benni Mini
201-02-8 Rear Suspension 201-02-8

Disassembly and Installation

The longibeam oscillating arm

The spareparts of the rear suspension
Disassembly must be last fastening when the vehicle is lowered
completely and unloaded.
1. Hoist the automobile. See Section 100-01 for
relevant information.
2. Use a jack to support the rear axle.
3. For the vehicle with ABS, Disassemble the nip of
the wiring harness of the wheel speed sensor from
the longibeam oscillating arm.

4. Disassembly the bolts and nuts of the longibeam

oscillating arm
1. disassembly the bolts and nuts A 、 B between
the longibeam oscillating arm and rear
axle .
2. disassembly the bolts and nuts C between the
longibeam oscillating arm and vehicle body
5. Remove the longibeam oscllating arm .

Nip

Installation
1. Install it according to procedures adverse to the
disassembly sequence.
Don’t tighten the nuts and the bolts.
2. Remove the jack from the rear axle.
3. Lower the vehicle.
4. Tighten the bolts between the the longibeam
oscillating arm and the rear axle and vehicle body
to the stated torque.

ALSVIN
201-02-9 Rear Suspension 201-02-9

Disassembly and Installation

Rear Axle
Base plate
Disassembly
1. Loosen the parking braking dragline. hoist the
automobile. See this section for relevant
information.

2. Loosen the tyre nuts, remove the tyre.

3. Disassemble the nip of the wiring harness of the
wheel speed sensor from the rear axle ,according to
the process of disassembly the wheel speed sensor.
See this section 203-06 for relevant information.
4. Disconnect the braking hose
1. Disassemble the E shake fixing clip of the
connector.
Warning: Do not damage the brake hose.
7. Disassemble the tie rod and the connecting
rubber cushion of the tie rod.
8. Use a jack to support the rear axle.
9. Disassemble the lower bolts of the rear shock
absorber assembly.

3. Disassemble the connector of the barking hose

10. Lower the rear axle by adjusting the jack, for

that to disassemble the spiral spring .

Warning: it is not allowed that the brake fluid

flow to the paint surface.

5. Disassemble the brake drum assembly.

6 Disassemble the brake base plate.

1. disassemble the fixing bolts of the brake base plate.
2.remove the base plate from the rear axle.

Benni Mini
201-02-10 Rear Suspension
Disassembly and Installation (Continued)
11. Disassemble the spiral spring .
12. Disassemble the connecting nuts between the
longibeam oscillating arm and rear axle, but do not
disassemble the bolts.
13. Use a jack to support the rear axle, disassemble
the connecting bolts between the longibeam
oscillating arm and rear axle.
14. Disassemble the rear axle.
Installation
1. Put the rear axle on the jack, assemble the
connecting bolts between the oscillating arm
and rear axle according to as the following
picture shows, assemble the nuts but do not
fastening.
2. Install the spiral spring to the upper seat of the
spiral spring, as the following picture shows:
Upper
201-02-10
Note:
1. when assembling the spiral spring, make the end
of the spiral spring fix to the spring retainer.
Upper seat
Spring retainer
2. Make your finger not to be hurt by the spiral
spring when ascending the rear axle .
3. Keep ascending the rear axle until lower bolts
installing hole of the rear axle shock absorber is
higher or equal to the lower bolts of the shock
absorber fixing hose.
4. Install the lower bolts of the shock absorber.
5. Remove the jack form the rear axle .
6. Install the tie rod and the connecting rubber
cushion of the tie rod
7. Install the brake base plate and last fastening to
the stated torque.
8. Install the brake drum, please see the section of
brake drum for relevant information .
9. Connecting the brake hose to the bracket of rear
axle , tighten the connecter C and A of the brake
hose to the the stated torque, and use a E shake
clip to fix it.
Benni Mini
201-02-11 Rear Suspension 201-02-11

Disassembly and Installation (Continued)

10. Connect the wheel speed sensor and braking

hose nips (if equipped).
11. Full the brake fluid and exhaust the braking
system. See Section 203-00 for relevant
information
12. Install the wheel, tighten the tyre nuts to the
stated torque.
13. After the work as hereinbefore, step on the
brake pedal 3 to 5 times, loaded with 30kg
（66lbs）,for that to make the clearance
between wheel drum and brake shoe properly.
14. Tighten the bolts of the parking braking handle
cover.
15 . Lower the vehicle
16. Tighten the bolts between the the longibeam
oscillating arm and the shock absorber, tighten
the nuts of the tie rod to the stated torque.

The spareparts of the rear suspension must

be last fastening when the vehicle is lowered
completely and unloaded.
17. Make sure that the brake drum is not block and
brake force is properly.
18.Perform the brake test.(Including the parking
brake and foot brake).

Benni Mini
201-02-12 Rear Suspension 201-02-12
201-03-1 Wheel and Tyre

Section 201-03 Wheel and Tyre

Applicable Vehicle Model: Benni Mini

Contents Pages
Specification

Specification ........................................................................................................................................ 201-03-2

Instruction and Operation

Safety Warning .................................................................................................................................... 201-03-3

Diagnosis and Test

Wheel and Tyre 201-03-4

Inspection and Verification 201-03-4
Failure Phenomenon Table .................................................................................................................... 201-03-5

Disassembling and Installation

Wheel and Tyre 201-03-8

Benni Mini
201-03-2 Wheel and Tyre

Specification

Torque Specifications
Description Nm lb-ft lb-in
Wheel Bolt 85±10 - -

Benni Mini
201-03-3 Wheel and Tyre

Instruction and Operation

DESCRIPTION AND OPERATION

Safety Warning

Warning: Tyres of various types, such as

radial tyre, diagonal tyre or diagonal textile
cord tyre, are prohibited to be mounted in
one vehicle in a mixing way.
Warning: Prohibit starting vehicle when tire
replacement is performed. When wheels are
on ground, vehicle may be caused to move.
Warning: Tyre sealant in market belongs to
inflammable substance. Such kind of
substance is prohibited to be served as a
reminder.
Warning: Wear safety protective glasses or
mask when wheel and tyre assembly are
repaired.
Warning: Wheel bolt should be re-tighten
when the vehicle drives for 800 Km (500 miles)
after the replacement of wheel or the loosing
of wheel bolt.
Warning: If the wheel bolt is not tightened
within the regulated mileage, wheels deviating
from vehicle body may be caused during
automobile running process.
Warning: Wheel and tyre have their own
maximum load, so don't exceed weight limit.
Warning: Prohibit using steel wool grinding
and cleaning agent to clean aluminum alloy
wheel.
Warning: Before dismounting tyre valve core,
pressing of the valve core piston is used for
reducing tyre air pressure.

Bodily injury may be caused for noncompliance with

the above guidance.

Benni Mini
201-03-4 Wheel and Tyre

Diagnosis and Test

Wheel and Tyre – Engine torque

Inspection and Verification
In order to play the maximum efficiency of the tyre,
inspection should be performed to make sure whether
the tyre pressure and the tyre are abnormal, if such as
an indicator appear, the need for dynamic balancing,
diagonal adjusting or front wheel alignment is
displayed. Inspection should be regularly performed to
make sure whether nick, scraping, wear abrasion,
bubbling, and substance embedded in the tread exist.
If a rapid rising of the tyre temperature occurs, or
when clastics are dispersed because of rough road
surface, tyre inspection should be performed
frequently.
That tyre wire indicating line is marked at the bottom
part of the tread to be serviced as a more direction
inspection of the tyre status. The exposure of the
indication line of the tyre wear indicates the need for
replacement of the tyre.
– Vehicle speed
– Engine rotating speed
– Vibration type - sensitivity: torque sensitivity,
vehicle speed sensitivity or sensitivity of the
engine rotating speed.
The following explanations can help identify the
source of the vibration.
Torque sensitivity
This indicates the condition can be improved and
worsened because of acceleration, deceleration,
sliding, constant speed, or exerting engine torque.
Vehicle Speed Sensitivity
This indicates that vibration happens under the same
vehicle speeds, and can not be affected by engine
torque, engine rotating speed or gear selection of the
driving axle.

Sensitivity of the Engine Rotating Speed

Tyre Wear Diagnosis
When indication line of the tyre wear is exposed, or
the tire shoulder is severely abrased, the tyre should be
replaced. Wear of the tyre shoulder is usually caused
by an overlarge camber angle of the radial tyre or an
overlarge toe in.
Sometimes, incorrect rear wheel toe-in setting wheels
or supporting column damage can lead to serious
“sunken” or “fan-shaped” tyre wear of the non-driving
tyre.
Seriously incorrect toe-in of the rear wheel can also
lead to other abnormal wear.
Road Test
This indicates that vibration occurs under the identical
gears and different vehicle speeds. It can be tested by
increasing or decreasing engine rotating speed on
Neutral Gear or under stall speed experiment. If the
condition is related to engine rotating speed, the
reason may have nothing to do with the tyre.
If road test indicates tyre whimper, but shaking or
vibration is not indicated, the noise is caused by the
contacting of the tyre and the road surface.
Huge noise usually indicates a flat tire, or the noise is
created by soft thing contacting with the road surface.
The tyre whimper is mistaken for wheel shaft. The
tyre whimper will last under a certain vehicle speed
scope.

Tyre vibration diagnosis procedure is started from A complete road test

road test. Road test and face to face taking with
customers (if possible) can provides much more
information required by the vibration source.
Road test should be performed on smooth road
without fluctuation. If vibration occurs, pay attention
to and record the followings:
– Vehicle speed when vibration occurs.
– Types of vibration happed in each speed scope.
– Mechanical or audible.
– When the following conditions are changed, what
influence is affected in vibration?

U-Shine
201-03-5 Wheel and Tyre

Diagnosis and Test

Failure Phenomena

Phenomena Possible Failure Causes Measures

Excessive Wear of the Edge of the • Insufficient tyre air pressure
Tyre
Excessive Wear of the Tyre Crown
• Excessive Wear of the other Tyres • Incorrect tyre air pressure
• Wheels are difficult to install.
• Wheels are rust out or eroded.
•The tyre air pressure is adjusted.
•Overload of the automobile • Correction should be performed if
necessary.
•High-speed turning • Correction should be performed if
necessary.
• Incorrect toe-in • Toe-in is adjusted. See section
•Incorrect camber angle 201-00 for relevant information.
•Over high tyre air pressure • Tyre air pressure is adjusted.
• Frequent acceleration or braking • Correction should be performed if
necessary.
• Tyre air pressure is adjusted.
• Tyer is need to be replaced. • Tyer is replaced.
• The automobile is overload. • Load specification should be
inspected according to
requirements.
• The front or the back damping • Parts should be tightened or
device is loose or leaks. replaced if necessary. See section
201-01(the front) or section 201-02
(the back).
• Wheel bearing is worn. • Wheel bearing and / or hub should
be repalced. See section 201-01(the
front) or section 201-02 (the back).
• Suspension parts, axle linings and • Inspection, repair or part
ball joint are worn or damaged. replacement should be performed if
necessary.
• Lateral or radial run-out of the • Run-out amount should be
wheel or the tyre is excessive. measured by dial gauge, and
inspection, repair or parts
replacement should be performed id
necessary.
• The method is incorrect or parts
are mismatched, the parts include
wheel bolts and nuts.
• Parts and components are eroded, • Clean or replace the parts.
abraded or damaged.
• The maintenance is improper. • Cleaning or coating for protection
should be performed.

U-Shine
201-03-6 Wheel and Tyre

Diagnosis and Test（continued）

Phenomena Possible Failure Causes Measures

• Wheel run-out is influenced by • Wheel is disabled (especially • Inspect
shaking or abnormal vibration.
• Excessive fluttering of
automobile and bad steering.
• Automobile vibration caused by • Tyre air pressure is excessive.
wheel and tyre.
external retaining ring of the front replacement should be performed if
wheel bearing and the rolling necessary.
column bearing are damaged.)
the • Suspending parts are loose.
• Wheel or tyre is out of balance.
• Tyre is unevenly worn.
• Brake disc is out of balance.
• Water enters into the tyre.
• The wheel is bent.
wheel rim. Parts
• The parts should be tightened or
replaced.
•Tyre air pressure should be
adjusted.
• Wheel and tyre assembly should
be balanced.
• The tyre should be replaced for
eliminating vibration.
• Inspect to make sure whether dirt
or fragments are on the brake disc.
If a damaged brake disc or
fragments are found, heavy dirt
may be on the brake disc.
• The accumulated water should be
drained.
• A new wheel should be installed.
Trying to repair the wheel may
leads to wheel break and reduce the
wheel intensity.

• Tyre edge is correctly assembled. • The wheel should be rotated on the

vehicle. The combining position of
the wheel and the tyre should be
inspected. If swing is found on
some part when rotation is
performed, wheel and tyre may not
be well assembled on this part.
Remove the tyre and clean the
combining position of the wheel
and the tyre.
•Radial run-out of the wheel or the •Radial run-out of the wheel or the
tyre is excessive. tyre should be measured by the dial
gauge. If the radial run-out amount
of the wheel or the tyre is not in the
regulated scope, a further
inspection on radial run-out of the
wheel bolt should be performed. If
the radial run-out amount of the
wheel bolt is out of the range, a
replacement should be performed.
•The wheel bolt is loose or damaged, • Tightening or replacement should
or bolt holes of the wheel are be performed if necessary.
expanded.

Benni Mini
201-03-7 Wheel and Tyre

Diagnosis and Test（continued）

• Foreign matters exist between •The installation surfaces should be

the installation surface of the wheel cleaned.
and the installation surface of the
hub.
• The radial run-out of the wheel or •Radial run-out of the wheel and the
the tyre is excessive. tyre should be measured by the dial
gauge. If the radial run-out amount
of the wheel or the tyre is out of the
scope, a further inspection on radial
run-out of the wheel bolt should be
performed. If some parts are out of
the range, replacements should be
performed.

• There are cracks at the bottom part • The vehicle is overloaded or • The wheel should be replaced and
of the wheel rim or the drain tank. abused. load and running conditions should
be inspected. An over high tyre air
pressure should be avoided. Tyre
rim specifications, work load, tyre
size, textile cord layer and the tyre
structure should be inspected.
•Tools are not properly used. •Installation, disassembly and
maintenance procedures should be
inspected.
•Bolt thread of the wheel is • Torque is too high. • Wheel bolt should be replaced, and
damaged. tightening should be performed
according to the regulated
requirements.
•Wheel bolt is break. • Wheel bolt surface is not well •The wheel bolt should be replaced,
processed. and tightening should be performed
according to the regulated
requirements.
•Overload • The wheel bolt should be replaced,
tightening should be performed
according to the regulated
requirements, and practical load
and the regulated load rate should
be compared.
• Bolt holes of the wheel are rusty. •The wheel bolts are loose. •Inspect the assembly, if damaged
parts are found, replace the
damaged ones. And tighten the
parts as required.

• Tyre bolts are damaged. •Wheel assembly is loose. • The wheel bolt should be replaced,
and tightening should be performed
according to the regulated
requirements.
• The wheel bolts are locked too •Correct tightening procedures
tightly. should be followed.

Benni Mini
201-03-8 Wheel and Tyre

Diagnosis and Test（continued）

• The wheel bolts are deadly blocked. • Eroded. • Cautious: Lubrication oil should
not be coated on the tapered surface
of the bolt hole or the tapered
surface of the wheel bolt. If
corrosion is not so severe, an iron
brush should be used for removal.
If the corrosion is severe, new
wheel bolts should be installed. If
the condition still remains, graphite
based lubricating oil should be used
for lubricating the first three
threads of the each bolt of the
wheel.
•Overload •The weight should be reduced.

Benni Mini
204-04-9 Wheels and Tires 204-04-9

Removal and Installation (Continued)

Wheel and Tyre

Disassembly
Warning: The method of heating should not
be used for loosing the locked wheel bolts.
Wheels and wheel rims may be damaged by
heating.
1. Loose the wheel bolts.
2. Hoist the vehicle. See section 100-02 for relevant
information.
3. Disassemble the wheel and tyre assembly.

Installation
Warning: Remove the rusty stain or dust on
the wheels, the wheel rims and the
installation surface of the brake disc.
Those things may lead to wheel bolt
looseness and wheel looseness during the
vehicle running. Bodily injury may be
caused for the incompliance of the above
instructions.
Clean the wheel hub and the installation
surface.
2. Install the wheel and tyre assembly.
3. Lay down the vehicle.
4. Tighten the wheel nuts.

Benni Mini
202-01-1 Driving Axle 202-01-1

Chapter 202-01 Driving Axle

Applicable Vehicle Model: BENNI MINI

Contents Page
Specification

Specification .......................................................................................................................................... 202-01-2

Instruction and Operation

Driving Axle ........................................................................................................................................ 202-01-3

The Working Principle of the Driving Axle ...................................................................................... 202-01-4
The Treatment Of the Driving Axle..................................................................................................... 202-01-4
Front Wheel Balancing ........................................................................................................................ 202-01-4
Automobile Hoisting............................................................................................................................ 202-01-4
Automoble Dragging............................................................................................................................ 202-01-5
Protection and Rust Prevention of the Vehicle Bottom ....................................................................... 202-01-5

Diagnosis and Test

Driving Axle ........................................................................................................................................ 202-01-5

Fuilure Phenomenon ............................................................................................................................ 202-01-5

Disassembling and Installation

Driving axle (left) ....................................................................................................... ………………. 202-01-7

Driving axle (right) ..................................................................................................... ………………. 202-01-11
The dust shield of the internal constant universal joint ........................................................... ……………… 202-01-14
The dust shield of the external constant speed universal joint（including universal joint ...... ……………… 202-01-18

Disintegrating and assembling

Semi-axle(movable joint) .................................................................................................................. 202-01-22

Semi-axle(fixing joint)................................................................................................ 202-01-26

BENNI MINI
202-01-2 Driving Axle 202-01-2

Specification

Oil, fluid, sealant and adhesive

Designation Model
High performance grease (color:Brown), constant speed universal joint G.A.Cpalex GTE

Other replaceable greases molybdenum disulfide

Capacity

High performance grease, external constant speed 70±10 g

universal joint
High performance grease, internal constant speed universal 65 ±10 g
joint

Torque specifications
Torque specifications Nm lb-ft lb-in
Locking nuts of the ball head of the tie rod -
From the front oscillating arm ball joint to steering -
knuckle inserting pin bolt
Retaining nuts of the wheel hub bearing 200±10 -
Tyre nuts -
Front supporting column and steering knuckle -
connecting bolts, nuts

BENNI MINI
202-01-3 Driving Axle 202-01-3

INSTRUCTION AND OPERATION

DESCRIPTION AND OPERATION

Driving axle

Constant speed universal joints are arranged at both The internal constant speed universal joint is fixed on
sides of the driving axle. the differential gear through a differential spring ring.
The internal constant speed universal joint (constant The external constant speed universal joint is fixed on
speed ball or three-pin universal joint, roller or steel the wheel hub bearing.
ball and housing of the universal joint) are installed on
the driving axle.
The external constant speed universal joint is fixed on
The external constant speed universal joint (composed
the wheel hub bearing.
of steel balls, rolling ball retaining frames and the
housings of the universal joints) are installed at sides of
the wheels.

The exploded view of the driving axle

BENNI MINI
202-01-4 Driving Axle 202-01-4
INSTRUCTION AND OPERATION (Continued)

The Working Principle of the Driving Axle

Serial Parts Designation tion

Number Number The torque is transmitted from the engine to the wheels
through the driving axle.
2203110-K Fixed end ball cage
1 In order to adapt to the upper and lower motion of the
01 universal joint
wheel and the engine, the driving axle is required to run
2 2203143-K01 Large nip in various lengths and angles.
3 2203151-K01 Dust shield
The Treatment of the Driving Axle
4 2203144-K01 Small clip at the outer end
Note: The clipping of the driving axle by the constant
5 2203133-K01 Left shaft lever speed universal joint is forbidden.
6 2203141-K01 Small clip at the inner end When dismounting, installation, disintegrating and
7 2203152-K01 Dust shield assembling it should be cautious. The following
instructions should be observed.
8 2203142-K01 Large clip at the inner end
– When the driving axle is dismounted, never push or
Movable three-pin type pull the constant speed universal joint
9 2203120-K01
universal joint – The working angle of the constant speed universal
2203110-K01 Fixed ball cage universal joint can not be more than 22.5 degrees.
10 – Check whether the polished surface and the spline
joint
are damaged.
11 2203143-K01 Large clip
– It is forbidden that the dust shield is contacted with
12 2203151-K01 Dust shield at the outer end the sharp edge and the hot engine or the exhaust
system.
13 2203144-K01 Small clip at the outer end
– Do not drop the driving axle, otherwise, it could
14 2203233-K01 Right shaft lever cause the inner damage of the dust shield, which
can not been seen from outside.
15 2203141-K01 Small clip at the inner end
– When other parts and components are installed,
16 2203152-K01 Dust shield at the inner end never use the driving axle as the prying tool. The
driving axle can not be hung at will.
17 2203142-K01 Large clip at the inner end – The hitting of the universal joint cage from
18 Three-pin type movable outside can cause the damage of the constant
2203220-K01
universal joint speed universal joint.

Front wheel balancing

Warning: When the vehicle is lifted above the
ground completely, using the portable wheel
balancing device can cause the damage of the
constant speed universal joint or the dust
shield, and this is caused due to the fact that
the bending angle of the universal joint is
overlarge.
When the portable wheel balancing device is used, the
hand pushing type jack can be positioned under the
lower cross arm. This can prevent the overlarge of the
bending of the universal joint when the vehicle is lifted.
If the conditions are satisfied, it is better to dismount
the wheels, which should be performed on the fixed
wheel balancing device.

BENNI MINI
 205-04-5 Driving Axle 205-04-5

INSTRUCTION AND OPERATION (Continued)

Automobile hoisting
Warning: It is forbidden to use the universal
joint or the driving axle as the jacking
position.
The protection and rust prevention of the vehicle
bottom
Note: When the protection and rust prevention of the
vehicle bottom are performed, the dust shield should be
covered.

Automobile dragging The dirt on the dust shield can lead to the premature
aging of the material, and the foreign matter on the
Caution: It is forbidden to tie the towing line semi-axle can cause the semi-axle to lose balance.
DIAGNOSIS AND TESTING
on the driving axle.

Driving Axle DIAGNOSIS AND TESTING

Table of failure phenomenon 2. Whether the dust shield or the dust clip has
Note: Before check the wear, please reinstall the problem can be judged by visually inspect that the front
driving axle. axle transmission semi-axle under the vehicle bottom
has the oil penetration sign.
1. Visually inspect the dust shield whether it is torn or
has cracks. 3. Check whether the casing of the connecting head
housing has oil dripping.
4. Make sure that the self-locking nuts of the
auxiliary vehicle frame has been installed.

Phenomena Possible faults Measures

• Sounds of breaking, knocking or
friction during running
• Vibration during high speed driving • The wheels losing balance.
• Fluttering during acceleration
• Insufficient lubrication or pollution • Inspect, clean and replace the grease
of the universal joint of the driving if nesssery.
axle
• The driving axle contacting with • Inspect and repair if nesssery
other components
• The wear or damage of the wheel • Inspect and repair if nesssery
bearing, the braking components,
the suspension components or the
steering components
• Balancing the wheels
• Radial run-out of the front wheels • Disassembling and installation
instructions of the driving axle
• Incorrect installation of the driving •
axle
• Inappropriate assembling height • Check the vehicle height of the
cause a larger angle of the vehicle and the height of the shock
three-ball-pin type universal joint absorbing spring
• The driving axle is excessively • Check and replace if necessary
worn or damaged

BENNI MINI
205-04-6 Driving Axle 205-04-6

DIAGNOSIS AND TESTING (Continued)

Phenomena Possible faults Measures
•Three-ball-pin type universal joint is • The retaining ring of the driving • Replace the retaining ring
parted from the sliding ball cage axle drops off or incorrectly
joint mounted in the differential gear

• The engine and the speed changer • Check the installation bracket of the
are not correctly mounted. engine for damages and wears

• Auxiliary vehicle frame or the • Measure the chassis

chassis is distorted or bended
• Components of the front suspension • Check the shaft lining for wear or
are worn or damaged check the components for
distortion(stabilizing rod,
suspended arm, etc.), make
replacement if necessary

BENNI MINI
202-01-7 Driving Axle 202-01-7

DISASEMBING AND INSATLLATION

REMOVAL AND INSTALLATION

Driving axle (left)

To use the special tool: puller（CA201-006）

General tool
Two-claw puller

Dismounting
1. Warning: The hexagonal socket wrench Is
used to prevent the piston rod from 4. The front oscillating arm ball joint are taken out
rotating. from the steering knuckle.
The fixing nuts of the front left supporting
column are loosened

5. Caution: The driving axle should be well

protected for fear that the constant speed
universal joint is damaged. The working
angle of the internal constant speed
2. The wheels and tyres are dismounted. See
universal joint should not be more than
Chapter 201-03for relevant information.
22.5 degrees. The working angle of the
external constant speed universal joint
should not be more than 45 degrees.
Use the suitable two-claw puller. The driving
axle is taken out from the wheel hub.

3. Warning: The wheel hub fixing nuts are

dismounted by using the socket and prevented from
being damaged.
1.The wheel hub nuts and washers are loosened.

BENNI MINI
202-01-8 Driving Axle 202-01-8

DISASSEMBLING AND INSTALLATION (Continued)

6. Caution: The driving axle should be well

protected for preventing the constant speed
universal joint from being damaged. The
working angle of the internal constant
speed universal joint should not be more
than 22.5 degrees. The working angle of the
external constant speed universal joint
should not be more than 45 degrees.
Caution: Make sure that the oil seal of the
driving axle is not damaged.
The driving axle is dismounted from the
variator by applying skillful strength. •
The transmission oil is allowed to be discharged
into a suitable container.

Installation

1. Caution: The driving axle should be well

protected for preventing the constant speed
universal joint from being damaged. The
working angle of the internal constant
speed universal joint should not be more
than 22.5 degrees. The working angle of the
external constant speed universal joint
should not be more than 45 degrees.
Caution: When the driving axle is inserted,
the installation device of the oil seals
(supplied with the oil seal) should be used
to protect the oil seal of the driving axle.
Note: New retaining ring is installed.
Note: Make sure the retaining ring is installed in the
groove.
The driving axle is installed on the driving axle.

BENNI MINI
202-01-9 Driving Axle 202-01-9

DISASSEMBLING AND INSTALLATION (Continued)

5. The wheel and tyre are installed. See Section

201-03 for relevant information.
2. 2. The driving axle is installed on the wheel hub
bearing. 6. The transmission oil level is checked. See Section
301-03 for manual transmission gear.

7. Warning: The wheel hub retaining nuts

should be locked through the socket for
preventing it from being damaging.
The wheel hub fixing nut is secured, and the
locking pin is inserted. (the torque should be
200±10Nm)

3. Note: The wheel hub fixing nut should be

reinstalled.
Note: The wheel hub fixing nut should not be locked
at this stage.
The wheel hub fixing nuts is installed.

4. The lower cross arm is installed in the steering

knuckle.

BENNI MINI
202-01-10 Driving Axle 202-01-10

DISASSEMBLING AND INSTALLATION (Continued)

8. Warning: The hexagonal socket wrench Is

used to prevent the piston rod from
rotating.
The fixing nuts on the front supporting
column assembly are secured.

BENNI MINI
202-01-11 Driving Axle 202-01-11

DISASSEMBLING AND INSTALLATION (Continued)

Driving axle(right)
3. Warning: The wheel hub fixing nuts are
loosened by using the socket.
Use the special tool 1. The wheel hub nuts is loosened.
puller（CA201-006）

General tool
Two-claw puller

Dismounting
1. Warning: The hexagonal socket wrench Is 4. The front oscillating arm ball joint are taken out
used to prevent the piston rod from from the steering knuckle.
rotating.
The fixing nuts on the front supporting
column assembly at left are loosened.

2. The wheels and tyres are dismounted. See Section

201-04 for relevant information.

BENNI MINI
202-01-12 Driving Axle 202-01-12

DISASSEMBLING AND INSTALLATION (Continued)

5. Warning: The driving axle is well protected

for fear hat the constant speed universal joint is
damaged. The working angle of the internal
constant speed universal joint should not be more
than 22.5 degrees. The working angle of the
external constant speed universal joint should not
be more than 45 degrees.

The driving axle is taken out from the wheel hub by

using a suitable two-claw puller.

6. Warning: The driving axle is well
protected for fear hat the constant speed universal
joint is damaged. The working angle of the internal
constant speed universal joint should not be more
than 22.5 degrees. The working angle of the
external constant speed universal joint should not
be more than 45 degrees.
Installation
1. Warning: The driving axle is well
protected for fear hat the constant speed
universal joint is damaged. The working
angle of the internal constant speed
universal joint should not be more than
22.5 degrees. The working angle of the
external constant speed universal joint
should not be more than 45 degrees.
Warning: When the driving axle is
inserted, the oil seal installation sleeve
(supplied along with the oil seal) is used to
protect the oil seals.
Note: New retaining ring is installed.
Note: Make sure the retaining ring is
correctly installed in the groove.
The driving axle is installed on the driving axle.

Warning: Make sure that the oil seals of

the driving axle are not damaged.
Note: The driving axle is plugged to prevent oil from
losing or dirt from entering.
The driving axle is dismounted from the
variator by applying skillful strength.
• The transmission oil is permitted to be discharged
into a suitable container.。

BENNI MINI
202-01-13 Driving Axle 202-01-13

DISASSEMBLING AND INSTALLATION (Continued)

2. The driving axle is installed on the wheel hub 5. Install the wheel and tyre. See Section 201-03 for
bearing. relevant information.

6. Check the transmission oil. See Section 302-03

for the manual transmission gear.
7. Warnings: use socket wrench to fix the
wheel hub fixing nut to prevent damage.
The fixing wheel hub fixing nut is inserted into the
locking pin. (The tightening torque shall be
200±10Nm)

3. Note: The wheel hub fixing nut should be

reinstalled.
Note: The wheel hub fixing nut should not be
secured at this stage.
The wheel hub fixing nuts and washers are
installed.

8. Warning: The hexagonal socket wrench Is

used to prevent the piston rod from
rotating.
Fix the upper nuts on the front supporting
column assembly.

4. The lower oscillating arm is installed on the

steering knuckle.

BENNI MINI
202-01-14 Driving Axle 202-01-14

DISASSEMBLING AND INSTALLATION

Dust shield of the inner constant speed universal joint

Using the special tool: installation tool (CA201-008)

General Tool 2. Hoist the vehicle.

Retaining ring caliper 3. Disassemble the front oscillating arm on the
Name Model steering knuckle.

High performance grease G.A.Cpalex GTE

Tape

Disassembly
1．Warning: The hexagonal socket wrench Is used
to prevent the piston rod from rotating.
Loosen the fixing nuts on the supporting column of
the suspension.

4. Notes: Use the protective shield.

Loosen the nip of the dust shield from the transmission
end. The sliding dust shield is nested on the driving
axle.

5. Disassemble the three-ball-pin type universal

joint.
Eliminate the universal joint inner grease.

BENNI MINI
202-01-15 Driving Axle 202-01-15

DISASSEMBLING AND INSTALLATION (continue)

6. Disassemble the triangular frame/ball-cage frame

and dust shield.
• Use the retaining ring caliper to take out the
retaining ring and pull out the three-ball-pin type
universal joint.
• Remove the dust shield. Installation
1. Notes
Replace all the retaining rings and nips.

2.Notes: the chamfer should point to the driving

axle.
Install three-ball-pin/ball-cage type
universal joint assembly.
• Cover the dust shield.
• Install and fix the three-ball-pin type universal
joint.

BENNI MINI
202-01-16 驱动轴 202-01-16

拆卸和安装 (续)

Use the special tool to fix the nip.

3. Fill the grease in the three-ball-pin type universal
joint (G.A.Cpalex GTE)。

The size C of the opening of the nip is not bigger than

1.5mm after the large and small nip are tightly hooped.

4. Configure a nip for the special tool 14-044.

• Material: aluminum plate or steel plate

5. Install the dust shield and fix with a nip.

Use the special tool to install the nip.
Notes: the fixing torque of the 0.8mm nip is 12Nm and
the fixing torque of the 1.1mm nip is 20Nm.

BENNI MINI
202-01-17 Driving Axle 202-01-17

DISASSEMBLING AND INSTALLATION (continue)

6. Install the front oscillating arm in the steering

knuckle.

7. Put down the automobile.

8. Warning: The hexagonal socket wrench Is used

to prevent the piston rod from rotating.
Fix the nuts of the front supporting columns of
the suspension.

BENNI MINI
202-01-18 Driving Axle 202-01-18

DISASSEMBLING AND INSTALLATION

Dust shield of the external constant speed universal joint (including the universal joint)
General Tool
Retaining ring caliper
Name Model
High G.A.Cpalex GTE
2. Disassemble the wheel and tyre. See Section
performance
201-03 for relevant information.
grease
Tape
Take out the locking pin, and use the socket wrench of
32mm to loosen the wheel hub nuts.
Disassembly
1．Warning: The hexagonal socket wrench Is used
to prevent the piston rod from rotating.
Loosen the fixing nuts on the left and right front

3. Automobile hoisting. See Section 100-01 for

relevant information.

4．Disassemble the front oscillating arm in the

steering knuckle.

BENNI MINI
202-01-19 Driving Axle 202-01-19

DISASSEMBLING AND INSTALLATION (Continued)

Disassemble the driving axle nut, and take out the

5. Loosen the nips on the dust shield. locking pin and the washer.
使用两爪拉出器从轮毂中压出左边驱动轴。
Slide the dust shield on the driving axle.

Installation
1. Notes
6. Warnings: the working angle of the inner • Replace all the retaining rings and nips.
constant speed universal joint can not 2. Notes: Make sure that the retaining ring is well
surpass 22.5°. The working angle of the installed.
external constant speed universal joint can
not surpass 45°. 安装驱动轴。

Warnings: slightly push the wheel suspension Install the driving axle.
outward avoiding the damage of the inner • Install new retaining ring in the driving axle
constant speed universal joint. groove.
Take out the driving axle from the universal joint of • Sliding the dust shield on the driving axle.
the driving axle. • Insert the driving axle into the universal joint of
• Take out the dust shield and fix the driving axle. the driving axle until the retaining ring (or
clipping ring) is clipped.
• Eliminate the grease in the universal joint.
• Use the retaining ring caliper to expand the retaining
ring and keep the retaining ring in expansion
state.
• Take out the retaining ring.

3. Fill in high performance grease (G.A.Cpalex

GTE).
Quantity: 70 plus or minus 10 grams.
4. Configure a nip for the special tool 14-044.

BENNI MINI
202-01-20 Driving Axle 202-01-20

DISASSEMBLING AND INSTALLATION (Continued)

• Material: aluminum plate or steel plate

6．Install wheel hub fixing nuts and washers, and

insert the locking pin. Fix the tyre nuts（The
torque is 85±10Nm）and the hub faxing nuts
（The torque is200±10 Nm）.
5. Well install the universal joint of the driving
axle and fix the universal joint of the driving
axle with a new nip.
• Use the special tool to clip the head of the nip.
• Install the nip.
Notes: The fixing torque of the 0.8mm nip is 12Nm and
the fixing torque of the 1.1mm nip is 20Nm.

• Use the special tool to fix the nip.

7. Install the front oscillating arm in the steering

knuckle.
8.

8. Install the wheel and tyre. See Section 201-03 for

relevant information.

长安·奔奔MINI
202-01-21 Driving Axle 202-01-21

DISASSEMBLING AND INSTALLATION (Continued)

Fix the nuts of the suspension supporting

columns.
9．Put down the automobile

10. 1．Warning: The hexagonal socket wrench Is

used to prevent the piston rod from
rotating.

BENNI MINI
202-01-22 Driving Axle 202-01-22

DISASSEMBLY AND ASSEMBLY

DISASSEMBLY AND ASSEMBLY

3. Disassemble the three-ball-pin/ ball-cage and

dust shield.
The special tool for semi-axle (movable 1. Disassemble the retaining ring.
joint): caliper (CA201-002) 2. Uncover the dust shield.
3. unlock three-ball-pin frame, and disassemble the
General Tool rolling column.
Retaining Ring Caliper

Name Model
High Performance Grease G.A.Cpalex GTE
Nip of Dust Shield

2. Uncover the inner constant speed universal joint

housing.
• Eliminate the grease.

unlock the ball pin assembly according to the following

diagram

4. Disassemble and discard the nip of the dust

shield.
1. Take off the sliding dust shield, and clear away
grease.
2. Take out the driving axle from the constant
speed universal joint.

BENNI MINI
202-01-23 Driving Axle 202-01-23

DISASSEMBLY AND ASSEMBLY (continued)

Assembly
1. Notes: replace all the retaining ring and nip of the
dust shield.
Configure a nip for the special tool 14-044.
• Material: aluminum plate or steel plate.

3 Warnings: do not damage the bearing seat

of the rolling column.
Install the ball pin frame (only for driving axle
side of the driving axle)
1．Use proper pipe to install the ball pin frame to the
place where is most near the driving axle.

2 Notes: the fixing torque of the 0.8mm nip is 12Nm

and the fixing torque of the 1.1mm nip is 20Nm..
Nest the dust shield and small nip on the axle
rod, place the nip in the groove of the dust
shield and fix the groove of the dust shield with
the special tool.

Notes: use a new retaining ring, and make sure the

retaining ring is well installed.
The front face of the three-ball-pin frame
points to the driving axle.
2. Install the nip of the inner dust shield on the driving
axle.
3. Install constant speed rolling column.
4. For the three-ball-pin frame, use the sharp nose pliers
to fix the new retaining ring (clipping ring on the
axle end).

BENNI MINI
202-01-24 Driving Axle 202-01-24

DISASSEMBLY AND ASSEMBLY (continued)

4. Notes: use new retaining ring, and make sure the

retaining ring is well installed.

5．Notes: do not damage the installing surface of

the dust shield.
Fill high performance grease in the constant
speed universal joint housing and dust shield.

Well install the movable universal joint

。
6. Notes: the fixing torque of the 0.8mm nip is 12Nm
and the fixing torque of the 1.1mm nip is 20Nm. Keep the dust shield in the length and size state in the
diagram
1. Move the dust shield of the constant speed
universal joint to installation position. Use a new
nip for fixing.
2. Insert the custom-made compression component
into the special tool.
3. Insert a small screwdriver under the edge of the
dust shield to make the air overflow.
4. Well install the special tool, and make the
compressor close to the clipping head of the nip.
5. Take out the screwdriver. Use the special tool to
fix the nip.
6. Take away the special tool.
The size C of the opening of the nip is not bigger than
1.5mm after the large and small nip are tightly hooped.

BENNI MINI
202-01-25 Driving Axle 202-01-25

DISASSEMBLY AND ASSEMBLY (continued)

BENNI MINI
202-01-26 Driving Axle 202-01-26

DISASSEMBLY AND ASSEMBLY

Semi-axle (fixing joint)

General Tool
Retaining ring caliper
Tape

Name Model
Take out the driving axle from the universal joint.
High Performance Grease
Take out the retaining ringfrom the universal joint.
Take out the dust shield.

1. Disassemble the dust shield of the fixing joint of

the driving axle.
1. Loosen the large and small nips with a
screwdriver.
2. Uncover the dust shield.
3. Eliminate the grease.

Rotate the ball cage and the ball-cage frame.

Take out the ball cage and the ball-cage fram

2. Take out the ball cage and the ball-cage frame in

the housing. (Wheel side)
Insert the clipping ring at the intermediate position of
the notch of the inner ring groove
Open the clipping ring with sharp nose pliers. Take out the rolling ball from the ball cage.

Slightly knock with a copper bar, and disassemble the

constant speed universal joint.

BENNI MINI
202-01-27 Driving Axle 202-01-27

DISASSEMBLY AND ASSEMBLY (continued)

3. Notes: make sure that the ball cage, housing, rolling 2. Install the ball cage and the ball-cage frame in the
ball and frame are free from the grease and engine oil. housing.
Inspect the wear of the motion surface.

Assembly

1. Configure a nip for the special tool 14-044.

• Material: aluminum plate or steel plate

3. Rotate the ball cage and the ball-cage frame.

2. Notes: the fixing torque of the 0.8mm nip is 12Nm

and the fixing torque of the 1.1mm nip is 20Nm.
Place the nip in the groove of the dust shield,
and fix with the special tool.

3. Install the ball cage.

1. Install the ball cage on the ball-cage frame.

BENNI MINI
202-01-28 Driving Axle 202-01-28

DISASSEMBLY AND ASSEMBLY (continued)

4. Notes: make sure the retaining ring is well installed.

Install the driving axle in the universal joint. • Nest the dust shield.
• Nest the dust shield and inner nip. • Use the special tool. Ensure that the special tool
nip vertical to the clipping head of the nip.
• Insert a new retaining ring in the universal joint
of the driving axle.
• Insert the driving axle in the universal

6. Fill the high performance grease in the outer

universal ring of the driving axle and then fix the
dust shield.

BENNI MINI
203-00-1 Steering System-General 203-00-1

Section 203-00: Steering System-General

Applicable Vehicle Model: BENNI MINI

Contents page

Specifications

Specification ........................................................................................................................... 203-00-2

Instruction And Operation

Braking System .................................................................................................................................... 203-00-3

Diagnosis and Test

Braking System ........................................................................................................................ 203-00-4

Inspection and Confirmation ....................................................................................................... 203-00-4
Road Test ............................................................................................................................... 203-00-4
Fixed Point Inspection ............................................................................................................... 203-00-7
Component Test ....................................................................................................................... 203-00-19
Inspection Braking System ......................................................................................................... 203-00-19
Inspection Brake Booster Function ............................................................................................... 203-00-19

Common Procedures

Exhausting of Braking System............................................................................... (12 141 0) 203-00-22

Pressure Exhausting of Braking System ................................................................... (12 141 0) 203-00-23
Run-Out of Brake Disc Measurement ...................................................................... (12 221 0) 203-00-24

BENNI MINI
203-00-2 Braking System-General 203-00-2

Specifications

Grease, Oil Fluid, Sealant and Bonding Agent

Name Model
Braking Fluid HZY4

Specifications of Disc Type Brake

mm
Diameter of Brake Disc 236
Normal thickness of Brake Disc 12.5
Disabled thickness of the brake disc 9.7
Maximum Run-out Amount of Brake Disc (arranged) 0.1
Maximum Thickness Variation Value of Brake Disc 0.015
Piston Diameter of Brake Caliper 48
Minimum Thickness of Brake Friction Block 3
* When the brake disc reaches the disabled thickness, the brake disc must be replaced. When the polishing treatment
is performed for the brake disc which does not reach the disabled thickness, special attention shall be paid.

Specifications of Drum Type Brake

mm
Normal Thickness of New Brake Drum 180
Disabled Diameter of Brake Drum 182
Inner Diameter of Braking Cylinder 17.46（ABS）15.87
（WITHOUTABS）
Thickness of Friction Lining Surface of New Master Brake Shoe 4.5
Thickness of Friction Lining Surface of New Distributed Brake Shoe 4.5
Disabled Thickness of Friction Lining Surface of Brake Shoe 1.5
* When the diameter of the braking drum reaches the disabled standard, the brake drum must be replaced. When the
polishing treatment is performed for the brake drum which does not reach the disabled thickness, special attention
shall be paid.

BENII MINI
203-00-3 Braking System-General
Instruction and Operation
DESCRIPTION AND OPERATION
Braking System
This braking system adopts the double loops and
diagonal arrangement, the front-disc-rear-drum or the
front-disc-rear-disc braking system.
Each pair of wheels is provided with the hydraulic
system of the independent loop. The front brake caliper
is arranged on the steering knuckle and is a floating
caliper type brake caliper, and then the equal size of the
braking force exerted on the two brake friction linings
can be ensured.
The brake drum adopts the conventional design and is
composed of the brake leading shoe and trailing shoe
bonded with thick/thin inner linings. The inner linings
adopt the thick/thin design allow the brake shoe
wearing at a certain rate. The braking system can be
freely adjusted in the foot braking.
203-00-3
The controlling rod of the parking braking is positioned
between two front seats, and the rear brake is controlled
by the dragline device. The parking braking can be
adjusted in the hollow box on the vehicle.
The master braking pump adopts the vertical series
connection design and is directly connected with the
booster, which can reduce the force exerted on the
brake pedal. The vertical series connection design can
ensure that when one braking loop fails and the other
braking loop still keep the perfect working state. The
master braking pump and the brake booster are
positioned at the left side of the engine compartment.
The proportioning valve is arranged below the outlet of
the master braking pump by the basic configuration.
The proportioning valve can control the hydraulic
pressure acted on the rear brake to reduce the danger of
locking when the rear wheel is bake
BENNI MINI
203-00-4 Braking System-General
Diagnosis and Test
Braking System
The braking system transmits the force exerted on the
brake pedal by the driver to the bake of each wheel.
The hydraulic system transmits the braking force to
each wheel. The vacuum brake booster can reduce the
force exerted on the brake pedal and increase the
braking pressure.
The parking braking is controlled by using the manual
controlling rod and acts on the rear wheel.
Inspection and Confirmation
Notes: Confirm that the warning indication lamp of the
barking system is normal before diagnosis.
1. Confirm the customer’s problem.
2. Visually inspect the obvious mechanical failure.
Visual Inspection Table
Machinery
– Tyre Pressure
– Wheel and Tyre
– Leakage of Braking Pipeline
3. If the obvious failure is found, the failure is settled
before performing the next step (if possible).
4. If the failure phenomenon is not obvious, confirm
this failure and refer to the Failure Inspection
Table.
Road Test
The implementation of the road test is to compare the
practical braking performance of the vehicle with the
standard braking performance the driver expected. The
driver’s correct comparison and his ability of
determining the braking performance depend on the
experience of the vehicle testing driver. The vehicle
testing driver must have the complete knowledge of the
working principle of the braking system and have
received the systematic direction to perform the correct
comparison and discover problems.
The experienced technician will select a route for the
braking diagnosis road test. The road surface of the
route shall be flat but not be the pebble or bumpy road.
It is mainly because that the pebble or bumpy road
Phenomenon Possible Reasons
• Brake Slip or Deviation • The brake shoe or the inner lining of • Replace the brake shoe or the brake
the braking disc is worn or damaged disc
• The front brake disc is improperly
worn or bent
• The rear braking adjustment is not
correct
203-00-4
makes the adhesive forces of the tyre and the road
surface different. The arch road is also not suitable,
because the weight of the vehicle body is mostly
concentrated on the two lower wheels. Once the route
is conformed and usually used, the road factor will not
be considered.
The description of the failure from the customer should
be known about before the road test. According to the
description, the technician can relate the possible
reasons with the symptom. Some parts can be seen as
the suspected reason, while the others can be
eliminated. What is more important is that the unsafe
hidden dangers can be inspected or eliminated before
the road test according to the description from the
customer. The problem can be concentrated on the
specific components, the vehicle speed or situation,
which is helpful to decide the method of road test.
The road test shall start with the common braking
performance inspection. According to the description
from the customer, inspect the braking of vehicles of
various speeds with various pedal pressures. When it is
judged whether the problem exists in the front or rear
braking system, the braking is implemented by first
using the pedal braking and then using the parking
braking. If the symptoms (hoisting, vibration and
rhythmic jumping) only occur in using the parking
braking, which indicates the problem exist in the
parking braking.
The brake locking and tyre lagging shall be avoided in
the road test. This situation does not indicate that the
braking is effective. The powerful braking and keeping
the wheel rotating can make the automobile stop in a
shorter distance than the brake locking.
If the failure is very obvious in the test, confirm this
failure is matched with the description. If the failure is
not obvious, try to re-appear the situation by using the
information from the description.
If the failure exists, resolve the problems in the specific
subsystem and the relevant status description by using
the Failure Inspection Table. The reasons can be
reduced to the specific portion or status by a list of the
possible reasons through using the described
phenomena.
Contents/results/measures
• Replace the front brake disc
• Adjust the parking braking dragline.
See 203-03
BENNI MINI
203-00-5
Diagnosis and Test (continued)
Phenomenon
• The brake caliper is deadlocked
• The brake warning indicating lamp • The level of the braking fluid is too • Fill the braking fluid. Inspect the
always light
• Vibration occurs in baking
• The brake disc or the brake shoe is • Replace the brake shoe or the brake
• The pedal is rapidly sunk
Braking System-General
Possible Reasons Contents/results/measures
• The wheel alignment is not correct • Perform the wheel alignment. See
201-00
• The load adjustment of the wheel • Adjust or replace the wheel bearing.
bearing is not correct See 203-02.
• The tyre pressure is not consistent • Adjust the tyre pressure
• The oil fluid or butter is adhered on • Replace the brake shoe or the brake
the brake shoe or the brake disc disc
• Turn to the fixed point inspection A.
low braking and clutch system including
the brake booster leakage.
• The primary piston cap of the • Replace the master braking pump
master braking pump leaks
• The parking brake control is not • Loosen and adjust the parking
completely released braking dragline. See 203-03.
Replace the component if necessary
• The short circuit occurs in the • Turn to the fixed point inspection B.
indication lamp circuit
• Oil is attached to the brake shoe or • Replace the brake shoe or the brake
the brake disc disc
worn or damaged disc
• The installation bolt of the brake • Tighten the installation bolt of the
caliper is loosened brake caliper
• The lubrication of the sliding • Fill oil if necessary
components is insufficient
• The contacting surface of the brake • Replace the brake drum
drum is damaged
• The bolts of the wheel hub is • Tighten or replace the bolts of the
loosened or lost wheel hub
• Turn to the fixed point inspection C.
• The hydraulic system leaks • Repair the leakage. Inspect the
entire hydraulic system. Fill up and
exhaust the braking system
• Air exists in the system • Inspect the leakage. The exhausting
of the braking system. See 203-00.
• The primary piston cap of the • Replace the master braking pump
master braking pump is worn or the
cylinder body is cracked
BENNI MINI
203-00-6 Braking System-General 203-0

Diagnosis and Test (continued)

Phenomenon Possible Reasons Contents/results/measures

• The pedal is slowly sunk
• The pedal position is low or feels
soft
• The braking is locked when slightly • The tyre pressure is not correct
step on the pedal
• The pedal travel is too large or
instable
• The brake is dragged
• The brake pedal is too largely forced • The brake booster does not act
• The braking noise
• The “aftershock” of the brake disc • Replace the brake disc. See 203-01
(The brake caliper piston is pushed
backwards into the brake caliper by
the friction plate due to the too large
axial run-out of the braking disc or
the loosened vehicle wheel bearing)
• The brake shoe or the brake disc is • Replace the brake shoe or the brake
abraded disc.
• Turn to the fixed point inspection D.
• Air exists in the system • The exhausting of the braking
system. See 203-00.
• The mater braking pump fails • Turn to the fixed point inspection E.
• The brake shoe is abraded • Replace the brake shoe or the brake
disc
• The hydraulic system • Turn to the fixed point inspection F.
• Adjust the tyre air pressure
• The tyre is abraded • Replace the tyre
• The brake shoe or the brake disc • Replace the brake shoe or the brake
slips or is abraded disc
• The brake booster • Turn to the fixed point inspection G.
• The brake shoe or the brake disc is • Replace the brake shoe or the brake
abraded disc
• The brake disc • Turn to the fixed point inspection H.
•The brake booster • Turn to the fixed point inspection.
• The brake lamp switch adjustment is • Adjust the brake lamp switch
not correct
• The control valve of the braking
pressure
• The brake caliper or braking pump
is deadlocked
• The parking braking acts or fails
• The parking braking dragline is
stuck
• The sliding pin of the parking
braking is stuck
• Perform the brake booster test
• The brake shoe or the brake disc is • Replace the brake shoe or the brake
abraded or polluted disc
•Turn to the fixed point inspection J.
• The brake shoe or the brake disc is • Replace the brake shoe or the brake
abraded disc
• The brake booster • Turn to the fixed point inspection K.

BENNI MINI
203-00-7 Braking System-General

Diagnosis and Test (continued)

Phenomenon Possible Reasons Contents/results/measures

• The pedal return is low or • The brake booster • Turn to the fixed point inspection L.
incomplete • The master braking pump

Fixed Point Inspection

Fixed Point Inspection A: Brake Slip or Deviation
Phenomenon Measures
A1: Road Test
1 The automobile performs the road test and steps on
the brake pedal
• Does the automobile deviate or slip?
　 Yes
Turn to A2
　 No
The automobile has no failure
A2: Tyre Air Pressure
1 Inspect the tyre abrasion and the tyre air pressure
• Is the tyre situation good?
　 Yes
Turn to A3
　 No
Adjust the tyre air pressure. Replace the severely
abraded tyre. Test and operate the system to see if
it is in the normal condition.
A3: Inspection of the brake shoe or the brake disc and the inner lining

1Inspect whether the inner lining of the brake shoe or

the brake disc leaks and the abrasion situation.
• Does the above situation exist?
　 Yes
Replace the brake shoe or the brake disc. Test and
operate the system to see if it is in the normal
condition.
　 No
Turn to A4
A4: Measure the right rear pressure control valve
１Connect the pressure gauge on the left front or right
rear air outlet. Step on the brake pedal, and the
reading of the left front wheel is 6895 kPa (1000 psi).
- Read the reading of the right rear wheel.
•Is the reading of the pressure gauge between 4692
kPa to 5164 kPa (680-750 psi)?
　 Yes
Inspect the brake caliper and replace the
components if necessary. Turn to A5
　 No

BENNI MINI
203-00-8 Braking System-General 203-0

Diagnosis and Test (continued)

Phenomenon Measures
Replace the pressure controlling valve of the right
rear wheel. The braking system exhausts. Refer to
the Chapter 203-00. Test and operate the system
to see if it is in the normal condition.
A5: Inspect the Left and Right Pressure Controlling Valve
1Connect the pressure gauge on the right front or left
rear air outlet. Step on the brake pedal, and the
reading of the right front wheel is 6895 kPa (1000
psi).
- Read the pressure of the left rear wheel.
•Is the reading of the pressure gauge between 4692
kPa to 5164 kPa (680-750 psi)?
　 Yes
Inspect the brake caliper and replace the
components if necessary. Test and operate the
system to see if it is in the normal condition.
　 No
Replace the rear brake controlling valve. The
braking system exhausts. Refer to the Section
203-00. Test and operate the system to see if it is
in the normal condition.
Fixed Point Inspection: B: Constant Lightening o Brake Warning Lamp
Phenomenon Contents/results/measures
B1: Inspect the brake warning
Notes: When the ignition key is turned to the START or RUN position and the parking braking acts, the brake
warning lamp will flash.
1 Turn the ignition key to the ON position.
2 Release the parking braking.
- Inspect the level of the braking fluid at the MAX
position.
• Does the brake warning lamp flash?
　 Yes
See Section 4０3-0２
　 No
转到B2
Turn to B2
B2: Inspect the leakage of the braking system
1 Inspect the leakage of the sealing points of the fluid
can of the master braking pump and the clutch
system. This section performs the master braking
pump component test.
• Does the system leak?
　 Yes
Repair if necessary. Add the liquid and exhaust.
See Section 203-00. Test and operate the system
to see if it is in the normal condition.

BENNI MINI
203-00-9 Braking System-General

Diagnosis and Test (continued)

Phenomenon Contents/results/measures
　 No
Turn to B3
B3: Inspect the brake warning switch or circuit
1 Turn the ignition switch to the ON position.
2 Disassemble the filtering cap or the switch of the
fluid can of the master braking pump. Allow the
liquid level being at the lowest (highest) point.
• Does the brake warning indicating lamp flash?
　 Yes
The switch or the circuit is normal. Test and
operate the system to see if it is in the normal
condition.
　 No
See Section 413-0２.
Fixed Point Inspection C: Vibration in Baking
Phenomenon Contents/results/measures
C1: Road Test
1 When the road test is performed to the automobile,
the braking is performed in 40-80 km/h (25-50 mph).
• Does the vibration occur?
　 Yes
See Section２０３-００. Test and operate the
system to see if it is in the normal condition after
being repaired.
　 No
Turn to C2
C2: Inspect the fluttering of the rear brake
Notes: when the parking braking control acts, keep the releasing button of the parking brake being at the releasing
position.
1 In the road test, when the automobile is in 40-80
km/h (25-50 mph), pull the parking braking to the
intermediate combining position.
• Does the fluttering occur?
　 Yes
Inspect whether the rear brake drum is over
abraded. Replace the components if necessary.
Test and operate the system to see if it is in the
normal condition.
　 No
Turn to C2
C3: Inspect the fluttering of the front wheel braking
1 In the road test, when the automobile is in 40-80
km/h (25-50 mph), slightly step down the braking.
• Does the fluttering occur?
　 Yes

BENNI MINI
203-00-10 Braking System-General 203-0

Diagnosis and Test (continued)

Phenomenon Contents/results/measures
Inspect whether the rear brake drum is over
abraded or cracked. Replace the components if
necessary. Test and operate the system to see if it
is in the normal condition.
　 No
The automobile is normal
Fixed Point Inspection D: the Brake Pedal is Rapidly Sunk
Phenomenon Contents/results/measures
D1: Road Test
１ When the road test is performed to the automobile,
step down the brake pedal.
• Is the force acted on the pedal normal?
　 Yes
The automobile is normal.
　 No
Turn to D2
D2: Inspect the level of the braking fluid
１Inspect the fluid level of the fluid can of the master
braking pump.
• Is the level of the braking fluid normal?
　 Yes
Turn to D3
　 No
Inspect the leakage of the sealing points of the
fluid can of the master braking pump. See
“Master Braking Pump Component Test” in this
section. For the relevant information of adding
the braking oil liquid and exhaust, please see
Section 203-00. Test and operate the system to
see if it is in the normal condition.
D3: Pressurize the system
1 Rapidly step the brake pedal for 5 times.
• Is the height of the brake pedal raised and kept?
　 Yes
Inspect the adjustment of the parking braking.
Adjust if necessary. Please see Section 203-0３
for the relevant information. If the failure
continues exist, exhaust to the braking system.
Please see Section 203-00 for the relevant
information. Test and operate the system to see if
it is in the normal condition.
　 No
Turn to D4

BENNI MINI
203-00-11 Braking System-General

Diagnosis and Test (continued)

Phenomenon Contents/results/measures
D4: Inspect the leakage of the braking system

１ Inspect the external leakage of the brake and clutch

system. Please read “Master Braking Pump Component
Test” in this section.
• Is the leakage discovered?
　 Yes
Repair if necessary. Add the braking fluid and
exhaust. Please see Section 203-00 for the
relevant information. Test and operate the system
to see if it is in the normal condition.
　 No
Turn to D5
D5: Perform one status inspection of the bypass of the master braking pump
１ Test the pass-by of the master brake pump. Please
read “Master Braking Pump Component Test” in this
section for the relevant information.
• Is the failure discovered?
　 Yes
Replace the master braking pump. Add the
braking fluid and exhaust. Please see Section
203-00 for the relevant information. Test and
operate the system to see if it is in the normal
condition.
　 No
The system is perfect.

BENNI MINI
203-00-12 Braking System-General 203-0

Diagnosis and Test (continued)

Fixed Point Inspection E: The Pedal is slowly Sunk

Phenomenon Contents/results/measures
E1: Inspect the running of the brake pedal
1 When the automobile runs, step down the brake
pedal and inspect the failure.
• Does the failure occur when the automobile is
stopped?
　 Yes
T rn to E2
　 No
Please read “Master Braking Pump Component
Test” in this section.
E2: Inspect the leakage of the braking system
1 Check the external leakage of the braking system.
See “Master Braking Pump Component Test” in this
section.
• Is th leakage found?
　 Yes
Repair if necessary. Add the braking fluid and
exhaust. See Section 203-00 for relevant
information. Test and operate the system to see if
it is normal.
　 No
Turn to E3
E3: Perform the pass-by test of the master braking pump
1 Test the pass-by of the master braking pump. See
“Master Braking Pump Component Test” in this
section for relevant information.
• Is the failure found?
　 Yes
Replace the master braking pump. Add the
braking fluid and exhaust. See Section 203-00 for
relevant information. Test and operate the system
to see if it is normal.
　 No
The system is normal. Test and operate the
system to see if it is normal.

Fixed Point Inspection F: The Pedal Position is Low or Feels Soft

Phenomena Contents/results/measures
F1: Perform the road test
1 When the road test is performed to the automobile,
step down the brake.

BENNI MINI
203-00-13 Braking System-General

Diagnosis and Test (continued)

Phenomena Contents/results/measures

• Does the brake pedal feel soft?

　 Yes
Turn to F2
　 No
The automobile is normal.
F2: Check the level of the braking fluid
１Check the fluid level of the fluid can of the master
braking pump.
• Is the level of the braking fluid normal?
　 Yes
Turn to F3
　 No
Check the sealing position of the fluid can of the
master braking pump. See “Master Braking Pump
Component Test” in this section. Add the braking
oil liquid and exhaust. See Section 203-00 for
relevant information. Test and operate the system
to see if it is normal.
F3: Check the ventilation hole on the cover of the oil storage can
１Check whether the ventilation hole on the cover of the
oil storage can is blocked or become dirty.
• Is the failure found?
　 Yes
Clean if necessary. Test and operate the system to
see if it is normal.
　 No
Turn to F4
F4: Exhaust the braking system
１Check the air in the braking system. Exhaust to the
braking system. See Section 203-00 for relevant
information.
• Does the situation continue to exist?
　 Yes
Turn to F5
　 No
The automobile is normal.
F5: Check the wheel hubs retaining nuts of the front wheels
１Check whether the wheel hubs retaining nuts of the
front wheels are loosened. See Section203-01 for
relevant information.
• Is the wheel hubs retaining nuts of the front wheels is
loosened?
　 Yes

BENNI MINI
203-00-14 Braking System-General 203-0

Diagnosis and Test (continued)

Phenomena Contents/results/measures
Replace the wheel hubs retaining nuts of the front
wheels, note: the wheel hubs retaining nuts of the
front wheels can not be used again. Test and
operate the system to see if it is normal.
　 No
Check the parking braking adjustment. See
Section 203-05 for relevant information.
Fixed Point Inspection G: Locked Brake after Being Slightly Stepped
Phenomena Contents/results/measures
G1: Perform the road test
１When the road test is performed to the automobile,
lightly step down the brake pedal.
Is the rear wheel locked?
　 Yes
Turn to G2
　 No
The automobile is normal.
G2: Check the tyres
１Check the excessive wear of the tyre or the incorrect
tyre air pressure.
• Is the status of all the tyres normal?
　 Yes
Turn to G3
　 No
Replace the tyre. Adjust the tyre air pressure. Test
and operate the system to see if it is normal.
G3: Check the brake shoe or the brake disc
１Check whether the brake shoe or the brake disc is
correctly installed or is polluted by the oil liquid or is
excessively worn.
• Do these situations exist?
　 Yes
Repair or replace the components if necessary.
Test and operate the system to see if it is normal.
　 No
Turn to G4
G4: Check the right rear braking and pressure reducing valve
1 Connect the pressure gauge on the left front and
right rear exhaust holes. Step on the brake pedal, and
the reading of the left front wheel is 6895 kPa (1000
psi).
- Read the pressure of the right rear wheel.
• Are the readings of the pressure gauge of the right
rear wheel between 4692kPa and 5164 kPa (680-750
psi)?

BENNI MINI
203-00-15 Braking System-General

Diagnosis and Test (continued)

Phenomena Contents/results/measures
　 Yes
Test the brake booster. Turn to the Fixed Point
Inspection I.
　 No
Replace the right rear pressure control valve. See
Section 203-00 for relevant information. Test and
operate the system to see if it is normal.
G5: Check the left and right pressure controlling valves
1 Connect the pressure gauge on the right front or left
rear exhaust holes. Step on the brake pedal, and the
reading of the right front wheel is 6895 kPa (1000
psi).
- Read the reading of the pressure gauge of the left
rear wheel.
•Are the readings of the pressure gauge of the right
rear wheel between 4692 kPa to 5164 kPa (680-750
psi)?
　 Yes
Test the brake booster. Turn to the Fixed Point
Inspection I.
　 No
Replace the left rear pressure control valve. See
Section 203-00 for relevant information. Test and
operate the system to see if it is normal.
Fixed Point Inspection H: Excessively Long and Unstable Free Travel of Brake Pedal
Phenomena Contents/results/measures
H1: Perform the road test
１Perform the road test on the rough road. Step the
brake pedal.
• Is the travel of the brake pedal normal?
　 Yes
The automobile is normal.
　 No
Turn to H2
H2: Check the wheel bearing
1 Check the loosening of the front wheel
bearings.
• Is the front wheel bearings loosened?
　 Yes
Check the fixing nuts of the hub of the front
wheel. Replace the worn or damaged front wheel
bearings. See Section 20３-01 for relevant
information. Test and operate the system to see if
it is in the normal condition.
　 No

BENNI MINI
203-00-16 Braking System-General 203-0

Diagnosis and Test (continued)

Phenomena Contents/results/measures
Check the changing situation of the thickness of
the braking disc. Replace the components if
necessary. Test and operate the system to see if it
is in the normal condition.
Fixed Point Inspection 1: Towing of the Brake
现象 内容/结果/措施
I1: Check Brake Booster
1 Check the travel of the push rod and brake pedal of
the brake booster.
• Is the travel of the brake push rod and brake pedal
normal?
　 Yes
Go to I2
　 NO
Replace the brake booster. Test and operate
whether the system is normal.
I2: Road Test
1 Perform the road test to vehicles, press the brake.
• Is the performance of the brake normal?
　 Yes
The vehicle is normal.
　 NO
Check whether there are lagged components on
the brake distributing pump or the brake caliper
of each wheel, replace the components if
necessary. Exhaust the braking system. See
Section 203-00 for relevant information. Test and
operate the system to see if it is in the normal
condition.
Fixed Point Inspection J: Too much Force on Brake Pedal
Phenomena Contents / Results / Measures
J1: Check the braking status
1 When the engine stops runing, press the pedal for 5
times to eliminate the vacuum in the brake booster.
Press the pedal and keep the slight pressure. Start the
engine.
• Is the brake pedal at the original position?
　 Yes
Turn to J2
　 NO
Turn to J6

BENNI MINI
203-00-17 Braking System-General

Diagnosis and Test (continued)

Phenomena Contents / Results / Measures

J2: Check the leakage of the brake booster
1Keep the idle running of the engine, release the
acceleration pedal and shut down the engine. Step
the brake after 90 seconds, the brake shall work
through press twice or more times.
• Does the brake booster work?
　 Yes
The vehicle is normal.
　 NO
Turn to J3
J3: Check the check valve of the brake booster
1 Take down the vacuum tube of the brake booster from
the intake manifold, blow air to the vacuum tube.
• Does air go through the check valve?
　 Yes
Replace the check valve of the booster. Test and
operate the system to see if it is in the normal
condition.
　 NO
Turn to J4
J4: Check the check valve vacuum of the brake booster
1 Remove the vacuum tube of the check valve from
the brake booster. Ensure idle running of the engine,
connect the vacuum gauge and check the vacuum.
• Is the vacuum pressure of the brake booster above
66.7 kPa (19.7 in-Hg)?
　 Yes
Turn to J5
　 NO
Repair or replace the vacuum tube. Test and
operate the system to see if it is in the normal
condition.
J5: Check the brake booster
1 Check the brake booster. See Component Test
Procedures in this Section.
• Is the brake booster normal?
　 Yes
Turn to J6
　 NO
Replace the brake booster. Test and operate the
system to see if it is in the normal condition.
J6: Check the brake pedal mechanism
1 Dismount the push rod from the braking pin axle,
press the brake pedal to the bottom.
• Is the brake pedal is freely moved?

BENNI MINI
203-00-18 Braking System-General 203-0

Diagnosis and Test (continued)

Phenomena Contents / Results / Measures

　 Yes
Turn to J7
　 NO
Repair or replace the bushing of the brake pedal.
Test and operate whether the system is normal.
J7: Check the control valve of the braking pressure
1 Check the pollution of the control valve of the
braking pressure.
• Is the braking fluid polluted?
　 Yes
Replace the control valve of the braking pressure.
Add the braking fluid. See Section 203-00 for
relevant information. Test and operate the system
to see if it is in the normal condition.
　 NO
The vehicle is normal.
Fixed Point Inspection K: Braking Noise
Phenomenon Contents / Results / Measures
K1: Check the noise of the brake pedal
1 Check the excessive wear of the brake disc and the
brake shoe.
- Ensure the idle running of the engine for 10
seconds, press the brake pedal, listen to the noise
and compare it with that in normal cases.
• Are there noises?
　 Yes
Turn to K2
　 NO
The vehicle is normal.
K2: Check the poistion of the push rod
1 Check the position and the travel of the push rod of
the brake booster.
• Is the push rod normal?
　 Yes
Exhaust the braking system for the braking
system. See Section 203-00 for relevant
information. Test and operate the system to see if
it is in the normal condition.
　 NO
Replace the brake booster. Test and operate the
system to see if it is in the normal condition.

Fixed Point Inspection L: the Return of the Brake Pedal is Slow or Abnormal

BENNI MINI
203-00-19 Braking System-General
Diagnosis and Test (continued)
Phenomenon
L1: Check the return of the brake pedal
L2: Check the jamming of the brake pedal
Component Test
Check hydraulic leakage
If the vehicle runs in the rain or snow, the leaking trace
may be rinsed away, for the braking fluid is
water-soluble. Press the brake for several times after
the braking fluid is added. Check the decrease of the
braking fluid in the system. Confirm and repair the
external leakage. If the liquid level decreases and the
leakage position can not be found, check whether the
oil seal at the hole end of the mater braking pump leaks.
Check the braking system
Contents/Results/Measures
1 Ensure the fast idle running of the engine, press the
brake for several times. Pull the brake pedal
backwards with the force of approximately 44.5 N
(10 lbs). Release the brake pedal and measure the
distance from the brake pedal to the floor. The brake
pedal should come back to the original position.
• Does the brake pedal return to the original position?
　 Yes
The vehicle is normal.
　 NO
Turn to L2
1 Check the free motion of the brake pedal.
• Does the brake pedal freely move?
　 Yes
Replace the brake booster. Test and operate
whether the system is normal.
　 NO
Repair or replace the bushing of the brake pedal.
Test and operate whether the system is normal.
Check the travel allowance of the brake pedal
When you feel the brake pedal is low or touches to the
bottom, check the travel allowance of the brake pedal.
1. Ensure the idle running of the engine, and put the
transmission in the neutral gear.
2. Slightly press the brake pedal for 3 or 4 times.
3. Maintain the booster to supplement vacuum for 15
seconds.
Notes: When the resistance is increased, you shall
feel that the brake is floored.
4. Press the brake pedal till the downward movement
stops or no increased resistance.
5. Keep the brake pedal at the position where causes
the brake to work, increase the engine rotating
speed to 2000 rpm.
Notes: The additional movement of the brake pedal is
the result of the increase of the vacuum degree in the
intake manifold of the engine. Therefore, the additional
travel is caused to act on the master braking pump, and
the braking system shall not touch the bottom.
6. Release the acceleration pedal, and observe the
downward movement of the brake pedal in the
BENNI MINI
203-00-20 制动系统 –概述
诊断和测试 (续)
process that the engine rotating speed reduces to
the idle speed.
Check the status of the brake booster
Check all vacuum tubes and connectors. All unused
vacuum connectors should be well blocked. The
vacuum tube and the connector should be correctly
fixed without leak or aging. Check whether the check
valve on the brake booster is damaged or not.
Check the function of the brake booster
1. Check the leakage or the low liquid level of the
hydraulic braking system.
2. Put the transmission in the neutral gear, shut down
the engine, and push the parking braking. Press
brake pedal for several times in order to eliminate
the vacuum in the system.
3. Start the engine. If the vacuum system works, the
brake pedal shall move downwards. If you can not
feel the movement, the vacuum power system does
not work.
4. Get down the vacuum tube from the brake booster.
When the engine is in the neutral gear with idle
speed, the vacuum in the intake manifold will act
at the brake booster end of the hose. Ensure that all
unused outlets well blocked, the connectors are
perfect, and the vacuum tube is normal. If the
vacuum degree of the air intake pipe can work, the
hose is connected back to the brake booster, and
repeat the third step. If the downward movement
can not be felt, replace the brake booster.
5. Ensure the engine to run at the fast idle speed for
10 seconds. Press the brake pedal with the force of
approximately 889 N (20 lb) 10 minutes after the
engine is shut down and the feeling to the brake
pedal should be the same as that when the engine
works. If the brake pedal feels too stiff, replace the
brake booster. If the brake pedal feels soft, exhaust
the braking system, See Section 203-00 for
relevant information.
Master Braking Pump
Generally, the first and most efficient method for any
failure of the braking system is to feel the brake pedal.
When the failure of the mater braking pump is
diagnosed, check the feeling of the brake pedal and
take the result as the evidence of the braking problem.
Check the flash of brake warning indicating lamp and
the braking fluid level.
203-00-20
Normal Situations
The following statuses are normal, which does not
indicate the master braking pump needs repairing.
– The new braking system design is different from
before: the required force for pressing the brake
pedal is lighter. Therefore, the complaint that the
action of the pedal is too light should be compared
with that of the automobile with the same model
and the same manufacturing year.
–The braking fluid level ascends when the brake is
normally operated, and descend when release. The
total amount of the braking fluid does not change.
– There are braking fluid traces on the brake booster
below the retainer flange of the master pump,
which is caused by the normal lubrication to the oil
seal of the end of the master pump cylinder
diameter.
– The height of the braking fluid shall decline along
with the wear of the brake block.
Abnormal Situations
Notes: Before the diagnosis, ensure the warning
indication lamp of the barking system be normal.
The change of the feelings of the brake pedal or the
travel indicates that problems may exist in the braking
system. The diagnosis procedures and skills comprise
the feeling of the brake pedal, the indications of the
brake warning indicating lamp and the height of the
low braking fluid when the system problems are
diagnosed. The following statues are abnormal, which
indicate that the master braking pump needs repairing.
– The rapid decline of the brake pedal may be caused
by the internal or external leakage.
– The automatic slow decline of the brake pedal may
be caused by the internal or external leakage.
– The brake pedal feels soft, which may be caused by
that there is no oil in the fluid can of the master
braking pump, the ventilation hole of the fluid can
is blocked or there is air in the hydraulic system.
– The force to the brake pedal is too large, which
may be caused by the clamping and the blocking of
the pedal or the push rod, the blocking of the liquid
control valve or the insufficient vacuum in the
brake booster.
– The rear brake locks when the brake pedal is
slightly pressed, which may be caused by that the
tyre air pressure is incorrect, there is oil on the
brake shoe or the inner lining, the parking braking
悦翔
203-00-21 Braking System – General
Instructions and Operations (Continued)
is adjusted improperly, or the control valve of the
braking pressure is damaged or polluted.
– The acting force of the brake pedal is unstable,
which may be caused by the failure of the brake
booster, the over large backward shock of the brake
caliper piston or the incorrect installation of the
brake shoe.
– The brake warning indicating lamp lights, which
may be caused by that the braking fluid level is low,
the ignition circuit is too close to the indicator lamp
of the braking fluid level, or the float assembly is
damaged.
Pass-by Status Test
1. Check the master braking pump. Add the braking
fluid if the fluid level of the fluid can of the master
braking pump is too low or short of oil.
2. Observe the liquid level of the fluid storage can of
the master braking pump. If the braking fluid level
is constant after the brake pedal is pressed for
several times, measure the required torque when
the vehicle wheel rotates backwards under braking
action according to the following methods:
203-00-21
Put the transmission in the neutral gear, and hoist the
automobile. See Section 100-01 for relevant
information.
Press the brake with force of at least 445 N (100 lb) and
maintain the action for 15 seconds. Exert a torque with
10.1 Nm (75 lb.ft) on the vehicle wheels under the
condition that the brake still works. Replace the master
braking pump if any wheel rotates.
Non-Pressure Leakage
Any empty situation of the fluid storage can of the
master braking pump may be caused by the two kinds
of non-pressure external leakage.
Type 1: Because of the incorrect position of the washer
and the cover, the external leakage may exist on the
cover of the fluid storage can of the master braking
pump.
Type 2: The external leakage may exist on the
installation sealing gasket of the fluid storage can of the
braking fluid. Install the new oil seal in order to repair
such leakage.
BENNI MINI
206-00-22 Braking System – General 206-00-22

General Procedures
GENERAL PROCEDURES

Exhausting of the Braking System (12 141 0)

8. Continuously press the brake pedal until the
braking not containing air flows into the
Exhausting exhausting tank.
Configure Anti-lock Automobile 9. Press the brake pedal and fasten the exhaust
1. Take down the negative electrode wire of the hole.
battery. See Section 407-00 for relevant
information. 10. Cautions: Ensure that the exhaust hole is
covered after the air in the braking
All Vehicle Models pipeline is exhausted. This can prevent the
Warnings: The braking fluid contains exhaust hole from eroding. Failure to
polyglycol ether and polyethylene glycol. follow this instruction may lead to
Avoid contacting with eyes. Thoroughly blocking of the exhaust hole.
wash hands after the treatment. Rinse eyes Repeat the procedures for other braking pipelines.
with cold water from the water tab for 15
minutes if eyes contact with the braking
fluid. Send to the hospital if the pain still
exists. If the braking fluid is inadvertently
swallowed down, drink water and induce
vomiting, and send to the hospital
immediately. Failure to follow the
instructions may lead to bodily injury.

Cautions: Immediately clean the affected

position if the braking fluid is splashed on
the paint.
Notes: Ensure that the vehicle stops on the flat
road.
Notes: The braking system is formed through
crossing the relatively independent loops of the
front/rear wheels. Each loop can exhaust
independently.
2. Cautions: The liquid storage can of the
braking fluid should be constantly added
with the new and clean braking fluid.
Connect the exhaust pipe to the exhaust hole.
3. Immerge the end of the exhaust pipe into an
exhausting tank with little qualified brake.
4. Put the exhausting tank at the position where the
bottom of which is at least 300 mm above the
exhaust hole to keep the hydraulic pressure and
avoid the air entering through the screw thread
of the exhaust hole.
5. Release the exhaust hole for one circle and a
half.
6. Floored the brake pedal (the pump sends the
braking fluid and air into the exhausting tank),
and make the brake pedal come back to the
stopping position.
7. Add the braking fluid into the braking fluid can.

BENNI MINI
206-00-23 Braking System – General 206-00-23

General Procedures

Pressure Exhausting of the Braking System (12 141 0)

2. Cautions: Please strictly comply with
Exhausting manufacturer’s instruments
The appropriate pressure exhausting
Warnings: The braking fluid contains machine is needed for pressurizing and
polyglycol ether and polyethylene glycol. exhausting the system. Please comply with
Avoid contacting with eyes. Thoroughly wash manufacturer’s instruments when use.
hands after the treatment. Rinse eyes with
cold water from the water tab for 15 minutes if
eyes contact with the braking fluid. Send to
the hospital if still feel pain. If inadvertently
swallow the braking fluid, drink water and 3. Cautions: Ensure that the exhaust hole is
induce vomiting, and send to the hospital covered after the air in the braking pipeline
immediately. Failure to follow the instructions is exhausted. This can prevent the exhaust
may lead to the bodily injury. hole from eroding. Failure to follow this
instruction may lead to blocking of the
Cautions: Ensure that the vehicle stops on the
exhaust hole.
flat road.
Add the brake fluid to the MAX position if
Cautions: Immediately clean the affected
necessary
position if the braking fluid splashes on the
paint.
Cautions: Confirm that the anti-lock brake
(ABS) vehicle is configured and the negative
electrode wire of the battery has been
detached.
Notes: The braking system is formed through crossing
the relatively independent loops of the front/rear
wheels. Each loop can exhaust independently.
Notes: Because the ABS hydraulic control unit (HCU)
has been filled with braking fluid during the
maintenance. Therefore, conventional exhausting
procedures can be satisfied.

1.Fill the fluid storing can with the braking fluid to

the MAX position.

BENNI MINI
206-00-24 Braking System – General 206-00-24

General Procedures

Run-out Measurement of the Brake Disc (12 221 0)

7. Notes: If the run-out amount exceeds the specified
value, measure the run-out of the wheel hub
surface.
Special Tool
Fixing Supporting Seat of the Use the appropriate dial gauge to measure the
Dial Gauge 205-070 (15-022A) internal and external surfaces of the brake disc.
1. Install the dial gauge at the position 10 mm (0.4
inch) away from the exterior braking margin.
2 .Slowly rotate the brake disc. The total readings
on the dial gauge should not exceed the given
General Tools standards. See the partial contents in this section
for relevant information.
Dial Gauge
Micrometer Caliper

Measurement
1. Loosen the tyre nuts.
2. Hoist automobile. See Chapter 100-01 for
relevant information.
3. Disassemble the tyre.
4. Disassemble the brake disc. See Chapter 203-01
for relevant information.
5. Install the tyre nuts in an opposite sequence,
and fix the brake disc in its position.
6. Install the dial gauge and fix the bearing on the
supporting column of the suspension.
8. Measure the thickness variation value of the
brake disc.
• Use the micrometer caliper to measure the
thickness of the brake disc at 8 positions where
the positions are 15 mm away from the exterior
margin of the brake disc with the interval of 45°.
• If the variation value reaches or exceeds 0.015
mm, or the thickness of the brake disc is smaller
than the minimum regulated value, the brake
disc should be replaced.

BENNI MINI
206-00-25 Brake System - General Information 206-00-25

GENERAL PROCEDURES (Continued)

9. Disassemble the brake disc. See Section

203-01for relevant information.
10. 10. Notes: Ensure the wheel hub is clean and
without dust and sundries.
Use the special tool to measure the run-out of
the wheel hub surface.
• • Slightly rotate the wheel hub and check the
run-out. If the run-out exceeds the regulated
scope, replace another wheel hub and check
again. See Chapter 204-01 for relevant
information.

11. If the run-out of the wheel hub is within the

specified value, install a new brake disc and
check the run-out of the brake disc again. See
Section 203-01 for relevant information.

G109096 en 09/2002 2003.50 Fiesta

203-01-1 Disc Type Brake of the Front Wheel 203-01-1

Section 203-01 Disc Type Brake of the Front Wheel

Applicable Vehicle Model: BENNI MINI

Contents Pages
Specifications

Specifications .......................................................................................................................... 203-01-2

Instruction and Operation

Disc Type Brake of the Front Wheel ............................................................................................. 203-01-3

Diagnosis and Test

Disc Type Brake of the Front Wheel ............................................................................................. 203-01-04

Disassembly and Installation

Brake Disc ........................................................................................................ (12 234 0) 203-01-05

Brake Caliper .................................................................................................... (12 243 0) 203-01-07
Brake Disc ..................................................................................................... (12 223 0) 203-01-09

Disintegration and Assembly

Brake Caliper .................................................................................................... (12 001 0) 203-01-11

BENNI MINI
203-01-2 Disc Type Brake of the Front Wheel 203-01-2

Specifications

Grease, Oil Fluid, Sealant and Bonding Agent

Name Model
Braking fluid HZY 4

Specifications of the Disc Brake of the Front Wheel

mm
Diameter of the brake disc 236
Thickness of the brake disc 12.5
Disabled thickness of the brake disc 9.7
Maximum run-out amount of the brake disc (Installed) 0.1
Maximum thickness variation value of the brake disc 0.015
Piston diameter of the brake distributing pump 48
Minimum thickness of the brake disc 3
z * When thickness of the brake disc reaches the disabled value, the brake disc has to be replaced. When the brake
disc which does not meet the disabled standard is processed, make sure the disabled value is not exceeded.

Torque Specification
Description Nm
Tyre nuts 85
Piston housing bolts of the brake distributing pump 27
Bracket fixing bolt of the brake caliper 83
Connector of the barking hose 23

BENNI MINI
203-01-3 Disc Type Brake of the Front Wheel 203-01-3

Instruction and Operation

DESCRIPTION AND OPERATION

Disc Type Brake of the Front Wheel

Serial Parts NAME

Number Number
1 Brake disc
2 Brake caliper
3 Brake disc

BENNI MINI
203-01-4 Disc Type Brake of the Front Wheel 203-01-4

Diagnosis and Test

DIAGNOSIS AND TESTING

Disc Type Brake of the Front Wheel

See Section 203-01for relevant information.

BENNI MINI
203-01-5 Disc Type Brake of the Front Wheel 203-01-5

Disassembly and Installation

REMOVAL AND INSTALLATION

Brake Disc (12 234 0)

Special Tool 5. Disassemble the brake disc.

206-005 (12-014)
Piston tractor of the brake
distributing pump
206-005 (12-014)

Name Model
Brake fluid HZY4

Disassembly Installation
Warning: If braking fluid is spattered on the 1. Warning: when tightly pressing the piston
painted surface, use clean water to rinse the of the brake distributing pump into the
braking fluid immediately. piston cylinder, braking fluid may puff up
from the master brake cylinder.
1. Loosen the tyre nuts. Use a special tool to compress the piston of the
2. Hoist the automobile. See Section 100-02 for brake distributing pump.
relevant information.
3. Disassemble the wheel.
4. Remove the brake caliper.
1. Disassemble the lower bolt of the brake caliper.
2. Rotate the brake caliper upwards.

BENNI MINI
203-01-6 Disc Type Brake of the Front Wheel 203-01-6

Disassembly and Installation (Continued)

2. Install the brake disc.

3. Install the lower bolt of the brake caliper.

4. Install the wheel.

5. Tread the brake pedal twice.

6. Inspect the level of the braking fluid. •

BENNI MINI
203-01-7 203-01-6Disc Type Brake of the Front Wheel 203-01-7

Disassembly and Installation

Brake Caliper (12 243 0)

4. Remove the brake caliper.

General Tool

Nip of the barking hose

Disassembly
Caution: If braking fluid is spattered on the
painted surface, immediately use cold water to
rinse the region.
1. Disassemble the brake disc. See the Part of brake
disc in this section for relevant information.
2. Remove the braking hose from the steering
knuckle assembly. 5. Warning: Seal the braking hose to prevent
oil fluid from running off and dirt from
entering into.
Disassemble the brake caliper.
• Rotate the brake caliper assembly.

3. Loosen the braking hose from the brake caliper.

1. Use a suitable nip of the barking hose to clip the
braking hose.
2. Loosen the braking hose.

BENNI MINI
203-01-8 Disc Type Brake of the Front Wheel 203-01-8

Disassembly and Installation (Continued)

Installation
1. Reverse the disassembly sequence for
installation.

2. Exhausting of the braking system. See Section

203-00 for relevant information.

BENNI MINI
203-01-9 Disc Type Brake of the Front Wheel 203-01-9

Disassembly and Installation

Brake Disc (12 223 0)

Disassembly
4. Caution: hang up the brake caliper, to
1. 1. Disassemble the brake disc. See the Part of prevent the braking hose from being
brake disc in this section for relevant stretched.
information. Suspend the brake caliper.
2. Remove the braking hose from the steering
knuckle assembly.

5. Disassemble the brake disc.

• If installed, disassemble and throw away the
3.. Remove the brake caliper. fixing clip.

BENNI MINI
203-01-10 Disc Type Brake of the Front Wheel 203-01-10

Disassembly and Installation

Installation
1. Reverse the disassembly sequence for
installation.

BENNI MINI
203-01-11 Disc Type Brake of the Front Wheel 203-01-11

Disassembly and Installation

DISASSEMBLY AND ASSEMBLY

Brake Caliper (12 001 0)

Name Model 3. Disassemble and throw away the piston oil seal.
Brake fluid HZY4

Disintegration
Warning: If braking fluid is spattered on
the painted surface, immediately use cold
water to rinse the region.
1. Warning: Place wood blocks (or stow
wood) or some pieces of wiping cloth
between the piston of the brake
distributing pump and the brake caliper
housing to avoid damaging the brake 4. Inspect the piston and the piston hole for
distributing pump. damage and abrasion. Replace the brake caliper
if necessary.
Use compressed air to remove the piston of the
brake distributing pump from the brake caliper
housing. Assembly
1. Use braking fluid to lubricate the piston hole,
the piston oil seal and the brake caliper.
2. Note: the piston oil seal must be installed in the
groove of the piston hole.
Install a new piston oil seal into the piston hole.

2. 拆卸并丢弃防尘油封。.

BENNI MINI
203-01-12 Front Disc Brake 203-01-12

Disassembly and Installation

3. Install a new dust-proof oil seal onto the piston of

the brake distributing pump.

4. Caution: Do not scratch the piston while

assembling the piston into the piston hole.
Assemble the piston of the brake distributing
pump into the piston hole.

5. Install the dust-proof oil seal.

BENNI MINI
203-02-1 Drum Type Brake 203-02-1

Section 203-02 Drum Type Brake

Applicable Vehicle Model:BENNI MINI

Contents Page

Specifications

Specifications .......................................................................................................................... 203-02-2

Instruction and Operation

Drum Type Brake ..................................................................................................................... 203-02-3

Diagnosis and Test

Drum Type Brake ..................................................................................................................... 203-02-4

Disassembly and Installation

Brake Drum ...................................................................................................... (12 275 0) 203-02-05

Brake Shoe........................................................................................................ (12 285 0) 203-02-07

BENNI MINI
203-02-2 Drum Type Brake 203-02-2

Specification

Grease, Oil Fluid, Sealant and Bonding Agent

Name
Name Model
Braking Fluid HZY 4

Specifications of Drum Type Brake

mm
Diameter of the new brake drum 180
Disabled diameter of the brake drum 182
Width of the brake shoe 30
Hole diameter of the brake distributing pump 17.46（ABS）15.87
（NO ABS）
Thickness of the leading shoe lining of the new brake 4.5
Disabled thickness of the lining sheet of the brake shoe 1.5
* When the diameter of the braking drum is up to the disabled standard, the brake drum should be replaced. When
the brake drum is not up to the disabled standard, the brake drum should be processed with caution.

Torque Specifications
Descriptions Nm
Wheel hub fixing nut 220
Tyre nuts 85
Fixing bolt of the brake distributing pump 10
Connector of the barking hose 15

BENNI MINI
203-02-3 Drum Type Brake 203-02-3

Instruction and Operation

DESCRIPTION AND OPERATION

DUDU Drum Type Brake

DAGNOSIS AND TESTING

DESCRIPTION AND OPERATION

Serial PARTS NAME

NO NO
1 Base Plate
2 Brake Distributing Pump
3 Brake Shoe
4 Brake Drum

BENNI MINI
203-02-4 Drum Type Brake 203-02-4

Diagnosis and Test

DIAGNOSIS AND TESTING

Drum Type Brake

See Section 203-00 for relevant information.

BENNI MINI
203-02-5 Drum Type Brake 203-02-5

Disassembly and Installation

REMOVAL AND INSTALLATION

Brake Drum (12 275 0)

Disassembly
1. Disassemble the decorative plate of the controlling rod of the parking brake See Section 501-05 for
relevant information.
2. Dismount the controlling rod of the parking brake and loosen the adjusting nut.

3. Loosen the wheel nuts.

4. Hoist the automobile. See Section 100-02 for relevant information.
5. Disassemble the wheels.
6. Cautions: If the sealing cover of the grease cap is damaged, replace it during the installation.
Disassemble the grease sealing cover.

BENNI MINI
203-02-8 Drum Type Brake 203-02-8

Disassembly and Installation (continued)

7. Loosen the fixing nuts of the brake drum

Disassemble the brake drum.

1. Disassemble the nuts.
2. Disassemble the brake drum.

Installation
Caution: If the wheel hub fixing nut is screwed, do not loosen it any longer. If the torque adjustment is
required, the wheel hub fixing nut must be screwed after being loosened for two circles.

1. The installation is performed according to the procedures opposite to the disassembly procedures.

长安·奔奔MINI
203-02-7 Drum Type Brake 203-02-7

Disassembly and Installation (continued)

2. Adjust the parking braking dragline. See Section 203-03 for relevant information.

Brake shoe (12 285 0)

NAME Model
Grease SAM1C-9107-A

Disassembly
1. Disassemble the brake drum, wheel axle and wheel hub assembly. See Brake Drum in this Section for
relevant information.
2. Disassemble the fixing spring of the brake shoe.

3. Fix the piston of the brake distributing pump with the rubber belt.
4. Caution: When the brake shoe is dismounted, do not damage the dust shield of the brake
distributing pump.
203-02-8 Drum Type Brake 203-02-8

Disassembly and Installation (continued)

5. Dismount the brake shoe from the connection supporting frame

6. Dismount the parking braking dragline.
1.Push the trailing shoe backwards.
2. Dismount the dragline from the trailing shoe.

3. Cautions: Do not damage the dust shield of

Installation the brake distributing pump.
Install the brake shoe to the brake distributing
1. Install the parking braking dragline. pump.
1.Connect the parking braking dragline.
2. Push the trailing shoe pushing rod forwards.

2. Disassemble the rubber belt.

长安·奔奔MINI
203-02-9 Drum Type Brake 203-02-9

Disassembly and Installation (continued)

4. Install the brake shoe to the special bottom

supporting pin of the base.

5. Install the spring of the brake shoe.

6. nstallation of the brake drum, the wheel

axle and the wheel hub assembly.

7. Adjust the parking braking dragline. See

Section 203-03 for relevant information.
203-03-1 Parking Brake 203-03-1

Section 203-03 Parking Brake

Applicable Vehicle Model: BENNI MINI

Contents Page

Specifications

Specifications .......................................................................................................................... 203-03-2

Instruction and Operation

Parking Brake .......................................................................................................................... 203-03-3

Diagnosis and Test

Parking Brake .......................................................................................................................... 203-03-4

Inspection and Confirmation ....................................................................................................... 203-03-4
Failure Inspecting Table ............................................................................................................. 203-03-4

Common Procedures

Adjustment of the Parking Brake Dragline ............................................................... (12 662 0) 203-03-7

Disassembly and Installation

Control Rod of the Parking Brake 203-03-8
Parking Brake Dragline ........................................................................................ (12 675 0) 203-03-9
Warning Lamp Switch of the Parking Braking .......................................................... (33 546 0) 203-03-9

BENNI·MINI
203-03-2 Parking Brake 203-03-2

Specifications

Torque Specifications
Description Nm
Adjusting Nut of the Parking Brake Dragline 4
Controlling Nut of the Parking Brake Dragline 23±2

BENNI MINI
203-03-3 Parking Brake 203-03-3

Instruction and Operation

DESCRIPTION AND OPERATION

Parking Brake

NO NAME
1 Parking Braking Rod Assembly
2 Parking Brake Dragline Assembly (Left)
3 Parking Brake Dragline Assembly (Right)

BENNI MINI
203-03-4 Parking Brake 203-03-4

Diagnosis and Test

DIAGNOSIS AND TESTING

驻车制动器

The Parking Brake

Inspection and Confirmation
1. Confirm the failure described by the customer Machinery Electric Appliance
through the operation of the parking braking system. – The Controlling Rod – Warning Circuit of the
2. Check whether machinery or electric appliance has of the Parking Brake Parking Braking. See
obvious damage. – The parking braking Section 403-01.
dragline
Visual Inspection Table
3. If the reason which caused the found or proposed
problem is found, the failure shall be eliminated
before next step (if possible).
4. If the problem can not be found through visual
inspection, confirm the failure and consult the
Failure Phenomenon Table for reference.

Failure Inspecting Table

Phenomenon Possible Failure Measures
• The parking brake does not work. • The control rod of the parking brake • Turn to the fixed point inspection A.
• The parking brake dragline
• The parking brake can not be • The control rod of the parking brake • Turn to the fixed point inspection B.
loosened. • The parking brake dragline
Fixed Point Inspection A: The parking brake does not work.

Phenomenon Contents/Results/Measures
A1: Check whether the rear dragline of the parking brake is well adjusted.
1 Operate the control rod of the parking
brake several times to adjust the
OOO
dragline.
• Is the parking braking in good
condition?
　 Yes
The vehicle is normal.
　 No
Turn to A2
A2: Check the abrasion status of the rear wheel brake shoe.
1 Check the excessive abrasion of the
brake shoe. See Section 203-00.
• Are the brake shoe and the the inner
lining intact?
　 Yes
Turn to A3
　 No
Replace the brake shoe. See
Section 203-02. Test and operate
the system to see whether it is
normal.

BENNI MINI
203-03-5 驻车制动器 203-03-5

诊断和测试 (续)

Phenomenon Contents/Results/Measures
A3: Check the damage of the parking brake dragline.
1 Check the damage and rustiness of
the parking brake dragline.
• Is the brake dragline intact?
　 Yes
Check the reason of loosing of the
control rod of the parking brake or
components of related braking
system. See Section 203-00.
　 No
Repair or replace when necessary
the parking brake dragline. Test
and operate the system to see if it
is in the normal condition.

Fixed Point Inspection B: The parking braking can not be loosened.

Phenomenon Contents/Results/Measures
B1: Check the parking braking dragline
1 Loosen the parking braking dragline
tightener.
- Manually rotate the rear wheel.
• Does the rear wheel rotate freely?
　 Yes
Replace the control rod of the
parking brake. Please see Section of
the control rod of the parking brake.
Test and operate the system to see if
it is in the normal condition.
　 No
Turn to B3
B2: Check the control rod of the parking brake.
1 Hoist the automobile. Tighten the
parking braking. See Section 100-01 for
relevant information.
- Drag upward the control rod and press
down the releasing button to release
the parking brake.
• Is the parking braking released?
　 Yes
Check other reasons, such as components of the
common braking systems. Repair or replace
component when necessary s. See Section
203-00.
　 No
Turn to B1

长安·奔奔 MINI
206-05-6 Parking Brake and Actuation 206-05-6

DIAGNOSIS AND TESTING (Continued)

Phenomenon Contents/Results/Measures
B3: Check the front dragline of the parking brake.
1 At the position of balancer, take off the front
dragline of the parking brake from the rear dragline
of the parking brake.
- Manually rotate the rear wheel.
• Does the rear wheel rotate freely?
　 Yes
Replace the front dragline of the parking brake.
Please see the section of the parking braking
dragline. Test and operate the system to see if it is
in the normal condition.
　 No
Turn to B4
B4: Check the rear dragline of the parking brake.
1 Take off the rear wheel parking braking dragline
from the rear brake.
- Manually rotate the wheel on which the parking
braking dragline is taken off.
• Does the wheel rotate freely?
　 Yes
Replace the parking braking dragline. Please see
the section of the parking braking dragline. Test
and operate the system to see whether it is
normal.
　 No
Check other reasons, such as components of the
common braking systems. Repair or replace
components when necessary. Please see Section
203-00.

BENNI MINI
203-03-7 Parking Brake 203-03-7

Common Procedures
GENERAL PROCEDURES

The adjustment of the parking brake dragline

4. Step on the brake pedal for six times.
Adjustment 5. Adjust the parking braking dragline.
1. Lift the control rod of the parking brake until
1. Disassemble the control cover plate of the presenting six ratchet sounds.
parking brake.
2. Firmly fix the adjusting nut.
2. Put down the control rod of the parking brake.

3. Loosen the adjusting nut.

6. Test the parking brake to see whether it works

normally.

7. Install the cover plate of the parking brake

203-03-8 Parking Brake 203-03-8

Disassembly and Installation

REMOVAL AND INSTALLATION

The control rod of the parking brake

Disassembly
1. Disassemble the cover plate of the control rod of Installation
the parking brake.
1. The installation procedures are opposite to the
2. Put down the control rod of the parking brake. disassembly sequence.

3. Disassemble the adjusting nut.

4. Disassemble the nut of the control rod of the

parking brake.

2. Adjust the parking braking dragline. For the

relevant information, please see the section of
the parking braking dragline.

5. Take out the dragline from the control rod of the

parking brake.

6. Disassemble the control rod of the parking brake.

1. Disconnect the switch connector of the warning lamp
of the parking braking.
2. Disassemble the control rod of the parking brake.

BENNI MINI
203-03-9 Parking Brake 203-03-9

Disassembly and Installation

The parking brake dragline (12 675 0)

Disassembly 6. Take off the rear dragline of the parking brake

from the vehicle body (both sides)
1. Disassemble the cover plate of the control rod of
the parking bake. 7. Disassemble the brake drum. For the relevant
2. Put down the control rod of the parking brake. information, please see section 203-02.

9. Take off the parking braking dragline.

1. Push backward the trailing shoe rod.
2. Take off the dragline from the braking trailing
shoe.

and loosen the adjusting nut.

Installation
1. The installation procedures are opposite to the
disassembly sequence.

2. Adjust the parking braking. For the relevant

information, please see the section of the
3. Loosen the nuts of the rear wheel tyre. parking braking dragline.
4. Automobile hoisting.
5. Take off the left and right parking dragline
from the balancer of the front dragline of the
parking brake

BENNI MINI
203-03-10 Parking Brake 203-03-10

Disassembly and Installation

The warning lamp switch of the parking braking (33 546 0)

Disassembly
1. Disassemble the control rod of the parking brake.
For relevant information, please see the section
of the control rod of the parking brake.
2. Disassemble switches.

Installation
1. The installation procedures are opposite to the
disassembly sequence.

长安·奔奔 MINI
203-04-1 Hydraulic braking system operating mechanism 203-04-1

Chapter 203-04 Hydraulic Braking System Operating

Mechanism
Applicable vehicle model：BENNI MINI
Contents Pages
Specifications

Specifications .......................................................................................................................... 203-04-2

Instruction and Operation

Hydraulic braking system ........................................................................................................... 203-04-2

Disassembling and Installation

Master braking pump........................................................................................... (12 343 0) 203-04-错误！

未定义书签。
The fluid can of braking fluid ................................................................................ (12 341 0) 203-04-5

BENNI MINI
203-04-2 Hydraulic braking system operating mechanism 203-0

Specifications

lubricating oil, grease, sealing component and binder

Items
HZY 4 braking fluid
Torque Specifications
Description Nm
Joining of the master braking pump and the oil pipe 16±2
Fixing nut of the master braking pump 20~30
Fixing nuts of the joining axle of the brake pedal
DESCRIPTION AND OPERATION
20~30
Hydraulic Braking System

NO Parts NAME
Number
1 Brake pedal
2 Oil storage can of the braking
fluid
3 Master braking pump

BENNI MINI
203-04-3 Hydraulic braking system operating mechanism

Disassembling and Installation

DIAGNOSIS AND TESTING

AL
拆卸与安装

Master braking pump

Disassembling
Notes: If braking fluid is carelessly splashed
onto the painting surface, clean with clean
water immediately。
1. Notes: The fluid storage can shall not be
polluted.。
Take off the cover of the fluid storage can.
1. Disassemble the warning lamp switch plug for
low braking oil level.。
2. Take off the cover of the fluid storage can.。
2. 注意: Notes: this procedure should be
performed on both sides to completely discharge all
the braking fluid in the fluid storage can.。
Discharge the braking fluid of the fluid storage
can.
1. Use a proper clean plastic pipe with one end
connected to the system exhausting nozzle, and
the other end communicated into a proper
container.
2. Loose the exhausting nozzle.
3. Repeatedly step the brake pedal until all the
braking fluid in the fluid storage can is
completely exhausted.
4. Screw the exhausting nozzle tightly.

3. Disassemble the oil pipe of the master pump。

BENNI MINI
203-04-4 Hydraulic braking system operating mechanism 203-04-4

Disassembling and Installation（Continued）

4. Disassemble the master braking pump and the Installation

brake fluid storage can assembly.
1.Disassemble the fixing nut. Warning: please confirm the pulling rod of
the brake booster is placed at the right
2 Take off the master braking pump.
position before installation.
Warning: please confirm the vacuum sealing
component of the master braking pump is
placed at the right position before installation.

The installation process is the reverse of the

disassembling sequence.

2. Refer to the chapter 203-00 for the relevant

information of exhausting the gas of the braking
system

BENNI MINI
203-04-3 Hydraulic braking system operating mechanism

Disassembling and Installation

Braking fluid storage can (12 341 0)

Dissembling
Warning: if the braking fluid is carelessly
splashed onto the vehicle paint surface, clean it
with clean water immediately.
1. Warning: ensure the cover of the oil filler
of the fluid storage not to be polluted
1. Disassemble the switch connector of the
warning lamp of the braking level.
2. Take off the oil filler cover.
2. Exhaust the braking fluid.
1. Use one end of a flexible pipe to
connect with the right front exhausting nozzle,
and the other end to connect into a proper
container.
2. Loosen the exhausting nozzle, repeatedly step
the brake pedal until all the oil fluid exhausted
out.
3. Screw the exhausting nozzle tightly.
• Perform the same operation on the left front
exhausting nozzle.

3. Disassemble the braking fluid storage can.

• Disassemble the fixing clips on both sides.

Installation
1. Notes: if necessary, replace with a new O-shaped
ring.
Install according to the adverse sequence of the
disassembling sequence.

2. Please refer to the chapter 203-00 for the relevant

information about exhausting of the braking
system

BENNI MINI
203-04-5 Hydraulic braking system operating mechanism 203-04-5

Disassembling and Installation

长安·奔奔 MINI
203-05-1 Booster Braking System 203-05-1

Section 203-05 Booster Braking System

Applicable Vehicle Model: benni-mini
contents page
Specifications

Specifications ........................................................................................................................ 203-05-2

Instruction and Operation

Brake booster .......................................................................................................................... 203-05-3

Diagnosis and Test

Booster braking system .............................................................................................................. 203-05-4

Disassembly and Installation

Brake booster .................................................................................................... (12 451 0) 203-05-5

CHANA·BENNI MINI
203-05-2 Booster Braking System 203-05-2

specification

Torque Specifications
Description Nm
Brake booster fixing bolt 20~30
Fixing bolt of the master braking pump 20~30

CHANA·BENNI MINI
203-05-3 Booster Braking System 203-05-3

Instruction and Operation

DESCRIPTION AND OPERATION

Brake Booster

Seri Parts Name

al Number
Num
ber
1 - Brake Booster

CHANA·BENNI MINI
203-05-4 Booster Braking System 203-05-4

Diagnosis and test

DIAGNOSIS AND TESTING

Brake Booster

Refer to Section 203-00

CHANA·BENNI MINI
203-05-5 Booster Braking System 203-05-5

Disassembly and Installation

REMOVAL AND INSTALLATION

Brake Booster (12 451 0)

Disassembly
Warnings: If the braking fluid is splashed on
the lacquer finish of the vehicle body
carelessly, the braking fluid should be flushed
with the clean water.
1. Disassemble the master brake pump
2. Disassemble the brake booster installing bolts

Installation
1. The installation is performed according to the
procedures opposite to the disassembly.
3. Disassemble the brake booster.
1. Dismount the connecting pins between the brake
pushing rod and the brake pedal arm.

2.Dismount the fixing pin and the fixing clip of the

pushing rod.

2. For the exhausting of the braking system is

operated, refer to Section 203-00.

CHANA·BENNI MINI
203-06-1 Anti-lock Braking System 203-06-1

Section 203-06 Anti-lock Braking System

Applicable Vehicle Models: BENNI MINI

Contents Page
1 Anti-lock braking system………………………………………………………………………………… 203-06-2

Specification

specification ....................................................................................................................... 203-06-2

Instruction and Operation

Anti-lock brake control ....................................................................................................... 203-06-3

General ................................................................................................................................. 203-06-3
Function................................................................................................................................ 203-06-3
Anti-lock brake control ....................................................................................................... 203-06-5
MK70 Anti-lock Braking System（ABS） .................................................................................... 203-06-5

Diagnosis and Test

Anti-lock Brake Control ....................................................................................................... 203-06-7

Inspection and Confirmation ....................................................................................................... 203-06-7

Disassembly and Installation

Hydraulic Control Module .......................................................................................................... 203-06-8

Anti-lock Braking System Module ............................................................................................... 203-06-8
Rear Rack of Speed Sensor of Wheel ...................................................................... (12 788 0) 203-06-10
Proportioning Valve……………………………………………………………………………….. 203-06-11

Specifications

Specifications ……………………………………………………………………………….. 203-06-11

Instruction and Operation
function……………………………………………………………………………….. 203-06-11
Malfunction insepection
malfunction inspect and malfunction diagnose 203-06-12

CHANA·BENNI MINI
203-06-2 Anti-lock Braking System 203-06-2

Specification

一、Anti-lock braking system

Lubricating oil, lubricating fat, sealing parts and binder
Name Model
Brake fluid HZY 4
Torque specifications
Description Nm
Fixing bolts of the hydraulic controlling module 8~10
M10:16±2
Braking oil pipe leading to the hydraulic control module
M12:18±2
Front：22~25
Fixing bolts of the wheel speed sensor
Rear ：8~10

CHANA·BENNI MINI
203-06-3 Anti-lock Braking System 203-06-3

Instruction and operation

DESCRIPTION AND OPERATION

Anti-lock Braking Control

General

.Function
seri Parts Description
al number As the closed loop controlling system in the braking
num system, ABS aims to prevent the failure of
ber non-serviceable steering and driving performance
when the wheel braking is locked.
1 - Hydraulic device of the
anti-lock Braking System ABS Control Module
2 - Data interface (DLC) The ABS control module continuously compares the
self-stored pressure reducing limit value with the
3 - Wheel speed sensor pressure reducing value detected by the speed sensor of
4 - Ignition switch each wheel, and thus the locking trend of each wheel
can be detected.
5 - Brake lamp switch
If the ABS control module detects that certain wheel is
6 - ABS warning lamp inside the tended to be locked, the relevant hydraulic valve inside
instrument panel the valve body shall be opened or closed.
Except the conventional loop of the diagonal The ABS control module also detects that the signal of
independently arranged braking system, the ABS also the wheel speed sensor is transmitted to the power
includes a hydraulic device, four wheel speed sensors controlling module
and an ABS warning lamp inside the instrument panel
The controlling software in ABS control module
controls the distribution of the braking force, and
continuously adjusts the braking force of each
front and rear wheel to accord with the changes of
the driving condition

CHANA·BENNI MINI
203-06-4 Anti-lock Braking System 203-06-4

Instruction and Operation

When the ignition switch is turned on, the ABS control

module shall turn on the warning lamp inside the
instrument panel. The warning lamp shall not
extinguish until the ABS finishes the system

Valve Assembly
The valve assembly contains four oil filling valves and
four oiling discharging valves. An oil filling valve and
an oiling discharging valve are arranged on one wheel.
The oil filling valve is opened and the oiling
discharging valve is closed in the no-power state.
The valve assembly also contains a low pressure fluid
storage can and a noise reducing chamber.
ABS Pump
The ABS pump provides sufficient pressure for the
master braking pump to ensure the independent
adjustment of each channel when ABS exerts effects.

ABS Adjusting Cycle

One ABS adjusting cycle includes three stages:
First stage-- Pressure maintaining stage
The oil filling valve is closed, and the pressure on the
wheel brake (sub-pump) remains the same, which
means that the pressure of the sub-pump shall not
change when the brake pedal is stepped down
again.
Second stage-- Pressure reducing stage
The oil discharging valve is opened temporarily, and
the pressure on wheel brake (sub-pump) is
gradually reduced according to controlling method
Third stage-- Pressure rising stage
• The oil filling valve is gradually opened, and the
braking pressure is increased according to the
controlling method so as to realize the most ideal
braking effect.

CHANA·BENNI MINI
203-06-5 Anti-lock Braking System 203-06-5

Instruction and Operation(continued)

Anti-lock Braking Control

MK70-M Anti-lock Braking System(ABS)

Seri Parts NO. Name

al
num
ber
1 - pump
2 - valve
3 - ABS control model

The MK70 ABS is specially designed for medium- and

small-scale vehicles. Compared with the MK20 ABS
system, the MK70 ABS greatly decreases the size of
electric controlling and hydraulic controlling
mechanisms (such as the hydraulic valve and the
electromagnetic valve) and the housing size.
Therefore, the weight of the whole ABS hydraulic
controlling mechanism is greatly reduced.
The hydraulic controlling mechanism comprises
pumps, valves (including 8 hydraulic valves) and
electric controlling units.
The ABS control module controls the lighting and
extinguishing of the ABS warning lamp inside
instrument panel through Wire K.
The MK70 ABS is a system called “4/4”, which means
that the wheel speeds of four wheels are separately
measured (using four wheel speed sensors).
The ABS separately controls the four wheels.

CHANA·BENNI MINI
203-06-6 Anti-lock Braking System 203-06-6

Instruction and Operation（continued）

Wheel Speed Sensor

Front Wheel Speed Sensor

Rear Wheel Speed Sensor

integrated with the driving axle. The gear rings of the

Seri Parts Name rear wheels are fixed on the core shafts of the rear
al number wheels.
num The received wheel speed signal is converted into the
ber digital signal through the integrated circuit inside the
1 - Sensor sensor and then sent to the ABS control module.

2 - Installatin location The sensor signal is transmitted to the ABS control

module through two wire cables.
The wheel speed sensor is a passive sensor The ABS control module calculates the vehicle speed
The sensor receives pulse signals from gear rings. The according to the signal of the wheel speed sensor and
gear rings of the front wheels are fixed on and

CHANA·BENNI MINI
206-09-7 Anti-lock control 206-09-7

DESCRIPTION AND OPERATION (Continued)

sends the signal to the power controlling module

(PCM).
The failure of the ABS control module can be
diagnosed through the data interface (DLC).
The hydraulic unit shall be refilled after repair.

G163291 en 09/2002 2003.50 嘉年华

203-06-8 Anti-lock Braking System 203-06-8

Diagnosis and Test

DIAGNOSIS AND TESTING

Anti-lock braking control

Refer to the relevant wiring diagram in Section

203-06A for relevant structure and connection.

Inspection and Confirmation

Confirm the problems described by customers.
2. Visually measure the obvious mechanical or electric
failure.

Visual Inspection Table

Mechanical Electric
• wheel speed sensor • Insurance
• Gear ring of the wheel
• Connector
speed sensor • Wiring harness
3. If the failure cause is obvious, repairing work shall
be performed as possible before the next operation.
4. If the failure cause is not obvious, confirm the failure
symptom and refer to WDS for failure cause.

CHANA·BENNI MINI
203-06-9 Anti-lock Braking System 203-06-9

Disassemble and Installation

拆卸与安装

Hydraulic Control Mechanism (HCU)

3. Notes: thoroughly discharging the braking fluid in
the fluid storage can is extremely necessary for the
operation at both sides.
Name Model
Discharge the braking fluid in the fluid storage
Brake fluid HZY4 can.
1. Select a proper clean plastic hose, one end is
connected with the exhaust valve and the other
Disassembly end put in a suitable container.
Caution: If the brake fluid is inadvertently 2. Release the exhaust valve.
spilled on the paint surface of the vehicle 3. Continuously step the brake pedal until all the
body, rinse it immediately with clean braking fluid is discharged.
water. 4. Tighten the exhaust valve.

1. Remove the negative electrode wire of the

battery. Refer to Section 407-00.
2. Caution: the oil filler cover of the fluid
can of the braking fluid can not be
contaminated.
Take down the oil filler cover.

4. Install the cover of the brake fluid storage can.

5. Remove the anti-lock (ABS) module connector

6. Warning: cover the braking oil pipe to

prevent the braking fluid from flowing out
or the dirt from entering.
Warning: block the hydraulic control
module (HCU) to prevent the braking
fluid from flowing out or the dirt from
entering.
Notes: please mark down the position of the braking
oil pipe for installation.
Disassemble the braking oil pipe (HCU) from the
hydraulic control module.

CHANA·BENNI MINI
206-09-10 Anti-lock Braking System 206-09-10

Disassemble and installation (continued)

Remove the fixing bolts at the lower part of the

hydraulic control module.

7. Warning: cover the braking oil pipe to

prevent the braking fluid from flowing out
or the dirt from entering.
Note: please mark down the position of the braking
oil pipe for installation.
Disassemble the braking oil pipe (HCU) Remove the fixing bolts of the hydraulic control
connected with the hydraulic control module from module and the ABS module.
the master braking pump.

12. Remove the hydraulic control module.

8. 8. Remove the braking oil pipe.

Installation
1. Install in sequence adverse to the disassemble
procedure.
2. Exhaust the system. Refer to Section 203-00.
203-06-11 Anti-lock Braking System 203-06-11

Disassemble and installation (continued)

Gear ring of the Rear Wheel Speed sensor (12 788 0)

Common Devices
Oil Hydraulic Press

Disassembly
1. Remove the brake drum. Refer to Section 203-02.
2. Remove and abandon the gear ring of the rear
wheel speed sensor

Installation
Warning: make sure that the gear ring will
not be knocked, damaged or stuck with
metal scraps in the operation process.
Warning: place a protective flat plate
without metal material to prevent damage.
Warning: make sure that the brake drum is
sufficiently supported and not allowed to be
stuck on the wheel bolt.
Warning: the force is applied slowly and
even until the brake drum is completely
seated in the installation process.
Warning: the force can not be more than
10KN.
Install new wheel speed gear rings with an
appropriate hydraulic machine.
2. Install the brake drum. Refer to Section 203-02.

CHANA·BENNI MINI
203-06-12 Anti-lock Braking Control 203-06-12

Malfunction Inspection

一、Proportioning Valve
Lubricating Oil, Lubricating Grease, Sealing Parts
3 、 Remove the installing bolts of the
and Binder proportioning valve.
Name Model
Brake fluid HZY 4
Torque Specifications
Description TorqueN.m Nm
Installing Bolts of the 20±2 9
Proportioning Valve
Connector of the Braking Oil 16±2 16±2
Pipe

Disassembly
Discharge the braking fluid in the fluid storage can.
1. Select a proper clean plastic hose, one end is
connected with the exhaust valve and the other
end is put in a suitable container.
2. Release the exhaust valve.
3. Continuously step the brake pedal until all the
braking fluid is discharged.
Installation
4. Tighten the exhaust valve.
Installation is adverse to disassembly.

2、Screw off the connector of the braking oil pipe.

206-09-13 Anti-lock Braking Control 206-09-13

Disassembly and installation(Continued)

CHANA·BENNI MINI
203-06-14 Anti-lock Braking Control 203-06-14

Malfunction Inspection

Malfunction Inspection and Malfunction Diagnose

A、Malfunction Inspection
The malfunction inspection methods just as the same with the air bag inspection section 405-00
b、Malfunction diagnose
Through the diagnotic instrument, the current malfunction record and the history malfunction record of the
ABS can be output directly. the belowing cable are the malfunction description and the malfunction
model:

NO. Malfunction Description Malfunction model

1 Controller fault
2 Controller, RAM fault
3 Controller outside RAM
fault
4 Controller， EEPROM fault
5 Controller inspect fault
6 Controller，
self-inspection fault
7 Controller， program fault
8 Controller， electric
fault
9 Controller， function
fault
10 Controller， timing
11 Controller ,inside-sensor
fault
12 the controller code does
not exit
13 Controller code not correct
14 Battery voltage KL30 fault
15 ABS abnormal work
16 data bus abnormal work
17 L,F wheel speed sensor
fault
18 R,F wheel speed sensor
fault
19 L,R wheel speed sensor
fault
20 R,R wheel speed sensor
fault
21 Brake lamp switch fault
22 Hydraulic pressure fault
23 tire pressure warning
Mechanical fault
defect
defect
defect
defect
defect
defect
defect
defect
defect
defect
No display
No display, mechanical fault,
unbelievable signal
above the max limited level, below the
mini limited level, unbelievable
signal
no display, unbelievable signal
defect
mechanical fault, unbelievable
signal, electric fault
mechanical fault, unbelievable
signal, electric fault
mechanical fault, unbelievable
signal, electric fault
mechanical fault, unbelievable
signal, electric fault
unbelievable signal
unbelievable signal, electric fault,
defect
No display
206-09-15 Anti-lock Braking Control 206-09-15

Disassembly and installation(Continued)

CHANA·BENNI MINI
204-00-1 Steering System-General 204-00-1

Section 204-00: Steering System-General

Applicable Vehicle Model: BENNI MINI

Contents Page
Specification

specification .......................................................................................................................... 204-00-2

Instruction and operation

steering system ...................................................................................................................... 204-00-3

steering column ...................................................................................................................... 204-00-3
Steering Mechanism .................................................................................................................... 204-00-3

Diagnosis and Test

Steering System .......................................................................................................................... 204-00-4

Check and Confirmation ............................................................................................................... 204-00-4
Failure Phenomenon Table............................................................................................................ 204-00-4
Element Test .............................................................................................................................. 204-00-5

CHANA·BENNI MINI
204-00-2 Steering System-General 204-00-2

Specification

General Parameters
Specifications
Minimum turning diameter 10.0
column electronic power assistant steering 200W、35A、12V(DC)

CHANA·BENNI MINI
204-00-3 Steering System-General 204-00-3

Instruction and operation

DESCRIPTION AND OPERATION

Steering System

Steering Column
The steering column is equipped with a multi-direction
steering wheel lock (or anti-theft lock) accepted the
strict test, and the steering wheel lock is equipped with
the lock core of the insurance degree. The steering
column and the upper end are fixed on the periphery of
an instrument panel.
The steering wheel is fixed on the steering column
assembly through a fixing nut, and the steering pinion
gear is connected with the steering column through a
flexibility universal joint. The flexibility universal joint
is fixed on the pinion gear through a locking bolt, and is
also fixed on the steering column through the fixing
bolts of the maintaining frame and axle positioning
device assembly. For the details, please refer to Section
204-04.
Steering Mechanism
The steering mechanism is the commonly-used gear
rack and gear type, for the details, please refer to
Section 204-02.

steering wheel

Machinary steering column

Steering mechanism

steering wheel

Electronic assistant
steering column

Steering mechanism CHANA·BENNI MINI

204-00-4 Steering System-General 204-00-4

Diagnose and test

DIAGNOSIS AND TESTING

Steering System

Working Principles Failure Phenomenon Table

The rotating motion of the steering wheel is transmitted Check and Confirmation
to the steering mechanism through the steering column. 1. Check the problems of the customer
The steering mechanism can convert the rotating
motion into the straight line motion though the gear 2. Inspect the obvious-damaged parts visually, as
rack in the steering mechanism. The straight line shown in the following table:
motion is transmitted to the steering knuckle of the visual inspection table
wheel through the steering tie rod and the external Electric Appliance
connector of the tie rod. Mechanical Aspect Aspect
The steering oil pressure is applied to the steering – tire and pressure – Controller harness
mechanism through the power steering pump. When
– wheel and tire – Motor
the steering wheel is rotated, the power steering oil
shall open valve at one end of the double-way piston
according to the rotating direction of the steering wheel, 3. If the reason of the problem is obvious, the problem
the piston is pushed to be moved by the oil pressure, to should be tried to be solved before the next operation is
supply the auxiliary power required in the steering. performed.
4. If the reason of the problem is not obvious, the
reason should be found out according the failure
phenomenon.

malfunction phenomenon Possible Reasons Measures

The steering is difficult or easy
The steering is not sensitive (when
the steering wheel is rotated, its
direction is not changed)
• speed signal lost or interference • check speed signal ,refer to
• engine signal lost or interference • check engine signal ,refer to
• power bad connection
• the suspension ball joint
inseparable
• steering mechanism damage
• steering column damage
• steering motor damage
• tie rod ball damage
• front suspension bush damage
• suspension ball damage
• steering mechanism anti-dust
cover damage
204-04
204-04
check power ,refer to204-04
• test the suspension ball, refer to
201-00
•Replace the steering mechanism
•Test the steering connect parts,
refer to ”steering connection
test “part
• Replace the power assistant
motor ,refer to the 204-01
• replace the tie rod if
necessary, refer to the 201-01
•inspect or replace, refer to
201-01
• check the suspension ball joint,
refer to the 201-00
•inspect or replace it if necessary,
refer to the 204-02

CHANA·BENNI MINI
204-00-5
Diagnose and test（continued）
malfunction phenomenon
•the steering wheel turning space • block plug loose
is too wide
•steering wheel is too heavy
•hard to back to the positive
•abnormal noise from the Rack and • fuel pipe and the chassis
pinion
•abnormal noise from the motor
Steering System-General 204-00-5
Possible Reasons Measures
•steering mechanism fixed bolt •check it and replace the fixed bolt
loose if necessary, refer to the204-02
•steering column fixed bolt loose • replace a new fixed bolt if
necessary
• the fixed bolt which connect the • check it and replace the fixed
steering column and the steering bolt if necessary。
mechanism gear loose
• Steering mechanism gap are too • Replace steering mechanism
wide
•tight again
• steering up bolt loose •tight again
• the ball bolt of the steering tie rod •tight again ,replace it if necessary
top defect or loose
• the power assistant does not •refer to 204-01
work ,the EPS lamp light steady
• the friction is too large of the tie •replace
rod ball joints
• block plug is two tight •tight again
• the inside tie rod or the ball joint •replace
defect
• steering and the vehicle bracket •tight
loose
• steering bearing and the valve •repair or replace
aging
• Curved rack •replace
• gear bearing damaged •replace
•layout the new fuel pip
interference
• steering installation bolt loose •tight
• tie rod ball joint loose •tight
•tie rod ball joint wear or aging •replace
•replace the motor The torque of the motor fixed
screw is 20-30N.M, in order to
keep the motor working in a better
position please make the screw in
the right situation before tight it,
then turn the steering wheel with
right hand and hold the motor
tosee if it’s swing. If not, tight the
screw, if it swing, adjust the motor’s
position then tight it. when you cannot
adjust it well ,repeat the operation above
CHANA·BENNI MINI
204-00-6 Steering System-General 204-00-6

Diagnose and test

Element Test

Steering Linkage Device

Check whether the dust shield of the steering mechanism is damaged, corroded or warped. The dust shield shall be
ensured to be safe and reliable, and if necessary, replace the dust shield or the nip.
1. Stop the vehicle on a dry and smooth road, and pull up the manual brake. Turn the direction to the central position.
2. Flame out the engine, and hold the steering wheel tightly with both hands. Shake the steering wheel vertically and
horizontally (don’t rotate the steering wheel), check the wear of the steering column bearing, and check whether
the steering coupling, the steering wheel or the steering column is loosened. If the loosening phenomenon is
found, the torque of the fixing bolts of the coupling and the steering wheel shall be checked. The steering
column can not be repaired, if necessary, replace the steering column. Please refer to Section 204-02.
3. If the steering linkage device is damaged, replace the steering linkage device if necessary. Please refer to Section
204-03. . The steering column can not be repaired, and if necessary, replace the steering column. Please refer to
Section 204-01. The clearance of the steering mechanism can not be adjusted, and if necessary, replace the
steering mechanism. Please refer to Section 204-02.

CHANA·BENNI MINI
204-01-1 Electric Power Assistant Steering Column 204-01-1

Chapter 204-01 Electric Power Assistant Steering Column

Applicable vehicle model: BENNI MINI

content page
specifications

specifications ...................................................................................................................... 204-01-4

Instruction and operation

Electric Power Assistant Steering Column ............................................... 204-01-3

disassembly and installation

Electric Power Assistant Steering Column .............................................................................. 204-01-4

controller instruction and inspection

Electric Power Assistant Steering Column .............................................................................. 204-01-5

BENNI·MINI
204-01-2 Electric Power Assistant Steering Column 204-01-2

Regulation

Torque Specifications
Description Nm lb-ft lb-in
Fixing nut of the steering wheel 25-40 -
Fixing bolts of the steering column 24±3 -
Clamping bolt between the steering universal joint and 20-30 -
the steering column
DESCRIPTION AND OPERATION

Basic technical parameters

description parameters
work temperature -40℃～＋85℃
work voltage 9～16V（DC）
DC permanent magnet controller motor basic
parameters

rated work time continue 3 min every single time

rated power 220W
rated work voltage 12V DC
rated motor speed （1050r±300 r ）/min
rated work current 35A±3A
rated output torque 1.8N·m±0.16N·m

BENNI·MINI
204-01-3 Electric Power Assistant Steering Column 204-01-3

Instruction and Operation

Electric Power Assistant Steering

Column

Steering motor

Up steering shaft
Connection joint

Down steering shaft

Controller

BENNI·MINI
204-04-4 Electric Power Assistant Steering Column 204-04-4

Disassembly and installation

REMOVAL AND INSTALLATI

1.Notice before the disassembly
1. Do not fall off during carrying.
(If the component falls off, the component shall be abandoned)
2. Check whether the injection mold is loosened.
3. Check whether the thread and spline of the upper axle are
damaged.
4. check the controller , the sensor harness and the power harness if
Damaged

2. Notice during the disassembly

1. Fix the bolts according to the sequence of the first,
second, third and fourth components.
2. Fix the bolts according to the sequence of the fifth
to sixth components.
3. Screw down the bolts according to the sequence
of the first, second, third and fourth components.
4. Screw down the bolts according to the sequence
of the fifth to sixth components. Make sure the
number sixth bolt was screwed down in the last to
release the assemble stress.

Attention
Above the number six bolt ,there is Another bolt,
do not make mistake when disassembly The number
six bolt can release the assemble stress False
installation or disassembly would cause Un-smoothly
when repair or rotate torque.

BENNI·MINI
204-01-5 Electric Power Assistant Steering Column
204-01-5

Controller instruction and inspection

1. Controller Maintenance Attention Issues

1. Remove the controller harness and make sure the

controller in a open status, please shut down the vehicle
Controller installation bolts
and the power when removing the connector
2. Disassemble and installation of the EPS controller
1） Take off the battery negative harness
2） Loose the installation bolts of EPS controller
3） Disassemble the connector
4） Disassemble the EPS controller

Installation:
The installation process is opposite to the disassembly process

BENNI·MINI
204-01-6 Electric Power Assistant Steering Column
204-01-6

Controller instruction and inspection

1、 Circuit Figure

*1 right rudder vehicle

*2 left rudder vehicle

1 EPS controller
2 diagnosis connector
3 torque sensor
4 shield harness
5 noise reducer
6 speed odometer
7 battery
8 ignition switch
9 motor assy
10 malfunction clear end
Socket C Socket B Socket A

BENNI·MINI
204-01-7 Electric Power Assistant Steering Column
204-01-7

Controller instruction and inspection

2、 Terminal Table（terminal position are in the circuit figure,12VDC is battery

voltage ）
Terminal Signal
Connect parts Signal status
No. input/output
Malfunction clear Effective to connect battery positive electrode
B1 input
terminal
B2 Diagnosis terminal input Effective to connect battery negative electrode
Impulse signal voltage is12V，high level
B3 EPS indicate lamps input
effective
Square-wave signal or impulse signal
B4 Engine signal input
maximum voltage is 12V
B5 Speed signal input Square-wave signal maximum voltage is 12V
B6 Ignition signal input 电压为12VDC的电平信号，高电平有效
B7 power＋ input battery positive electrode with 12VDC
B8 power－ input battery negative electrode with 12VDC
A9 empty
A10 empty
Impulse signal ,maximum12V，invariable
A11 motor output
width impulse
Impulse signal ,maximum12V，invariable
A12 motor output
width impulse
C1 empty
C2 Torque sensor power Output battery positive electrode with 5VDC
Torque sensor ground
C3 output battery negative electrode with 5vDC
line
Torque sensor vice Voltage between 0VDC to 5VDC simulation
C4 input
road voltage signal
Torque sensor main Voltage between 0VDC to 5VDC simulation
C5 input
road voltage signal

BENNI·MINI
204-01-8 Electric Power Assistant Steering Column
204-01-8

Controller instruction and inspection

3、 Malfunction Diagnose
Diagnose the malfunction code
Example: only when DTC21

Code 21 Code 21 Code 21

multiindicator

Tim
Code
contents diagnose
EPS lamp wave figure no other code
normal then show this
code

Torque
sensor

VSS speed
signal

Engine speed sensor Accordin

g to DTC
flow
figure
motor

EPS controller

3.1 Malfunction Code Diagnose

3.1.1 （DTC）indicate
1） Connect the diagnose terminal B2 to the battery negative terminal by repair harness
2） Pull the hand brake

BENNI·MINI
 204-01-9 Electric Power Assistant Steering Column
204-01-9

Controller instruction and inspection

3） start the engine （engine don’t start，it will indicate DTC22）。

4） EPS indicator start to show the malfunction code one by one from the minimum code to the
maximum code，Each code shows three times

3.1.2 Clear the diagnose malfunction code

Because DTC are stored in the EPS controller backup memory, so after repair work, connect
terminal B2 to the battery negative terminal five seconds above by a repair wire, cut down it
when indicate DTC12

3.1.3 Attentions in the diagnose malfunction

1） It’s forbidden to connect the battery positive terminal to the terminal B1 and B2
2）when open ignition switch but don’t start engine，indicate DTC22（no engine speed signal），
but when the engine started, if it’s not indicate DTC22， that means normal.
3） Write down the indicate malfunction code

3.1.4 Diagnose flow chart

steps operation yes No
1）confirm the battery voltage above 11V or higher 2）
Go to nest page A-1。
when turn on the ignition switch, attention the EPS lamp Go to
1 （EPS indicator line
3）when turn on the ignition switch, if the EPS lamp lights step two
inspection）
for 2 seconds
1）connect the terminal of the diagnose with harness2） Go to
Go to nest page A-2 （EPS
2 pull the hand brake (MT to center A/T to P） 3）start step
indicator line inspection）
engine 4）if the EPS lamp lights? three
repair and check
3 If the EPS lamp indicate DTC12 according to the flow
chart
Alarm：
After finished inspection and repair, please recheck the system as below
1)After start engine and it works smoothly, connect the terminal B1 to the battery negative
terminal for above 5 seconds, cut off it after indicate DTC12 in order to clear the diagnose code
that stored in the EPS controller .
2） Test according to provision
3） Block the wheel put M/T to center (A/T to P)
4） Connect diagnose terminal B2 to battery negative terminal by repair wire
5） Start engine ,observe the EPS lamp
6） Check the diagnose malfunction code is DTC12

Attention:
　 when ignition switch on but engine was not started，indicate DTC22 ,but when start engine,
indicate DTC12 it means normal.

BENNI·MINI
204-01-10 Electric Power Assistant Steering Column
204-01-10

Controller instruction and inspection

　 when there are two or more malfunctions，DTC indicate from the minimum code to the
maximum code

attachment：A-1 EPS indicator line inspection

（when ignition switch on，EPS indicator does not light）

1 battery
2 main fuse
3 ignition
switch
4 circuit
fuse
5 EPS
controller Plug C Plug A
6 EPS lamp Plug B
7 main fuse

steps operation yes no

If main fuse and line fuse are in Main fuse and line
1 Go to step two
good condition fuse were break
1） turn on the ignition switch
2 Check the voltage between B/W line disconnect or
2 Go to step three
terminal B6 and controller short circuit
3） is it battery voltage
1 ） Check the voltage between
B/R line disconnect or
3 terminal B6 and controller Go to step four
short circuit
2）is it battery voltage
1）turn off ignition switch，cut off
controller B from p/s
2） Cut off B3 and connect it to Lamp burned or V/G
4 Go to step five
ground line disconnect
3 ） turn on the ignition switch
again，EPS lamp lights or not ?
●B line disconnect
● terminal A1、B2、A5 B4
bad connect
Does the connect between terminal ●B line bad connect
5 Bad connect to ground
and controller in good condition? ● EPS controller bad
connect, if ok, replace
a new controller and
check again

BENNI·MINI
204-01-11 Electric Power Assistant Steering Column
204-01-11

Controller instruction and inspection

Applicable : step four

1 Controller plug A B
2 Repair line
3 body bottom panel
Plug B Plug A

BENNI·MINI
204-01-12 Electric Power Assistant Steering Column
204-01-12

Controller instruction and inspection

attachment：A-2 EPS indicator line inspection

EPS indicator does not light or when connect the diagnose switch terminal and ground
terminal, it still lights

1 EPS controller
2 diagnose plug

steps operation yes no

If the Plug B（terminal B2）connect
1 Go to step two Bad connection
to EPS controller all
1） When the plug and EPS controller
are connected, connect the terminal ● repair line disconnect Replace new EPS
2 B2 to ground ●B1/W line disconnect or B bad controller and
2）turn on the ignition switch ,is connect to the ground check again
EPS indicator lighting?

Applicable :step two

1 EPS controller plug A,B

2 Repair line
3 ground body bottom panel
Plug B Plug A

BENNI·MINI
204-01-13 Electric Power Assistant Steering Column
204-01-13

Controller instruction and inspection

3.2 Malfunction mode and diagnose

3.2.1 DTC11 Torque sensor main line（main line open circuit or short circuit）

1. EPS controller
2. diagnose plug

steps operation yes no

1）Disassemble the EPS controller cover
●C5 line disconnect
2） turn on ignition switch，put the
● C5 bad connection. if
1 steering wheel in return place, check Go to step two
it’s ok ,replace new
the voltage of torque sensor terminal
controller and check it
C5,if it’s about 2.5V?
1 ） turn off ignition switch ， disconnect
●replace new EPS
torque sensor plug
2 controller and Torque sensor defected
2 ） check torque sensor resistance
check it
between C5 and C3,is if beyond 400Ω
适用于步骤2

Plug C

1 Torque sensor plug

3.2.2DTC11torque sensor Torque sensor output signal has big difference between main
line and sub line

BENNI·MINI
204-01-14 Electric Power Assistant Steering Column
204-01-14

Controller instruction and inspection

1 EPS controller
2 diagnose plug

step operation yes no

1 ） shut down ignition switch ，
disassemble EPS controller cap
2）power on but don’t start the engine
3） follow below status, check torque
sensor side plug voltage between each
terminal

about2.5V（steering wheel
i
Between C3 s back to the right place）
and C4 Terminal C3 bad connection
below1.5V（steering wheel Torque
Terminal C5orC4 bad connection.
1 turn to right end） sensor
if it’s ok above ,replace better
beyond3.5V （ steering controller and check again fault
wheel turn to left end）

about2.5V（steering wheel
Between back to the right place）
C5 and C3
beyound3.5V （ steering
wheel turn to right end）
below1.5V（steering wheel
turn to left end）

Applicable :step one

BENNI·MINI
204-01-15 Electric Power Assistant Steering Column
204-01-15

Controller instruction and inspection

1 Torque sensor plug

3.2.3 DTC14 torque sensor （torque sensor power voltage too high or very low）

3 EPS controller
4 diagnose plug

step operation yes No

1）shut down ignition switch，disassemble EPS
controller cap
2）power on but don’t start the engine Torque sensor
1 Go to step two
fault
3）check the voltage between torque sensor plug
C2 and C3,is it about 5V?
1） shut down ignition switch，cut off torque
Replace better
sensor plug Torque sensor
2 controller and check
2）check the resistance between C2 and C3 ,If fault
again
it’s below 100Ω

Applicable: step two

BENNI·MINI
204-01-16 Electric Power Assistant Steering Column
204-01-16

Controller instruction and inspection

Plug C

1 Disconnect torque
sensor plug

3.2.4 DTC15 torque sensor sub line （sub line open circuit or short circuit）

1 EPS controller
2 diagnose plug
1

step operation yes no

1） shut down ignition switch，disassemble EPS
controller cap
Torque
2） power on but don’t start the engine
1 Go to step two sensor
3） check the voltage between torque sensor plug C4
fault
and C3,is it 2.5V?（steering wheel at the right
position）
1） steering wheel turn to the left end，check the
voltage between torque sensor plug C4 and C3,is it
Replace better
beyond 2.5V?
2 sensor and check
2）steering wheel turn to the right end，check the again
voltage between torque sensor plug C4 and C3,is it
below 2.5V?

Applicable : step two

BENNI·MINI
204-01-17 Electric Power Assistant Steering Column
204-01-17

Controller instruction and inspection

Plug C

1 Disconnect torque
sensor plug

3.2.5 DTC21 VSS line

Engine speed is 2500r/min or higher ,after started the speed goes to 4000r/min or higher in a short
time and there is no vehicle speed signal input for 60 second continuously

3.2.6 DTC23 VSS line

Engine speed is 2500r/min or higher ,after started the speed goes to 4000r/min or higher in a short
time and there is no vehicle speed signal input for 60 second continuously

3.2.7 DTC24 VSS line

there is no speed signal input for 5 seconds continuously after found the engine speed reduce
beyond the standard

BENNI·MINI
204-01-18 Electric Power Assistant Steering Column
204-01-18

Controller instruction and inspection

Plug C Plug B Plug A

1 EPS controller
2 ignition switch
3 speed odometer
4 speed sensor

operation yes no

step
1 Is it DTC23 go to step three go to step two
1） refer to clear DTC
2 ） start engine choose
first gear（L），move car
about one minute in
2 go to step three Open circuit fault
4000r/min
3）refer to “indicate of DTC”
check DTC when idling
4） is it DTC21 or 24
Whether the odometer Odometer, VSS or its
3 go to step two
indicate speed harness bad
1 ） when ignition off ，
disassemble EPS controller
and connect it to
controller plug
2 ） add a voltage gauge
between terminal B5 and
body ground line
4 Open circuit fault go to step three
3 ） lift the vehicle and
lock the front right wheel
4）when ignition on，rotate
the front left
wheel ,check the voltage
if it’s between 0-1Vand
4-6V
The voltage is Voltage is 4-6V,V line
0-1V ,B5 bad short circuit and
5 If the voltage is 0-1V connection or the V combination odometer bad
line short connection. if connection
circuit .if and the line are normal

BENNI·MINI
204-01-19 Electric Power Assistant Steering Column
204-01-19

Controller instruction and inspection

connection and line replace a better odometer

are normal replace a and check again
new speed meter and
check again

Applicable : step four

Plug C Plug B Plug A

1.voltage gauge

3.2.8 DTC22 engine speed signal （no signal input）

1，EPS controller
2，Silencer
3，Odometer
4，Self-ignition switch
Plug B Plug A

steps operation yes no

whether the speed meter indicate the Go to step two ● silencer fault。
engine speed ● silencer plug bad
1
connection。
● open circuit
1）when ignition off，disassemble EPS B4 bad connection, if it’s open circuit
controller and connect it to controller plug normal replace a better
2 2） when ignition on, check the voltage controller and check again，
between terminal B4 and ground line
3） is it 10-14V

BENNI·MINI
204-01-20 Electric Power Assistant Steering Column
204-01-20

Controller instruction and inspection

Applicable: step two

Plug C Plug B Plug A

1. EPS controller
2. voltage gauge

3.2.8 DTC41 motor（voltage too high or very low）

3.2.9 DTC43 motor （current too high）

3.2.10 DTC42 motor （there are big differences between inspection current and actual
current）

3.2.11 DTC44 motor（EPS controller make an rotate order but the motor does not start）

3.2.12 DTC45 motor （the actual current lower than the inspection current）

BENNI·MINI
204-01-21 Electric Power Assistant Steering Column
204-01-21

Controller instruction and inspection

Plug C Plug B Plug A

1. EPS controller
*1 right rudder
2. motor
*2 left rudder

steps operation yes no

1 Is there showing DTC44 Motor fault Go to step two

1） Disassemble steering column cap

2） when ignition off, cut off motor and
clutch plug
2 Go to step three Motor fault
3） check the continuity between A11 and
A12
4） is it continuity

●“R”or“B1”line open circuit。

1） check the resistance between terminal ●“R”or“B1”line short circuit
3 A11 and body ground line ● plug bad connection. if it’s normal Motor fault
2） Is it infinity replace a better P/S controller and check
again

Applicable: step two Applicable: step three

Plug C Plug C
Plug B Plug A Plug B Plug A

5. motor and clutch plug 3. motor and clutch

6. voltage gauge plug
BENNI·MINI
4. voltage gauge
204-01-22 Electric Power Assistant Steering Column
204-01-22

Controller instruction and inspection

3.2.13 DTC54 EPS controller power line （low battery voltage）

1. battery
2. main fuse
column
3. ignition
switch
Plug C Plug B
4. circuit fuse Plug A

5. EPS
controller

steps operation yes no

1 ） when ignition switch off,
disassemble EPS controller and
connect EPS controller plug ●B7 terminal bad connection .if it’s
Battery
1 2） when ignition on, check the EPS normal replace a better EPS
fault
controller voltage between controller and check again .
terminal B7 and the ground
3）is it 10-15V？

3.2.14 DTC51 EPS controller fault

Replace a new EPS controller ,check again.

3.2.15 DTC52 EPS controller fault

Replace a new EPS controller ,check again.

3.2.16 DTC55 EPS controller fault

Replace a new EPS controller , check again.

BENNI·MINI
204-01-23 Electric Power Assistant Steering Column
204-01-23

Controller instruction and inspection

4 System inspection
4.1 Check the EPS controller and its line
Through measure the EPS controller plug voltage and resistance we can check the EPS controller and its line

4.2 Check the voltage

1） When the ignition switch off, disassemble the EPS controller
2） Connect the EPS controller plug to the EPS controller
3） when the ignition switch on, check the EPS controller plug voltage between every terminal
4.3 Check the line
When the ignition switch off, disassemble the EPS controller check the line

Attention :because of the battery voltage, when the ignition switch on make sure the battery
voltage is 10V or higher

BENNI·MINI
204-01-24 Electric Power Assistant Steering Column
204-01-24

Controller instruction and inspection

Plug C Plug B Plug A

Terminal line Normal voltage Phenomenon

B1 malfunction clear —— ——
terminal
B2 diagnose switch end 5V Ignition switch ON
B3 “EPS” lamp 0-2V engine on idle, the EPS indicator lights

10-14V engine on idle, the EPS indicator does not

lights
B4 Engine speed —— ——
signal
B5 VSS indicator repeat When the ignition ON ， the front left wheel
deviate 0-1Vand rotate fast in the lock status.
4-6V
B6 Ignition switch 10-14V Engine idle
signal
B7 EPS controller 10-14V Engine idle
power
B8 connect to ground —— ——
A9 empty
A10 empty
A11 motor output 1V Engine idle ，the steering wheel is Fixed in
the right position
A12 motor output 1V Engine idle ，the steering wheel is Fixed in
the right position
C1 empty
C2 Torque sensor About 5V When the ignition switch on, check voltage
power between terminal C2 and C3
C3 Torque sensor 0V ——
（GND）
C4 Torque sensor line About 2.5V Engine idle ，the steering wheel is Fixed in
（Sub） the right position ,check voltage between
terminal C4 and C3
C5 Torque sensor line About 2.5V Engine idle ，the steering wheel is Fixed in
（Main） the right position ,check voltage between
terminal C5 and C3

BENNI·MINI
204-01-25 Electric Power Assistant Steering Column
204-01-25

Controller instruction and inspection

5 Self-diagnosis
When the simulated malfunction occurred ,the EPS controller circuit board should stop working, that is
when the motor、electromagnetic clutch、relay are in the open circuit ,the EPS lamps are lights all the
time. turn on the self-diagnose switch ,the DTC code are show up.

1 When the engine signal frequency below 13HZ or above 500 HZ ,indicate code :DTC25

2） When the engine signal is zero，indicate code :DTC22

3） when the clutch on open circuit or short circuit status ，indicate code:DTC51(only to DFL-01)

4） when the battery voltage below 5V，indicate code:DTC54

5） when there is no enhance voltage，indicate code:DTC55

6） when the sensor voltage is too high or very low, indicate code: DTC14

7） when the sensor main line open circuit or shot circuit ,indicate code:DTC11

8）when the sensor sub line open circuit or short circuit, indicate code:DTC15

9） when the sensor output differences between vice line and main line are too large，indicate code:DTC13

10） when the DC motor’s voltage are too high or very low，indicate code:DTC41

11） when the current of the DC motor are too high，indicate code:DTC42

12）when the current of the DC motor are very low，indicate code:DTC45

13）when the speed signal open circuit in the process, indicate code:DTC24

6、EPS common malfunction analysis and solution

6.1 Abnormal noise
Reason
Abnormal noise when steering

Solution
Replace motor ,adjust the motor bolt fixing torque as20～30N.m

Attention
To keep the motor in a good working status ,before tight the bolts, please put the bolts in the right position
then steering the wheel with your right hand, and hold the motor with your left hand to feel whether the motor is
vibrating. If it not vibrate then tight the bolt, if it vibrates then adjust the motor position till it stable, after that
tight the bolt. If you cannot adjust the position then replace the motor and repeat the operation above

6.2 Deviation reason:

Sensor potential displacement

Solution:
Connect one of the Multimeter end to the sensor plug(white harness),the other end to the ground. Check

BENNI·MINI
204-01-26 Electric Power Assistant Steering Column
204-01-26

Controller instruction and inspection

whether the sensor’s main voltage are 2.5±+0.05v then adjust the sensor voltage to 2.5±0.05V.Before adjust the
sensor potential, you can disassemble the sensor and rotate the slide pad to a new angle

Attention:
1） The steering wheel should not bearing force when adjusting potential
2） When tight the sensor，fixing torque are 6～7N.m
3） Loose the slot after tight the sensor

6.3 Failure
Connect the diagnose switch to the ground(B2 terminal) ,then the “EPS” indicator flash and the P/S control box
output the code
Malfunction code reason solution
41；42；43；44；45；51 motor failure replace motor
11；13；14；15 sensor failure replace column assy
52；54；55 controller failure replace controller
22 No engine speed signal input Check speed signal harness in order to connect well
21；23；24 No vehicle speed signal Check vehicle speed signal harness in order to connect
input well

6.4 Stagnant
Reason:
Motor power decreased temporarily due to abnormal work and heat

Solution:
Replace motor

6.5 Power assistant unstable

Reason:
Engine signal does not match the controller

Method
Replace ECU controller

BENNI·MINI
204-02-1 Steering Mechanism 204-02-1

Section 204-02 Steering Mechanism

Applicable Vehicle Model:CHANA. BENNI

Contents Page
Specifications

Specifications ....................................................................................................................................... 204-02-2

Instruction and Operation

Steering Mechanism ............................................................................................................................. 204-02-3

Diagnosis and Test

Steering Mechanism ............................................................................................................................. 204-02-4

Disassembly and Installation

Ball Head of the Tie Rod ................................................................................................ ………………. 204-02-5

Dust Shield of the Steering Mechanism ........................................................................... ....................... 204-02-7

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204-02-2 Steering Mechanism 204-02-2

Specification

Torque Specifications
Description Nm lb-ft lb-in
Fixing nuts of the ball head of the steering tie rod 42.5±12.5 -
Locking nuts of the ball head of the tie rod 42.5±12.5 -
Wheel nuts 85±10 -

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204-02-3 Steering Mechanism 204-02-3

Instruction and Operation

Steering Mechanism

– Steering tie rod

S/N Parts Name
– Ball head of the tie rod
Number
– Steering knuckle
1 - Steering mechanism
The ball head of the steering tie rod is firmly connected
2 - Dust shield of the steering with the tie rod by using the locking nuts.
mechanism
The connecting position of the steering tie rod and the
3 - Steering tie rod steering mechanism is protected by the rubber dust
shield to prevent the dust from entering the inner ball
4 - Locking nuts of the ball head of
head of the tie rod.
the tie rod
When vehicles run on uneven road, considering motion
5 - Ball head of the tie rod
of the suspension, the steering tie rod is connected
6 - Fixing nuts of the ball head of between inner and outer ball joints.
the tie rod
7 - Cotter pin

The steering tie rod is connected with the steering

mechanism, and the motion of the steering mechanism
is transferred to the wheels through the following parts:

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204-02-4 Steering Mechanism 204-02-4

Diagnosis and Test

DIAGNOSIS AND TESTING

Steering Mechanism

See Section 204-00 for relevant information.

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204-02-5 Steering Mechanism 204-02-5

Diagnosis and Test

Disassembling and Installation
REMOVAL AND INSTALLATION

Ball Head of the Tie Rod

5. Warnings: When the ball head of the
steering knuckle is separated from the ball
Special Tool head of the tie rod, protect oil seal of the
ball universal joint.
Separate the ball head of the tie rod from the
Ball joint separator steering knuckle.
1. Loosen the ball head of the tie rod.

2. Screw off the fixing nuts.

Disassembly
1. Loosen the front wheel nuts.
2. Support and hoist vehicles. See Section 100-02
for relevant information.
3. Disassemble the front wheels
4. Loosen the nuts of the ball head of the tie rod.
1. Loosen the locking nuts.
2. Disassemble the cotter pin.
3. Loosen the fixing nuts.

6. Notes: Record the rotation number shall be made

when the ball head of the tie rod is disassembled.
Disassemble the ball head of the tie rod and
locking nuts.

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204-02-6 Steering Mechanism 204-02-6

Disassembling and Installation (Continued)

Installation
Notes: Make sure that the tightening circle number
of the thread of ball head of the tie rod is the same
with the record of the rotation number during
disassembling. If the rotation number is unknown,
visual thread length at both sides of the tie rod
should be the same when the tie rod is installed.

1. Install according to the opposite sequence to the

disassembly procedures.

2. Check the toe-in and adjust as required. See

Section 201-00 for relevant information.

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204-02-7 Steering Mechanism 204-02-7

Disassembling and Installation

Dust Shield of Steering Mechanism (13 134 0)

Disassembly
1. Disassemble the ball head of the tie rod. See the
relevant disassembling sequence in this section.
2. Disassemble the fixing clip of the dust shield of
the steering mechanism.

3. Warnings: Make sure that the tie rod is

clean before disassembling the dust shield
of the steering mechanism.
Disassemble the dust shield of the steering
mechanism.
1. Take down the ventilation pipe.
2. Take down the dust shield on the tie rod.

Installation
1. Install according to the opposite sequence to
disassembly procedures.

U-shine
204-03-1 Steering Column 204-03-1

Chapter 204-03 Steering Column

Applicable Vehicle Model: BENNI MINI

Contents Page
Specifications

Specifications..................................................................................................................................................... 204-03-2

Instruction and Operation

Steering Column ................................................................................................................................... 204-03-3

Disassembly and Installation

Steering Column ….
204-03-4

CHANA.BENNI -MINI
204-03-2 Steering Column 204-03-2

SPECIFICATION

Torque Specifications
Description Nm lb-ft lb-in
Fixing nut of the steering wheel 25-40 -
Fixing bolts of the steering column 24±3 -
Clamping bolt between the steering universal joint and 20-30 -
the steering column
DESCRIPTION AND OPERATION

Steering Column

CHANA.BENNI -MINI
204-03-3 Steering Column 204-03-3

Description and Operation

Up steering shaft

Connection joint

Down steering shaft

CHANA.BENNI -MINI
204-03-4 Steering Column 204-03-4

Description and Operation

REMOVAL AND INSTALLATION

1. Notice before the disassembly

1. Do not fall off during carrying. (If the component
falls off, the component shall be abandoned)
2. Check whether the injection mold is loosened.
3. Check whether the thread and spline of the upper
axle are damaged.

2. Notice during the disassembly

1. Fix the bolts according to the sequence of the first,
second, third and fourth components.
2. Fix the bolts according to the sequence of the fifth to
sixth components.
3. Screw down the bolts according to the sequence of
the first, second, third and fourth components.
4. Screw down the bolts according to the sequence of
the fifth to sixth components. Make sure the number
sixth bolt was screwed down in the last to release the
assemble stress.

CHANA.BENNI -MINI
205-01-1 Manual Transmission Gear/External Controlling System of the Transmission Driving Axle205-01-1

Section 205-01 Manual Transmission Gear/External

Controlling System of Transmission Driving Axle
Applicable Vehicle Model: CHANA.BENNI-MINI

Contents Page
Instruction and Operation

External Controlling System ................................................................................................................. 205-01-2

Diagnosis and Test

External Controlling Mechanism ........................................................................................................... 205-01-3

Fixed Point Inspection .......................................................................................................................... 205-01-3

Disassemble and Installation

Gear-shifting Mechanism .............................................................................................. (16 534 0) 205-01-4

CHANA.BENNI-MINI
205-01-2 Manual Transmission Gear/External Controlling System of the Transmission Driving Axle205-01-2

Instruction and Operation

DESCRIPTION AND OPERATION

External Controlling System

（1.0MT）

General – Gear-shifting mechanism

Serial Parts Name

Number Numbe
r
1 Gear-selecting Rod
2 Base Seat
3 Installation Nuts

In order to separate the external gear-shifting

mechanism from the vehicle body to reduce vibration,
four rubber shock adsorbing cushions are installed at
the position of the installation nuts on the base seat.
The gear-shifting mechanism housing is connected
with the transmission gear through gear-shifting and
position-changing dragline.

CHANA.BENNI-MINI
205-01-3 Manual Transmission Gear/External Controlling System of the Transmission Driving Axle205-01-3

Diagnosis and Test

The External Controlling Mechanism

Because the vehicle failure repair and the failure Mechanical Components
diagnosis are carried out simultaneously, it is advised
– Obviously damaged or abraded components
to adopt the following steps.
– Loosened or lost nuts or bolts
1. Confirm the failure related by the customer and
reset the failure when necessary. 3. If the failure can be easily discovered, after repair,
check whether the system works normally?
2. If the failure related by the customer can not be
discovered, the road test or visual inspection 4. If the failure can not be easily discovered, accurate
according to the following table shall be carried inspection shall be carried out according to the
out: following Failure Phenomenon Table.
Failure Phenomenon
Phenomenon Possible Reasons Procedures
• The gear-shifting mechanism • The connection of the external gear • Adjustment according to Section
motion is difficult. shifting mechanism distorts. 301-03.
• The gear-shifting rod is damaged. • Turn to fixed point inspection A
• The gear-shifting and • Turn to fixed point inspection A
position-changing dragline is
damaged.
Fixed Point Inspection
Fixed Point Inspection A: The gear-shifting mechanism motion is difficult.

Inspection Items Concrete Procedures/Results/Measures

A1: Check the gear-shifting rod.
1 Separate the gear-selecting rod from the
transmission gear.
• Is the external gear shifting mechanism motion
difficult?
　 Yes
Dismantle the gear-shifting rod and research
failure components, referring to section 205-01.
　 No
Turn to A2
A2: Check the Gear-shifting and Position-changing Dragline.
1 Dismantle the gear-shifting and position-changing
dragline from the transmission gear.
• Is the gear-shifting and position-changing dragline
damaged?
　 Yes
Search the failure and replace.
　 No
For the transmission gear failure, see Section
301-01.

CHANA.BENNI-MINI
205-01-4 Manual Transmission Gear/External Controlling System of the Transmission Driving Axle205-01-4

Disassembly and installation

Gear-Shifting Mechanism (16 534 0)

CHANA.BENNI-MINI
205-01-5 Manual Transmission Gear/External Controlling System of the Transmission Driving Axle205-01-5

Disassembly and installation

Disassembly
All automobiles

1. Dismantle the gear-shifting dust shield from the

gear-shifting controlling box.

2. Dismantle the gear-shifting controlling box.

3. Dismantle the gear-shifting dragline.

4. Dismantle the gear-shifting mechanism seat.

Installation
All automobiles
1. Install the gear-shifting mechanism seat.
2. Tighten the engine/transmission bracket.
3. Install the gear-shifting dragline
4. Adjust the draglines

CHANA.BENNI-MINI
301-01-1 Engine summarize 301-01-1
Chapter 301-01 Engine summarization
Applicable vehicle model: chana·benni mini
Content
Summarization 301-01-2
Engine mechanical maintenance 301-01-1
Cylinder pressure inspection 301-01-1
Oil pressure inspection 301-01-1
Valve clearance inspection and modulation 301-01-1
Cylinder head cover 301-01-1
Oil pan and oil filter 301-01-1
Timing mechanical 301-01-1
Oil pump 301-01-1
Installation 301-01-1
Camshaft 301-01-1
Valve and cylinder cover 301-01-1
Cylinder head gasket installation 301-01-1
Piston、piston ring、connecting rod、cylinder、
crank pin and connecting rod bearing shell 301-01-1
Intake system 301-01-1
Filter core of air filter 301-01-1
Throttle valve body and intake manifold 301-01-1
Exhaust system 301-01-1
Assembly 301-01-1
Installation or connection
Overhaul 301-01-1
Engine assembly 301-01-1
Main bearing shell、crankshaft and cylinder body 301-01-1
Assembly and inspection of crankshaft、main bearing shell 301-01-1
Assembly and inspection of the bearing shell 301-01-1
Rear oil seal 301-01-1
Screwing torque 301-01-1
Special tool 301-01-1
Required maintenance material 301-01-1

Chana·Benni MINI
301-01-2 Engine summarize 301-01-2

Summarization
Engine JL466Q5-J is one of chana series c engines, which are high power、high quality and low petrol
consuming. JL466Q5-J is a transverse engine for benni mini, which is developed on the base of
JL466Q1 and assembled new intake system and suspension system. All good qualities of C10 are taken by
JL466Q5-J such as DOHC、16 valves、gapless bevel wheel、all balance crankshaft and wave water
jacket. The output per liter can be 51.2kw. Smoothly passed repeated strict reliability test
and 30,000 km high-rigidity road test in every round of five as well as test under severe
conditions such as heat、coldness and plateau climate.It has 36 technical patents which make
it be on the top of the same series engines in china.
The advantage of 16 valves and DOHC:
1. reduce the friction of engine parts、control the valves exactly and reduce the loss
of power;
2. sustain the high speed moving of the valves better and reduce the loss of oil;
3. improve the power and reduce the petrol consuming;
4. two intake valves and two exhaust valves in every cylinder make the engine product
larger power and reduce petrol consuming through increasing the amount if intake
air and burning the petrol better;
5. putting the spark plug in the center of four valves improves the sparking efficiency.
At the same time, high torque during low rotating speed is as same as the top grade saloon
cars. The torque can get to 80% of the largest value during 2000 to 3500 which the rotating
speed is in most time. The external characteristic curve is as below:

Output torque[N·M]

Output power [KW]

Engine speed [rpm]

Chana·Benni MINI
301-01-3 Engine summarize 301-01-3

Engine mechanical maintenance

Cylinder pressure inspection
Inspect the compression pressure of 4 cylinders as
follows:
1) Preheat the engine.
2) Close the engine after the engine is preheated.

Notes:
After the engine is preheated, the gear-shifting rod of
the transmission gear is placed in the position of the
neutral gear, fixes the parking brake and holds the
driving wheel.

3) Disconnect the wiring harness connector of the fuel

injector.
4) Take off the ignition coil assembly and all the spark
plugs.
5) Fill the spark plug hole into the special tool (the
compression pressure gauge).
6) Step on the starting load of the clutch and press the
accelerator pedal of the throttle to the maximum
extent so as to completely open the valve.
7) Use the fully charged battery to start the engine,
and read the maximum pressure from the compression
pressure gauge.
Compression
pressure
Notes： 1250kPa
Limit
In order to read the compression pressure,
when use the fully charged battery to start the Maximum
pressure
engine, keep the speed being at least 300rpm and 100kPa
difference
the sparking time being no more than 10s. between two
cylinders
8）The compression pressure gauge is in the form
above.
9) Operate either cylinder according to Procured 5) to
Procedure 7) to obtain 4 readings.
10) After inspection, install the spark plug and the
ignition coil assembly, and well connect the wiring
harness connector of the fuel injector.

Chana·Benni MINI
301-01-4 Engine summarize 301-01-4

Oil pressure inspection

Notes:
The following items shall be inspected before the
inspection of the oil pressure:
1. The oil lever of the oil pan.
If the oil level is low, fill oil until the oil level mark
reaches to the full oil level on the dipstick.
2. Oil quality
If the oil color or quality is changed, replace the oil.
3. Oil leakage
If oil leakage is found, repair should be performed.
1. Low oil level mark

2. Full oil level mark

Maintanence
1）Disassemble the oil pressure sensor.
2）Fill the special tool (the oil pressure gauge) into the
vacated thread hole..

3）Fix the oil pressure gauge well.

4）Start the engine and preheat it to be at the normal b
working temperature.
5）After the engine is preheated, improve the rotating
speed of the engine to be 3000 r/min, and measure
the oil pressure.

The standard of the oil pressure is:

130～350Kpa, idle speed
260-480kPa, 3600±50r/min
340～520kpa, 5600±50r/min

6）After the oil pressure is inspected, turn off the engine

and take off the oil pressure gauge.

7）replace the sealent on the screw thread, reinstall the oil

pressure sensor and screw the switch according to the
specified torque.

Notes:
If the edge of the sealing adhesive tape protrudes,
align it with the switch thread.

8）Start the engine and inspect whether the oil pressure

switch leaks oil.
9）Turn off the engine and connect the terminal and the
pressure switch terminal.

Chana·Benni MINI
301-01-5 Engine summarize 301-01-5

Valve clearance inspection and modulation

1）take off the cylinder head cover

2）rotate the crankshaft until the base circle of
camshaft is over the bucket tappet.

Check the valve clearance with feeler

Notes:
Insert the feeler between the camshaft and the
bucket tappet when check the valve clearance.

3）If the valve clearance is not up to standard,

modulate the valve clearance by changing the
bucket tappet, and check it angain. Keep doing
this until it is up to the standard.

Cold condition The way of sellecting bucket tappets is as below:

(coolant temperature:15-25℃）
Valve 1）the grouped table is as below.
0.16-0.24mm
clearance intake
standard 2）firstly, select one group as the standard
0.24-0.32mm
exhaust bucket tappets(from 631 in the 8th group to 648 in the
14th group), such as 640 in the 11th group.

3）install the selected standard bucket tappets into the

cylinder head cover assembly, check the clearance
and record. For example, the first clearance of
intake valves is 40.

4）In accordance with the grouped table and the

checked result, select the suitable one. For
example, if we select 660 in the 20th, the
clearance will be 20.

Chana·Benni MINI
301-01-6 Engine summarize 301-01-6

The grouped table of bucket tappets

5 ） The bucket tappets are marked as D × 100. for

example，6.10×100=610 is the first group.

Chana·Benni MINI
301-01-7 Engine summarize 301-01-7

Cylinder head cover

Disassembly and assembly
1）take off the engine oiling port cover
2）take off ignition coil、high voltage
dampcoil and spark plug.
3）take off PVC tube and steam hose.
4）take off the cylinder head cover assembly.
5）take off the cylinder head cover gasket and
spark plug gasket.

Notes:
1、check every part and replace all damaged
parts before assembly.
2 、 check the spark plug gasket 、 cylinder
headcover gasket and washer assembly carefully
before install the cylinder head cover. 6）assemble the cover in reverse order.
3、Check and make sure the cylinder headcover
is over the half-circle gasket which is at the rear of
the headcover.

Oil pan and oil filter

Disassembly and cleaning

1）Remove the oil draining plug, and exhaust the
engine oil.
2）disassemble the parts in the order of bolts and nuts
of oil pan、oil pan、gasket、bolts of oil filter
and oil filter.
3）Clean the matching surface between the oil pan and
the cylinder body.
4）Remove the oil on the matching surface, old sealing
agent and inner part of the oil pan.
5）Clean the suction filter screen of the oil pump.

Chana·Benni MINI
301-01-8 Engine summarize 301-01-8

Installation
1）Install the suction filter screen of the oil pump.The
screwing torque is 10 N·m.
2 ） Install sealing agent on the combining
surface in the ellipses.
3）Install the oil pan and gasket immediately, screw
the bolts in cross order according to appendix C. The
screwing torque is 7±1N·m.

4）Screw the bolts of the oil pan. The screwing

torque is 30～40N·m.
5）Fill the engine with new oil.

Timing mechanism
Disammembly
1 ） Remove the compressor belt of the air
conditioner.
2）Loosen the water pump tension pulley and remove the
water pump belt pulley.
3）Remove the water pump pulley and initiative tri-angle
belt pulley.
4）Remove the front cover casing of the timing belt
5）Remove the timing belt、tension wheel and timing
belt pulley.

In order to install the timing belt, align it with the rotating

crankshaft. The four timing marks are shown as in the
figure.

Chana·Benni MINI
301-01-9 Engine summarize 301-01-9

Notes：
1 、 After removing the timing belt, the rotating
concave wheel shaft and the crank shaft must not be
rotated beyond the range as shown in the figure. If so,
interference generated between the piston and the valve
may damage relevant parts of the piston and the valve.
2、The timing belt must not be bent.

Checking
1）Inspect the timing belt for abrasion and crack, and replace
it if necessary.

2）Inspect the tensioning wheel for flexible rotation.

Installion
1）Install the tension wheel
Install the tension wheel with assembled bolts、torsional
spring、torsional spring lining and screw by hand.
Just as the left fingure.

2）Install the timing belt

Check the timing marks whether they are in the same line,
if not, turn the crankshaft and camshaft in the prescript
range.
Methords：
Keep the timing marks which are on the timing
pulley and the rear cover casing in the same line.
At the same time, rotate the crankshaft to make the
timing marks which are on the timing pulley and the
rear cover casing camshaft in the same line. Make
sure that all marks face the upward side. Then
install the timing belt.

3）Install the torsion spring before screw the bolts which

connect the tension wheel. Note: Screw the assembled
bolts first.
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301-01-10 Engine summarize 301-01-10

4）Install the front cover casing, and screw the

bolts which connect the front and rear cover casing.
Screwing torque: 10N·m.

5）Install the initiative tri-angle pulley. Put the

half-circle key of the camshaft into the hole of the
pulley, and screw the pulley bolts according to the
prescriptive torque.
Screwing torque:80-87N·m.

6）Install the pump pulley and pump belt. Adjust the

tension.
7）Install the compressor belt of the air conditioner. Adjust
the tension as the left fingure shows.
8）Connect all the pipelines, and fix them.

Oil pump

Disassembly
1）Remove the compressor、 the compressor bracket and
compressor belt.

2）Remove the parts in the order of motor 、generator

bracket、water pump belt、initiative tri-angle belt.
3）As stated previously, remove the front cover casing.
4）As stated previously, remove the timing belt and
timing wheels.
5）As stated previously, remove the oil pan and the oil
filter.
6）Remove the oil pump.

Checking
Inspect the lip of the oil seal for defects or damages and
replace it if necessary.Before installation, engine oil should be
applied on the lip of the oil sealing component.
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301-01-11 Engine summarize 301-01-11

Notes：
1、When installing the oil seal, it should be pressed to
ensure that the end surface of the oil seal is 0.5 mm
lower than that of the oil pump casing.
2、During inspection, inspect the rotor cover plate and
the casing of the oil pump for excess abrasion or
damage.

Measurement
1）Radial clearance
Use a thickness gauge to check the radial clearance
between the outer rotor and the housing. If the clearance exceeds
the limit, replace the outer rotor or the housing.
The limit of the radial clearance between the outer rotor
and the housing: 0.310 mm
2）Side clearance
0.15mm Use a ruler and a thickness gauge to measure the
side clearance.
The limit of the side clearance: 0.15 mm

Installion
1）Install two oil pump pins and the spacer of the oil pump
on the cylinder body. Note a new spacer is to be used.
2）When the oil pump is installed on the crankshaft, the
special tool (guide of the oil seal) shall be installed on the
crankshaft and the engine oil is coated on the special tool in
order to avoid the lip of the oil seal being destroyed or coiled
upward.
3） Install the oil pump on the cylinder body.
See figure above for correct use as there are two bolts
of the oil pump, and screw the bolts with the specified torque.
Screwing torque:11 N·m
4）Install the wheel key of the timing belt and the crankshaft
timing belt wheel.
5）As described previously, install the tension wheel, the
timing belt, the suction filter of the oil pump, the oil pan , the
front cover casing, the initiative tri-angle belt and other parts.
6）Check to ensure that all the dismounted parts have been
installed in position. Install other required parts.
7）Adjust the water pump belt tension.
8）Adjust the tension of the air-conditioner compressor belt.
9）Fill up the engine oil to the engine again
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301-01-12 Engine summarize 301-01-12

Camshaft
Disassembly
1）Remove the camshaft position sensor, ignition c
oil and high pressure damp line.
2）Remove the timing cover case and wheels.
3）Remove the cylinder cover.
4）Remove the camshaft cover and camshaft.
5 ） Remove the bolts of the camshaft
cover,from the sides to the center,and a bit
one time.

Notes：
Before removing the bolts of the
camshaft, rotate the camshaft until the
position bolt is at the top of the zero
camshaft cover.Use the position bolt to
connect the driven gear and the separating
gear in order to make sure matching correctly
when assemble again.

Cam
standard limit
Height Cam Abrasion
Air Intake
40.11mm-40.19mm 40.102mm
Cam
Measure the cam height with the micrometer. If the
Exhaust
37.26mm-37.34 37.252mm
measured height is below the limit value, replace the camshaft.
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301-01-13 Engine summarize 301-01-13

Camshaft Radial Run-out

Put the camshaft between two V-shaped blocks. If the
radial run-out exceeds the limit, replace the camshaft.
Radial run-out limit: 0.10 mm

Abrasion of the Axle Journal of the Camshaft

Check the axle journal of the camshaft and the camshaft
cover for pitting, scratch, abrasion and damage. If any
unfavorable condition is found, replace the camshaft or
the cylinder head and the camshaft cover. Do not replace
the cylinder head under the condition that the camshaft
cover is not replaced.

Detect the clearance with the plastic plug gauge.

The procedures are as follows:
1）Clear the camshaft cover and the axle journal of the
camshaft.
2）Install the camshaft on the cylinder head.
3）Put a piece of plastic plug gauge along the full width
of the axle journal of the camshaft (parallel to the
camshaft).
4）Install the camshaft cover, see the latter installation
procedures.
5）According to the sequence shown in the figure, screw
the bolts of the camshaft cover in sequence until they are
screwed to the specified torque. The sequence is from the
center ones, 2 and 6, to the two sides, a bit once. Keep
screwing 3 or 4 times, and then screw them to the
specified torque.
Screwing torque(a): 11 N·m

Note：
Do not rotate the camshaft when the plastic
plug gauge is installed.

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301-01-14 Engine summarize 301-01-14

6) Remove the camshaft cover and measure the width of

the camshaft cover at the widest point of the plastic plug
gauge with the plastic scale ruler. If the measured clearance
of the axle journal of the camshaft exceeds the limit value,
Standard Limit measure the aperture of the axle journal (camshaft cover)
clearance 0.040-0.082mm 0.12mm and the outer diameter of the axle journal of the camshaft.
If the difference is bigger than the specification,
replace the camshaft or the cylinder head assembly.
Item Standard
Aperture of the
24.0000-24.021mm
Axle Journal of the
Camshaft
Outer Diameter of
23.947-23.960mm
the Axle Journal of
the Camshaft Assembly
Add the oil on the cam and the axle journal of the camshaft
and put the camshaft on the cylinder head. Align at the timing
mark which is on the exhaust camshaft assembly as the
fingure shows.Install the camshaft cover on the camshaft and
the cylinder head.

Notes：
In order to make the separating gear reduce
the noise, remove the position bolt which
connects the driven gear and the separating gear
as the left fingure shows, after assembling the
camshaft cover.

2）Add the oil on the sliding surface of the axle journal of the
camshaft related to each camshaft cover.

3）Add the sealing agent on the matching surface of the cover

No. 1 matched with the cylinder head，and make sure no
sealing agent is on the matching surface of camshaft or the oil
seal.
4）There are stamped marks at the top of each camshaft cover,
which indicate the installing position and the direction (“←”
points to the fore.).Indicate to perform the camshaft cover
installation according to these marks.

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301-01-15 Engine summarize 301-01-15

5）After the oil is added on the cover bolts, screw them

temporarily at first, and then screw them from middle to
1. Crankshaft oil seal the sides.Evenly force, screw the bolts a little once,
repeat the screwing sequence for three to four times, and
then screw them to the specified torque. Screwing torque:
11 N·m
6) Install the camshaft oil seal.After the oil is added to
the lip of the oil seal, press and install the camshaft oil
sea until the surface of the oil seal flushs with the cover
surface.

7) Install the camshaft timing belt wheel on the

camshaft, and locate it with dowel. Screw the belt pulley
bolts to the specified torque with the special tool.
Screwing torque: 80 N·m.

8) Install the belt tensioning wheel, the timing belt, the

fore cover, the camshaft belt pulley and the fore belt
according to the described methods.
9）Adjust the valve clearance as described above.
10) Install the cylinder head cover.
11) Install the camshaft position sensor 、
ignition coil、high voltage damp line on the
cylinder head, connect the camshaft position sensor
connector, screw the fixing bolts. Install the high
voltage correctly and connect the connector hard.
12) Fill up the coolant again and exhaust the air in the
system.

13) Connect the cathode conducting wire on the

battery.

14) Check that there is no coolant leaking at each

connector when the installation is completed.

15) Check that the ignition timing is within the

technical requirement scope.
16 ） Remove the locating bolt on the intake
camshaft which connects the driven gear and the
separating gear.

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301-01-16 Engine summarize 301-01-16

Valve and cylinder head

Disassembly
1) Decrease the oil pressure as the described
pressure decreasing procedures of the oil pressure；
2) Remove the conducting wire on the battery and
the battery；
3）Exhaust the cooling system；
4) Remove the pipeline and the reinforcing plate
related with the cylinder head and the air intake
manifold；

5) Remove the cylinder head as described above；

6) Remove the timing belt and the camshaft as
described above;
7) Remove the exhaust manifold；
Notes: 8) Loose the cylinder head bolts and remove
Once removed, the oil seal can not them according to the sequence as shown in the
be used any more. figure;
The new oil seal must be used during 9) Check around the cylinder head for
assembly. components requiring removing or disassembly,
and remove and disassemble such components;
10) Remove the cylinder head of the air intake
manifold and separate the air intake manifold and
the cylinder head.

Assembly
1）Extrude the valve spring with the valve raiser,
and then remove the locking block of the valve
with the tweezers.
2）Relieve the tool and remove the spring seat and
the valve spring.
3 ） Remove the valve from one side of the
Notes: combustion chamber.
Once removed, the valve guide can not be 4）Remove the valve oil seal with the special tool
used any more. from one side of the valve guide and then the
The new valve guide (enlarged size) must be bottom seat of the valve spring.
used during assembly. 5) Push the valve guide to one side of the valve
spring from one side of the combustion
chamber with detacher of the valve guide.
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301-01-17 Engine summarize 301-01-17

6) Besides the valve oil seal and the valve guide, put the
removed components in turn in order to assemble them at the
original position.
Inspeciton
Valve Guide
Measure the reading of the diameter of the valve rod and the
guide with the micrometer and the bore gauge to check the
clearance between the valve rod and the guide.

Measure the reading of the diameter at more points on the

whole length of the valve rod and the valve guide. If the
clearance exceeds the limit value, replace the valve and the
valve guide.

Measure the derivation limit of the end of the valve rod with
the dial gauge in case of absent bore gauge. Move the end of
the valve rod at the directions 1 and 2 to check the derivation
value of the end. If the derivation value exceeds the limit
value, replace the valve rod and the valve guide.

Item Standard Limit

Diameter of Air
4.952-4.966mm 4.947
the Valve intake
Rod Exhaust 4.926-4.940mm 4.921
Inner Air
Diameter of intake
5.00 -5.012mm 5.020
the Valve
Exhaust
Guide
Clearance Air The dimension of the valves are as the left figure
0.034-0.060mm 0.073mm shows.
between the intake
Valve Rod
and the Exhaust 0.040-0.086mm 0.099mm
Guide

Derivation Limit of the Air Intake 0.14 mm

Derivation Limits of the End of the Valve Rod are as the
End of the Valve Rod Exhaust 0.18 mm left figure shows.

Thickness of the Valve Head

Standard Limit Thickness of the Valve Head is as the left figure shows.

Air Intake 0.85-1.15 mm 0.6 mm

Exhaust 0.7 mm

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301-01-18 Engine summarize 301-01-18

Valve
1）Clear all carbon deposit on the valve.。
2 ） Check whether the working surface of each
valve and the valve rod are worn, burnt loss or deformed,
and replace the valve if necessary.
3）Measure the thickness of the valve head. If the
measured thickness exceeds the limit value, replace the
valve.

4）Check the end surface of the valve rod for dent or abrasion. If
so, the end surface of the valve rod can be flattened but not
flattened too much as to burnish its chamfer. If the chamfer is
worn, the valve shall be replaced.

Chana·Benni MINI
301-01-19 Engine summarize 301-01-19

5）Contacting width of the pressure seat:The contacting

trace shape is usually made on each valve, for example, a
layer of trace film is evenly coated on the valve seat, and
then the valve seat and the valve head is checked by
rotating. The valve grinding tool must be used (this tool is
used for grinding valves).

Standard Minimum is
Width Shown Air 1.25mm，
in the Valve Intake unevenness is
Trace 0.5mm

6）Repair of the valve seat: if the trace generated by the

contacting of the valve seat and the valve is uneven, it must be
repair grinded again, or cut, grinded and finely grinded and
polished.

（1）Exhaust valve seat: repair twice with the valve seat reamer
as shown in the figure. The exhaust valve seat must be repaired
with two reamers: the first reamer is in the angle of 20°, and the
second reamer is in the angle of 45°. The required valve seat
width must be modified.
Exhaust valve seat width: 1.3-1.55mm

（2）Air intake valve seat: the restoration procedures are

identical to that of the exhaust valve seat.　
Air intake valve seat width: 1.2-1.45 mm

3）Valve grinding: the valve grinding is divided into two steps:

firstly, add the rough grinding paste on the end surface to
perform grinding; secondly, use the fine grinding paste to grind.
Use the valve grinding tool in each step with the common
grinding method.

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301-01-20 Engine summarize 301-01-20

Cylinder head
1 ） Clear the carbon deposit of the combustion
chamber.
2）Check the air intake and exhaust hole of the
cylinder head, the combustion chamber and the cylinder head
surface for scratches.

Notes:
The carbon deposit is not allowed to be
scraped with any sharp tool. Note not to
damage or scuff the metal surface, which is

3）Flatness of the cylinder head surface:

Check the surface in 6 points with the ruler and the clearance
gauge. If the value exceeds the below derivation limit, use the
＃
flat plate or the sand paper of 400 (waterproof emery paper) to
smooth the cylinder head surface: put the sand paper on the flat
plate, and make the cylinder head surface grind on the sand
paper to grind the high point. If the reading of the clearance
gauge still can not be reduced to the limit scope, the cylinder
head shall be replaced. The combustion gas leaked from the
cylinder head combining surface often results from the crinkle
and the distortion of the cylinder head surface, which will cause
the decrease of the output power as well as the highness and the
over heat of the water temperature of the engine.
Derivation limit: 0.05 mm

4）Distortion of the matching surface of the manifold

Check the matching surface of the manifold of the cylinder head
with the ruler and the clearance gauge for the necessity of
flattening or cylinder head replacing.
Derivation limit: 0.05 mm
Valve spring：Check whether each spring is good, or has the sign
of damage or weakening according to the data in the following
figure. Remember that the valve spring with the weak elastic
force will cause vibration, and the air leakage will be generated
due to the decreased valve seat pressure, so that the output
power is reduced.

Chana·Benni MINI
301-01-21 Engine summarize 301-01-21

Item Standard Limit

Free Length
of the Valve 35.37mm 35.14mm
Spring
Valve Spring 27.9mm for
Preload 109-127N
Verticality of the valve spring:
Check the verticality of each spring with the ruler and
the flat plate according to the clearance between the valve
spring end and the ruler. If the clearance exceeds the limit
value given below, the valve spring must be replaced.
Verticality limit of the valve spring: 1.0 mm

Assembly
1、Before the valve guide is arranged in the cylinder head, use
the reamer of 9 mm to ream the conduit hole to remove the
deckle edge.（φ9 ＋0.28 ＋0.43 ）。

2、Install the valve guide into the cylinder head.

Under normal temperature, press the new guide of the new
valve into the hole with the tool until the valve guide installer
contacts the cylinder head. Ensure the valve guide to extend
9.15±0.2mm out of the cylinder head after being installed.

Notes:
1. Once being removed, the valve guide
can not be used again. Install a new valve
guide (oversized).
2. It is the same to the air intake and the
exhaust valve guide.

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301-01-22 Engine summarize 301-01-22

3 ） Enlarge the valves: 0.028mm. Extend amount

of the valve guide (air intake and exhaust): 9.15±
0.2mm.
4 ） The 5.0 mm reamer is used to ream the hole
diameter of the valve guide. After being reamed, the conduit hole
should be cleaned.
5）A valve spring seat is installed on the cylinder head.
6）Oil seals of the new valve rod are installed on the
valve guide.After oil is filled into the oil seal and the main axle of
the installer handle of the valve guide, the oil seal is installed on
the main shaft, then the installer handle of the valve guide is
pressed by a hand, and the oil seal is installed on the valve guide.

Notes:
1. The removed oil seals should not be used again. Use the
new seals when assembling.
2. Never strike the installer handle of the valve guide with
hammer or something else when assembling. Just press the
installer handle of the valve guide with hand when installing
the oil seals. Striking the installer handle of the valve guide
may break the oil seals.

6）The valve is installed on the valve guide. When the valve

1．Large pitch end
2. Fine pitch is installed on the valve guide, oil should be filled on the
3. upper seat side of
the valve spring valve oil seal, the hole of the valve guide and the valve rod.
4. Bottom seat side
of the valve spring

7）The valve spring and the spring seat are installed. Each
valve spring has a top (large pitch end) and a bottom end (fine
pitch end). When the spring is installed, the bottom end of it
(small screw pitch end) must face to the bottom part (the bottom
seat of the valve spring).

8）The valve raiser and the valve spring are used to install the
two locking blocks of the valve into the concave groove the
1．Locking block of
the valve valve rod.

Chana·Benni MINI
301-01-23
Cylinder gasket installation
Engine summarize 301-01-23
Remove the old cylinder gasket and apply oil on the matching
surface, then install a new cylinder washer as shown in the
figure（the TOP sign on the spacer should be upturned and put
the two main oil path holes of the cylinder washeeeer and
body on the same line.）
The cylinder head bolts must be tighten gradually according to
the following methods.
1）All bolts must be tightened to 45 N.m from the middle to
the ends；
2）Tighten to 67±2N.m Nm according to method 1；
3）Installation should be performed according to the reversed
procedures of the disassembly.
4）The clearances of the intake and the exhaust valve should
be adjusted as stated previously.v
5）Check and confirm all removed components have been put
on the original places. Reinstall all components which are
not installed.
6）Refill the coolant, and discharge the air in the system.
7）Install a storage battery, and connect its conducting wire.
8）Check each connection for fuel leakage, coolant leakage
and exhaust gases leakage.
9）Verify the ignition timing is within the specified scopev
10 ） Install a gear-shifting controller and connect the
gear-shifting controlling dragline to the gear-shifting
controlling rod.
11）Pay attention to the check and adjustment of parking
braking, and adjust the parking braking.
Piston, Piston Ring, Connecting Rod and Cylinder
Disassembly
1）Remove the cylinder head from the cylinder body as stated
previously.
2）Discharge the engine oil.
3）Remove the oil pan and the suction filter of the oil pump as
stated previously.
4）Mark cylinder number on all pistons, connecting rods and
connecting rod bearing covers with a pencil or quick drying
paint.
5）Remove the connecting rod bearing cover.
6）Install a rubber protecting sleeve on the bolt thread of the
connecting rod for fear that the axle journal bearing and the
bolt thread of the connecting rod is damaged when being
removed from the connecting rod.
7）Remove carbon deposits on the cylinder before the
Chana·Benni MINI
301-01-24 Engine summarize 301-01-24
piston is taken out of the cylinder.
8）Push out the piston and the connecting rod from the upper end of
the cylinder.

Notes：
Install a rubber protecting sleeve on the bolt
thread of the connecting rod for fear that the axle
journal bearing and the bolt thread of the connecting
rod is damaged when being removed from the
connecting rod.

Disassembly
1）Remove the two compression rings (the first and the second ring)
and the oil scraping ring from the piston through the extender of
the piston ring.
2）Remove the piston ring from the connecting rod.
（1）As shown in the figure, loosen the retaining ring of the piston
ring carefully.
（2）Force off the piston pin.

Cleaning
Clean up the carbon on the piston head and the piston ring groove
through an appropriate tool.

Cylinder
1）Observe whether there are obvious scraping trace, rugosity or
protuberance on the cylinder wall. If the cylinder is very
rough or uneven due to deep scraping traces, it should be
replaced.
2）As shown in the figure, the cylinder is measured by using
the cylinder gauge at three positions and in two directions
(10mm、47mm and 84mm to the top of cylinder body); and
the cylinder should be replaced measurement is out of
tolerance.
（1）The cylinder diameter is out-of-tolerance.
（2）The measuring difference value of the circular degree
and the cylindricity at the two positions is out-of-tolerance.
（3）The measured difference value in the thrust and the axial
direction exceeds the non-roundness scope.
The cylinder diameter limit: φ66.02 mm
the circular degree limit: 0.008mm
the cylindricity limit：0.008mm；

Piston
1）Inspect the piston for abrasion, cracks or other damages,
Chana·Benni MINI
301-01-25 Engine summarize 301-01-25
and replace the damaged or faulty piston by a new one.
2）Piston diameter：
As shown in the figure, the measurement for the piston
diameter should be started from the piston skirt bottom to 10
mm of the piston pin in the vertical direction (no painting
graphite).
3）Piston clearance：
Piston clearance is the difference value between the cylinder
diameter and the piston diameter. The piston clearance should
be within the following specifications scope. If
out-of-tolerance exists, check the diameter of the cylinder
hole or the piston and replace the parts.
Piston clearance: 0.0131-0.047mm(the piston skirt bottom
is painted.)
The diameter of the piston and the piston
piston φ65.58- pin hole are as the left figure shows.
standard
diameter φ65.82mm
piston pin
φ16.006-
hole standard
φ16.012mm Piston ring groove clearance：
diameter
The piston ring groove must be clean, dry and carbon free
before the inspection is performed.The piston ring should be
installed in the ring groove, and the clearance between the
ring and the ring groove is measured by a thickness gauge.If
the clearance is out of tolerance, inspect the piston ring
groove width and the piston ring height and replace the
unqualified parts.
Clearance of the piston ring groove
The first ring: 0.04-0.08mm
The second ring: 0.03-0.07mm
Piston pin
Inspect the piston pin, the small end hole of the connecting
rod and the piston hole for abrasion or damages. If badly
abraded or damaged, replacement is needed. Clearance of the
piston pin.The piston pin clearance should be inspected at the
small end; if badly abraded or damaged or the clearance is out
of tolerance, the connecting rod or the piston pin should be
replaced.

Chana·Benni MINI
301-01-26 Engine summarize 301-01-26

Item Standard
clearance of the small end
the small end hole of the connecting rod diameter：φ16.003-
hole of the connecting rod 0.003-0.016mm
φ16.011mm
and the piston pin
piston pin diameter：φ15.995-φ16mm
clearance of the piston pin
0.006-0.017 mm
hole and the pistion pin

Piston ring
Note:
The end clearance measurement: embed the piston ring
Clean the top part of the cylinder and remove
into the cylinder and measure the clearance through a
the carbon before the piston ring is embedded.
thickness gauge. If the clearance is out of tolerance, the
piston ring should be replaced.

Item Standard Limit

piston ring the first
0.15-0.30mm （0.5mm）
working ring
clearance the
(after second 0.30-0.45mm （0.5mm）
installion) ring

Connecting rod
Side clearance of the large end: Connect the connecting rod
Item Standard Limit with the crankshaft pin under a normal state, and inspect the
clearance of the big end of the connecting rod. If the
side clearance measured value of the clearance is out of tolerance, the
0.10-0.20mm 0.35mm
of the large end connecting rod should be replaced.
Connecting rod alignment: Put the connecting rod on the
straightener and inspect for bending or distortion; if out off
tolerance occurs, replacement must be performed.
Bending limit: 0.05 mm
Twist limit: 0.10 mm
Crank pin and connecting rod bearing shell
Inspect the crank pin for irregular abrasion or damage. The
taper degree or the non-roundness of the crank pin can be
measured by the micrometer. If the crank pin is damaged, or
the non-roundness or the taper degree is out of tolerance, the
crankshaft should be replaced, or the crank pin should be
bored grinded according to the following six steps.

Chana·Benni MINI
301-01-27 Engine summarize 301-01-27

Model of the Connecting

Crankshaft pin diameter
Rod Bearing Shell
Standard Dimension φ37.982-φ38.000mm

Roundness and taper degree limit of the crank pin ：

0.005mm。

Connecting rod bearing shell

Inspect the bearing shell for melt signs, pits, ablation or
surface layer peeling and observe the contacting shape. If
some obvious conditions as stated above appear, replacement
must be performed.

Connecting rod bearing clearance:

1) Clean the bearing shell and the crank pin before the clearance
of the bearing shell is inspected.
2) Install the bearing shells on the connecting rod and the shell
cover.
3) When being connected with the bearing shell, put a piece of
plastic plug gauge running parallel to the axial line of the
crankshaft on the full width of the crank pin, avoiding the oil
holes.

4 ） connecting rod bolt: When the bearing shell of the

connecting rod is installed, make sure the arrow direction
mark on the shell cover is positioned at one side of the fly
1．Bearing shell
2．Arrow direction mark wheel transmission. Tightening torque: 35±2N.m.
3．One side of the
crankshaft pulley

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301-01-28 Engine summarize 301-01-28

1. Plastic plug gauge

2. Scale
5）Remove the shell, put the scale on the surface of the plastic
plug gauge, and measure the width of the plastic plug gauge
at the widest point of the clearance.If the clearance is out of
tolerance, a bearing shell with a new standard size can be
used, and the clearance should be measured once more.

6）If a new standard bearing shell is used and the clearance is

still out of tolerance, the crankshaft should be replaced.

Intake system

Filtering Core of Air Filter

Disassembly and Installation
1) Take down the retaining clip of the housing of the
air filter.
2) Take out the filtering core of the air filter from the
housing.
3) Inspect whether the filtering core of the air filter
has dirt or not.
4) If necessary, use the compression air to blow the
dirt off the air outlet end of the filtering core.
5) Install according to the sequence opposite to the
disassembly sequence.

Throttle Body and Intake Manifold

Disassembly
1）Disconnect the schnorkel、vacuum booster hose and
blow down hose controlled by canister wich connect
with the intake manifold.
2）Disconnect the fuel main assembly with injector、
knock sensor assembly and bracket.
2）Disconnect the throttle valve assembly.
3）Disconnect the intake manifold.

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301-01-29 Engine summarize 301-01-29

Assembly
1）Screw the bolts which connect the intake
manifold and the head cover according to the
prescriptive torque.
Screwing torque:23 N·m.
2）Assemble the intake manifold and screw the
nuts.
3 ） Assemble the throttle body, the screing
torque of bolts is 10 N·m;assemble the intake
air pressure and temperature senso, the
screwing torque is 9.5 N·m;assemble the fuel
main and knock sensor bracket.
2）Inspect and make sure all parts are at where
they were,and assemble other parts.

Exhaust manifold

3-way catalytic converter

The 3-way catalytic converter and the exhaust
manifold of transverse engine C10 are welded to
be one body. It is installed at the right side
of the engine and fixed on the body by the bracket
underneath it to enhance the whole exhaust system.
Heat shield is installed at the outside of the
3-way catalytic converter and the exhaust
manifold to avoid the oil being too hot and
lighten the heat harm of other parts in the
highter temperature envirment. The main
effection of the 3-way catalytic converter is to
improve the emission standard by reducing the
Notice： concentration of HC、CO and NOx in the exhaust
gas.
The brackets disassembled from the
flecible tubes should be kept as spare parts.
Warning：

Warning: Catalyst carrier will be melted

if the temperature of the enviroment is highter

than 900°C. in order avoid such accident, the
reason of malfunction must be described
particularly and repaired carefully.

3-way catalytic converter poisoning

Chana·Benni MINI
301-01-30 Engine summarize 301-01-30
The sulfur in the gasoline will poison the
catalyst. If the lead in the gasoline is more
than 5 mg./l, the catalyst will be poisoned
seriously. All vehicles which are equipped
catalytic converters are not allowed to fill
leaded petrol. If the consumption rate of oil is
too high, the lead and phosphor in the petrol
will poison the catalyst. The smell of H2S is
like the bad eggs, so it is very easy to be
detected. It can be solved by changing the brand
of petrol. In order to decrease the emission of
H2S, the idling emission of CO is measure up and
the exhaust system of engine is working very well.
Generally, the higher temperature of activator
carrier is because of the ignition system or the
petrol system. The fire when the engine speed is
very high will melt the carrier instantaneously.
The melted activator will jam the exhaust system,
augment exhaust backpressure and decrease the
power performance.
Disassembly
1. Lift the vehicle
（1）Disassemble the wiring harness of rear
lambda sensor.
（2. Disassemble the assembly of the hook bolt
and muffler.
（3）Disammble the bracket of exhaust manifold
and bolts.
2. Get down the vehicle
（1）Disconnect the connector of front lambda
sensor.
（2）Disassemble the connecting nuts of exhaust
manifold and and take down the exhaust manifold
assembly.
3. The disassembled exhaust manifold assembly
and parts of catalytic converter are as the
fingure shows.

Warning：
In order to avoid scald, do not do the
maintenance when the exhaust manifold is
hot. It only can be done when the system
is cool.
Assembly
The assembly is contrary to the disassembly.
Notice：
⑴.The part fabrication of some parts should be
done first, such as the eshaust manifold
assembly 、 the high and low heat shields of
catalytic converter and the high and low heat
shields of exhaust manifold.
⑵ When the exhaust manifold assembly is
assembled, the nuts of exhaust manifold are
screwed after the bolts of catalytic converter
Chana·Benni MINI
301-01-31 Engine summarize 301-01-31
bitt being assembled.
⑶. The bolts of catalytic converter bitt are
screwed on request of torque after the nuts of
exhaust manifold being screwed on request of
torque.
Overhaul
Engine Assembly
Disassembly
1) The oil pressure in the fuel pipe can be reduced according
to the fuel depressurizing procedures stated previously.
2) Disconnect the inserting connector of the wiring hardness
connected with the engine and the inserting plug of the sensor.
3) Remove the storage battery and the battery box.
4) Discharge the transmission case oil.
5) Discharge the cooling water.
6) Remove the air intake pipe.
7) Disconnect all connectors connected with the engine fuel
system.
8 ） Disconnect all connectors connected with the engine
cooling system.
9) Disconnect all connectors connected with the engine
controlling air channel pipeline.
10) Disconnect all clips related to wiring hardness of the
engine.
11) Hoist the automobile.
12) Discharge the engine oil.
13) Disconnect the connection of the exhaust manifold and
the muffler.
14) Disconnect the dragline of the clutch of the releasing arm
Oil pressure siren assembly of the clutch and the transmission case.
15) Disconnect the speed changing and selecting dragline of
the transmission case.
16）Remove the left, right and rear engine soft gasket bolt.
17）Remove the engine with the transmission gear from the
engine compartment.
18）Separate the engine and the transmission gear.
19）Disassemble the timing mechanism as stated previously.
20）Disassemble the cylinder head, the intake and the exhaust
manifold as stated previously.
21）Disassemble oil pan as stated previously.

Installation
1) Link the engine and the transmission gear.
2) Tighten the engine bracket bolts as shown in the figure.
3) The installation procedure is reverse to the disassembling
Chana·Benni MINI
301-01-32 Engine summarize 301-01-32
and installating procedure and the bolts should be tightened
according to the specified torque.
4）Connect the dragline of the gear-shifting mechanism
to the controlling rod of the gear-shifting mechanism; see
Controlling Installation of the Gear-shifting Mechanism
for information.
5）Connect the parking brake dragline to the controlling
rod of the parking brake. Referring to Inspection and
Adjustment of the Parking Brake, adjust the parking
brake.
6）Adjust the free travel of the clutch.
7）Connect the corresponding plug of the wiring hardness
on the engine.
8）Inspection should be performed to make sure all
disassembled parts are installed back to the proper
position.v
9）Refill engine oil referring to the article of Engine Oil
Replacement.
10）Fill coolant and discharge the air.
11）Inspect each connector for fuel leakage, coolant
leakage and waste gas leakage.v
Main Bearing Shell, Crankshaft and Cylinder Body

Disassembly：
1 ） Disassemble the engine assembly from the
vehicle body as described previously.
2)Disassemble the start motor and transmission
from the engine, and then disassemble the clutch
housing, the clutch plate and the flywheel.
3 ） Remove the generator,generator adjusting
stand, compressor and generator bracket.
4 ） Remove the driving tri-angle belt
pulley,pump belt pulley,front cover
caasing,tension wheel,timing gears,pump and rear
cover casing.
5）Remove the pipe strap connecting the exhaust
water tube and the thermosister.
6）Removve the head cover assembly.
7）Remove the oil pan,oil filter and the main
bearing cover.
8）Removvee the oil level gauge,crankshaft rear
cover and oil pump.
9）Loosen the bolt and the bearing cover of the
crankshaft bearing cover.
10）Remove the crankshaft from the cylinder body.
Chana·Benni MINI
301-01-33 Engine summarize 301-01-33
Assembly and inspection of the crankshaft and the
main bearing
Crankshaft
Name Standard Limit
Radial Run-out of Crankshaftv
Crankshaft
0.16～0.36 Measure the radial run-out at the central axle journal with
Retaining 0.36m
mm the dial gauge. Slowly rotate the crankshaft. Replace the
Clearance
crankshaft if the radial run-out exceeds its limit value.
Radial run-out limit value：0.06 mm

Crankshaft Retaining Clearancev

According to the conventional method, namely,
adopting the installation thrust washer and the journal
bearing cover, position the crankshaft in the cylinder
body to measure the clearance.
Read the misplacement amount of the crankshaft in
the axial (thrust) direction with the dial gauge.Use a
new crankshaft if the misplacement amount exceeds
the limit value, and replace the thrust washer which
exceeds the limit value with a standard thrust washer.
Ovality and Taper Degree of Axle Journal (uneven
wear)
The crankshaft with uneven wear indicates a
difference in the the diameter of the cross section or
along the length (or both). The difference can be
confirmed through the reading of the micrometer
caliper.If serious damage or uneven wear of any axle
journal in the axle journal exceeds the following limit
value, regrind or replace the crankshaft.
Limit value of the ovality and the taper degree: 0.005
mm

Main Bearing
General Instructions
1）The standard main bearing shell and the bearing
shell with the increased size of 0.25mm are useful for the
maintenance, and they are respectively divided into 5
groups of allowance sizes.
2）Carve arrow marks and serial numbers on each main
bearing cover as shown in the figure.When all main
bearing covers are installed on the cylinder body, point
the arrow marks to one side of the crankshaft pulley, and
arrange all bearing covers at one side of the flywheel
according to the rising sequence of numbers, such as 1, 2,
3, 4 and 5. Screw the bolt of the bearing cover to the
specified torque,.
Chana·Benni MINI
301-01-34 Engine summarize 301-01-34
Inspect the condition of the spot corrosion, scratch, wear or
damage of the bearing shell. Replace the upper and lower
Bearing Standard Limit halves of the bearing shell if there are any defects. Never replace
shell one half bearing shell only.
0.020- 0.026-
clearance Clearance of Main Bearing Shell
0.040mm 0.046mm
Inspect the clearance with the plastic plug gauge according to
the following procedures.
1) Remove the bearing shell cover.
Notes: 2) Clean the bearing shell and the main journal bearing.
Do not rotate the crankshaft when the 3) Place a full width plastic plug gauge of the bearing on the
plastic plug gauge is installed. main journal bearing (parallel with the crankshaft), and avoid
the oil hole.
4）Install the main bearing cover according the schematic
diagram mentioned above, and evenly screw the bolts to the
specified torque. The main bearing cover shall be screwed to
the required screwing torque.
5）The main bearing cover shall be screwed to the required
screwing torque.
Screwing torque：63±2N.m
6）Remove the main bearing cover, and measure the
width of the widest point of the plastic plug gauge. Replace the
main bearing shell if the clearance exceeds the limit value.
Always take the upper and lower shells as a whole for
replacement.A new standard bearing shell may generate correct
clearance. If there is no correct clearance, it is necessary to
Printed regrind the axle journal of the crankshaft with a bearing shell
Axle journal diameters
numbers with the increased size of 0.25 mm.
1 Φ54～Φ54.006 Recheck the clearance after a new bearing shell is selected.
2 Φ54.0061～Φ54.012
3 Φ54.0121～Φ54.018 Selection of Main Bearing Shell

Standard bearing shell:

If the bearing shell is incorrect, or the clearance of the
bearing shell exceeds the technical requirements, select a
new standard bearing shell and install it according to the
following procedures.
1）The printed first,second, third, fourth and fifth numbers
on the bottom of the cylinder body respectively represent
the axle journal diameters of the bearing covers 1, 2, 3, 4
and 5.
2）The axle journals are separated into three groups. The
diameters they stand are as the left figure shows.
3）There are differences in thickness among the five
standard bearing shells. Print the mark of first, second,
third, fourth and fifth numbers on the steel back surface of

Chana·Benni MINI
301-01-35 Engine summarize 301-01-35
the shells in order to distinguish them. Group the thickness
of the bearing as the A3 figure.
the dimension group of the main journal,the main
bearing hole and the main bearing shell Unit：mm

the group of the crankshaft main journal

diameterφ50 0−0.018
fit clearance
0.020～0.040
group mark
1 2 3
g
r group
The 0 −0.0061 −0.0121
o mark dimension φ50 − 0.006 φ50 − 0.012 φ50 − 0.018
diameter
u range
of the
p
crankshaft
+0.006 −0.01 −0.007 −0.004
case main 1 1 φ54 0 05 2.0 − 0.014 04 2.0 − 0.011 03 2.0 − 0.008
axle
+0.012 −0.007 −0.004 −0.001
+0.018 2 2 φ54 + 0.0061 04 2.0 − 0.011 03 2.0 − 0.008 02 2.0 − 0.005
φ54 0

+0.018 −0.004 −0.001

3 3 φ54 + 0.0121 03 2.0 − 0.008 02 2.0 − 0.005 01 2.0 ± 0.002

5）Check the bearing shell clearance of the newly

selected standard bearing shell with the plastic plug
gauge. If the clearance still exceeds its limit value,
replace with a thicker bearing shell and recheck the
clearance.
6）Refer to the numbers printed on the new crankshaft
or the letters on the matching surface of the new cylinder
body when the crankshaft and the cylinder body are
replaced, and select the new standard bearing shell to be
installed.
Assembly and inspection of the bearing shell:
1）inspect the group mark of the sector connecting
rod journal, for example 2223；
2）inspect the group mark of the connecting rod
hole diameter,for example 3333；
3 ） choose the connecting rod bearing shell
according to A2, the group mark is 2221;
4）the clearance of the connecting rod bearing
shell is as A2 shows:

Chana·Benni MINI
301-01-36 Engine summarize 301-01-36
Check the clearance of the big end of the connecting
rod and the mandrel of the crankshaft with the
plastic plug gauge. It should be between 0.01 mm
and 0.20 mm.

the group of the crankshaft connecting rod journal

diameter
Fit clearance
1 2 3
0.020～0.040
group mark
A B C
group
grou 0 −0.0061 −0.0121
the mark dimension φ38 − 0.006 φ38 −0.012 φ38 −0.018
p
diame scope
ter +0.006 −0.01 −0.007 −0.004
1 1 φ41 0 05 1.5 − 0.014 04 1.5 − 0.011 03 1.5 − 0.008
of
the +0.012 −0.007 −0.004 −0.001
2 2 φ41 + 0.0061 04 1.5 − 0.011 03 1.5 − 0.008 02 1.5 − 0.005
conne
cting +0.018 −0.004 −0.001
3 3 φ41 + 0.0121 03 1.5 − 0.008 02 1.5 − 0.005 01 1.5 ± 0.002
rod
hole +0.024 −0.001 +0.005
4 4 φ41 + 0.018 02 1.5 − 0.005 01 1.5 ± 0.002 00 1.5 + 0.001

Rear Oil Seal

Carefully check the abrasion and damage status of the oil
seal. Replace the oil seal if the lips of the oil sealing
component are abraded or damaged.

For the installation of the oil seal, clean

and steadily press, to ensure that the end surface
of the oil seal is 0.5 lower than the end surface
of the oil sealing cover.
Flywheel
Replace the flywheel if the gear ring is damaged cracked
and abraded.Replace the flywheel if the surface of the
clutch plate is damaged or excessively worn.Check the
end surface run-out of the flywheel with the dial
gauge.Replace the flywheel if the end surface run-out
Name Standard Limit exceeds its limit value.
Flatness 0.05mm 0.10mm Run-out limit value of the end surface: 0.2 mm

Chana·Benni MINI
301-01-37 Engine summarize 301-01-37
Cylinder Body Distortion of Sealing Surface
Check the derivation status of the sealing surface with the ruler
and the thickness gauge, and repair it if the flatness exceeds its
limit value.

Qualified screwing torque

No. code Name position screwing
torque
1 1002019D crankshaft main bearing cover Crankshaft case 61～65
bolt assembly
2 1004015D connecting rod bolt connecting rod 33～37
assembly
3 1000150E cylinder cover connecting cylinder headcover 65～69
assembly bolt assembly
4 1005014D1 fly wheel bolt fly wheel assembly 45～50
5 Q1841225-M12*1.25 crankshaft timing belt pully crankshaft 80～87
bolt
6 Q1841225-M12*1.25 camshaft timing belt pully camshaft assembly 80～87
bolt
7 1000154E camshaft cover first bolt cylinder headcover 10±1
assembly
8 1000155E camshaft cover second bolt cylinder headcover 10±1
assembly
9 1000146-01 water sealing end cover crankshaft case 8±1
assembled bolt assembly
10 GB/T5783-2000-M6*20 hexagon headed bolt oil pan assembly 8±1
11 3707010E spark assembly cylinder headcover 20～25
assembly
12 3810010D oil pressure annunciator crankshaft case 12～15
assembly assembly
13 1012010D2 oil filter assembly oil filter 12～16
connecting tube
14 1012031D oil filter connecting tube crankshaft case 20～25
assembly
15 1009018D oil draining plug oil pan assembly 18～28
16 3808010-02 water temperature sensor thermolator 13～17
assembly setting assembly
17 3742040E/3742040A10 oxygen sensor assembly exhaust manifold 42～48
assembly
18 1000290E tension pulley tightening tension pulley 23±2
assembled bolt assembly
19 3752010E/E1 detonation sensor assembly crankshaft case 23±2
Chana·Benni MINI
301-01-38 Engine summarize 301-01-38
assembly
20 GB/T5783-2000-M8*16- hexagon headed bolt clutch cover 23.5±1.5
9.8 assembly
21 1000156E ornament cover fixing bolt engine ornament 10±1
cover assembly

C.2 The srewing torque of grade 8.8 bolt is as the fingure C2 shows.

Thread Specifications Screwing Torque

M6×1.0 9～11

M8×1.25 21～25

M10×1.25 45～55

M12×1.25 78～96

C.3The srewing torque of grade 10.9 bolt is as the fingure C3 shows.

Thread Specifications Screwing Torque

M6×1.0 12～14
M8×1.25 29～35
M10×1.25 63～77
M12×1.25 113～138

C.4 the transmission wearing parts

Thewearing parts of MF508C01 are confirmed as below, according to other transmissions：
NO. CODE NAME
1 62/22-2RS P53 Right bearing of the input shaft
GB/T276-1994
2 1709402-MF514A01 left bearing of the input shaft
3 1709420-MF514A01 right bearing assembly of the intermediate
shaft
4 1709431-MF514A01 left bearing of the intermediate shaft
5 1709161-MF514A01 right oil seal of different
6 1709161-MF514A01 left oil seal of different
7 1709110-MF514A01 oil seal of the input shaft
8 3729610-MF514A01 switch assembly of backup light
9 32008X GB/T 297-1994 different bearing assembly
10 1709330-MF514A01 coamping bolt assembly of of the third and
fourth gear
11 1703130-MF514A01 speedometer sensor assembly
C.5 The torque of the transmission bolts are shown as below:
Chana·Benni MINI
301-01-39 Engine summarize 301-01-39
NO. NAME NUMBER SCREWING TORQUE（N·m）
1 coamping bolts of the fifth rear gear 1 10～16
2 coamping bolts of the first and second gear 1 10～16
3 striking fork bolt of rear gear 1 10～16
4 striking fork bolt of the fifth gear 1 7～10
5 speedometer assembling bolt 1 5～7
6 gear shaft bolt of the rear gear 1 10～16
7 shaft hold-down plate bolt 7 8～12
8 nuts of the input and intermediate shaft 2 60～80
9 connecting bolts 16 19～25
10 switch assembly of backup light 1 15～20
11 oil loading plug screw 1 20
12 oil pouring plug screw 1 20
13 gear box bolts 4 7～10
14 left case cover bolts 8 19～25
15 coamping bolts of the third and fourth gear 1 15～20
16 release bearing assembling bolts M6×1.0×20 3 7～10
17 assembling bolts of zipper bracket 2 19～25

Special Tools

Schedule 1 special tools for engine repairing

1．09915-64510-001Pressure gauge
2．09915-64510-002Connector
09915-67310 09915-77310 09915-78211
3．09915-64530Hose
Vacuum gauge Oil pressure gauge Fixer of the oil pressure gaug
4．09915-67010Fixer

Chana·Benni MINI
301-01-40 Engine summarize 301-01-40

1．09916-14510Valve Opene 09916-34542 09916-34550 09916-38210

2．09916-14910Fixer of the valve Reamer handle Reame（5mm） Reamer（9mm）
opener

09916-44910 09916-56011 09916-58210 09916-77310

Disassembly of the valve catheter Fixer of the valve catheter installer Installer handle of the valve catheter Compressor of the piston ring

09916-84511 09917-18210 09917-68220 09917-98221

Tweezer Wrench for adjusting the valve Fixing wrench of the timing belt Sealing installer of the valve rod
clearance wheel of the camshaft

09918-08210 09926-18210
Hose connector of the vacuum gauge Catheter of the oil seal
09924-17810 Ethylene based resin
Flywheel fixer

Schedule 2 special tools for transmission repairing

Chana·Benni MINI
301-01-41 Engine summarize 301-01-41

Socket
wrenches 10、
Ratchet spanner 12、13 and 34

Rubber hammer Copper bar

Two long flat

Fixed wrench screw-drivers

Bent retaining
Auxiliary installing ring calipers
tool of the right used for holes
bearing of the
intermediate axle

Auxiliary
Auxiliary tool of the installing tool
of the Gear-IV
gear axle
Gear I axle sleeve of sleeve of the
the intermediate axle input axle

Chana·Benni MINI
301-01-42 Engine summarize 301-01-42

Bearing clamp of Clipping tool

right bearing of the for installing
input axle the Gear I axle
sleeve of the
intermediate
axle

Inner ring of the Auxiliary tool

bearing of the Gear II
axle sleeve of
the
intermediate
axle

Auxiliary
Auxiliary installing installing tool
tool of the left of the right
bearing of the bearing inside
intermediate axle track of
differential

Clipping tool for Auxiliary

installing the bolts of installing tool
differential of signal
panel

Auxiliary
installing tool
Auxiliary installing of the right
tool of the right oil bearing outer
seal of differential race of
differential

Chana·Benni MINI
301-01-43 Engine summarize 301-01-43

Clipping tool for Auxiliary

installing the outer installing tool
race of the of the oil seal
differential bearing of the
intermediate
axle

Auxiliary installing
tool of the oil seal
of the intermediate
axle

Required Maintenance Materials

Material Recommended Product Usage
Sealant Silicone rubber plane sealant: Letai 5900 ● Binding the cylinder body and oil pan surface
● Binding the camshaft housing surface
Thread Letai 262 Used for the threads to be locked
clocking glue

Chana·Benni MINI
301-02-1 Cooling System of Engine 301-02-1

Section 301-02 Cooling System of Engine

Applicable Vehicle Model: Benni.MINI

Contents

General............................................................................................................................................................... 301-02-2
Cooling Circulation ......................................................................................................................................... 301-02-2
Cooling Fan ..................................................................................................................................................... 301-02-2
Temperature Sensor of Engine Coolant........................................................................................................... 301-02-3
Failure Diagnosis................................................................................................................................................. 301-02-3
Maintenance ........................................................................................................................................................ 301-02-4
Coolant ............................................................................................................................................................ 301-02-4
Fluid Level of Coolant .................................................................................................................................... 301-02-5
Maintenance of Cooling System ..................................................................................................................... 301-02-5
Emptying and Refilling of Cooling System .................................................................................................... 301-02-6
Water Pump Belt Tension ................................................................................................................................ 301-02-6
On-vehicle Maintenance ..................................................................................................................................... 301-02-7
Draining of Cooling System......................................................................................................................... 301-02-7
Water Pipe or Hose of Cooling System..................................................................................................... 301-02-7
Thermostat..................................................................................................................................................... 301-02-8
Water Pump Belt ............................................................................................................................................. 301-02-9
Heat Radiator................................................................................................................................................... 301-02-9
Water Pump ..................................................................................................................................................... 301-02-9
Required Maintaining Material ........................................................................................................................ 301-02-10

长安•奔奔.MINI
301-02-2 Cooling System of Engine 301-02-2

General
The cooling system comprises a heat radiator, a water storage bottle of the coolant, a hose, a water pump, a cooling
fan and a thermoatat. The heat radiator adopts the pipe-piece type.
Cooling Circulation
1) When the engine is warmed, (the thermoatat is closed), the circulation of the coolant is shown as follows:
Water pump Cylinder body Cylinder cover thermosistor

Throttle valve body

Water outlet pipe of the heat radiator
Warming and ventilation radiator
2)When the coolant is heated to be at the normal temperature, the thermoatat is opened, and the coolant can flow
through the core of the heat radiator, and circulates according to the following circuit.

1. Radiator 2.Water inlet pipe of the heat radiator

3.Heating and ventilation device
4. Water outlet pipe of the heat radiator
5. Throttle valve body 6.Water pump pulley
7. Water pump 8.Thermoatat
9. Water storage bottle
10. Water storage bottle cover 11.Cylinder cover
12.Cylinder body

Cooling Fan
The cooling fan is driven by a motor, and the motor is driven by ECU (and the ECT sensor). See Generator and
Emission Controlling System for detailed information.

Warning:
In order to avoid the danger of being scalded:
When the coolant is “boiling”, the cover of the water
storage bottle can not be opened.
When the motor and the heat radiator are still hot,
the cover of the water storage bottle can not be opened.
The boiling fluid or vapor may be sprayed outwards
under the effect of the pressure, because the cover of the
water storage bottle is opened early.

长安•奔奔.MINI
301-02-3 Cooling System of Engine 301-02-3

Water Temperature Sensor of Engine

(ECT Sensor)
The ECT sensor is positioned at the thermoatat seat. The sensor can drive the water temperature gauge and the
cooling fan.

Failure Diagnosis
Failure Cause Solution

· The water pump belt is loosened or cracked Adjust and replace

· The coolant is insufficient Check the water level of the
· The thermosistor has a failure coolant, and if necessary, add the
· The water pump failure coolant to be full.
· The heat radiator sheet is dirty or bent Replace.
· The coolant is leaked from the cooling system Replace.
· The cooling fan motor or switch is out of order Clean or modify.
The engine is
· The heat radiator is blocked Repair.
overheated
· The cover of the water storage bottle has a failure Check, and if necessary, replace.
· The ignition timing is maladjusted Check, and if necessary, replace the
· The brake is bitten deadly heat radiator.
· The clutch slides Replace.
Adjust.
Adjust the brake.
Adjust or replace.

长安•奔奔.MINI
301-02-4 Cooling System of Engine 301-02-4

Maintenance

Coolant used.
The cooling and circulating system is a standard · When the coolant is required t be added, the ethylene
system. The coolant in the heat radiator can expand glycol cooling tower shall be added, to avoid that the
when being heated, and the overflow is collected in anti-freezing temperature is lower than -36℃ (-33℉).
the water storage tank. After the system is cooled
down, the coolant can flow back to the heat radiator. Notes:
Before the cooling system leaves the factory, the · The coolant of alcohol or methanol or the coolant
high-quality anti-freezing coolant of water and only adopting water can not be used in the cooling
ethylene glycol with a 50/50 proportion is filled fully system, otherwise, the failure of the cooling system
(when the freezing temperature can not be expected to can be caused.
be reached in the market, the proportion is 70/30). · Even if the ambient temperature can not be expected
The temperature of the anti-freezing fluid with a to reach the freezing point, the coolant with 70% of
50/50 proportion can reach -36℃ (-33℉). water and 30% of the ethylene glycol
The anti-freezing temperature of the cooling system (anti-freezing/anti-rust coolant) shall be used, to avoid
shall be kept at -36℃ (-33℉), to ensure that the rust the rusting and lubrication.
resistance and the coolant loss due to the ebullition.
Even if the ambient temperature is not lower than the
freezing temperature, the anti-freezing fluid shall be

Anti-freezing Fluid Proportion Table

Anti-Freezing Fluid Proportion Table

℃ -16 -36
Freezing point temperature
℉ 3 -33

Concentration of the
% 30 50
anti-freezing/anti-rust coolant

ltr. 2.1/4.9 3.5/3.5

Matching proportion of the
USpt. 4.43/10.34 7.39/7.39
coolant

lmp pt. 3.7/8.62 6.16/6.16

Heat radiator of the engine and the heating and About 1.8L
ventilation core（1.5+0.3） （6.12/5.1 US/lmp.pt.）
Coolant capacity

About 1.5L
Water storage bottle
（4.22/3.52 US/lmp.pt.）
About 2.9L
Others
（4.43/3.70 US/lmp.pt.）
About 6.2L
Total value
（14.77/12.32 US/lmp.pt.）

长安•奔奔.MINI
301-02-5 Cooling System of Engine 301-02-5

Fluid Level of Coolant

In order to check the fluid level, open the engine bonnet and observe the “transparent” water storage bottle of the
coolant.

Warning:
In order to avoid the danger of being scalded, when
the engine and the heat radiator are still hot, the cover
of the water storage bottle shall not be disassembled.
The boiling fluid or vapor may be sprayed outwards
under the effect of the pressure, because the cover of the
water storage bottle is opened early.

When the motor is cooled, check the fluid level of the

coolant in the water storage bottle. The normal fluid level
of the coolant shall be positioned between the Max mark
and Min mark of the water storage bottle.
When the fluid level of the coolant is lower than the Min
mark, the water storage bottle shall be opened, and an
amount of coolant shall be added, to ensure that the water
level is raised up to the Max mark. Then, the cover of the
water storage bottle shall be well installed again.

Notes:
● If the coolant with same quality is used, the extra
inhibitor or additive is not required to be added to protect
the system. The extra inhibitor or additive is harmful to
the operation of the system and also is unnecessary waste.
● When being installed, the cover of the water storage
Servicing of Cooling System bottle is installed properly.
The servicing of the cooling system shall be
performed as follows:
1) Check whether the cooling system has leakage or is damaged.
2) When the engine is cooled, the cover of the water storage bottle shall be removed, and the cover of the water
storage bottle and the filling mouth shall be cleaned.
3) Check the fluid level of the coolant for appropriateness or for the anti-freezing function.
2
4) Check whether the pressure of the cooling system is kept within 145±10KPa(1.45kg/cm ).
If the cooling system is found to have any leakage, the failure point shall be repaired.
If the cover of the water storage bottle is found to have some problems, the new cover shall be used for replacement.
5) Tighten the hose, and check all hoses, replace the broken, expanded hoses or other the hoses with other defects.
6) Clean the front part of the core of the heat radiator.
Emptying and Refilling of Cooling System
长安•奔奔.MINI
301-02-6 Cooling System of Engine 301-02-6

1) After the engine is cooled, the over of the water storage bottle shall be disassembled. The cover
shall turn the cover of the water storage bottle slowly in the anti-clockwise direction, and after the
pressure is released, the cover shall be pressed down, and turned continuously in the anti-clockwise
direction.
2) After the cover of the water storage bottle is opened, the engine shall operate until the upper hose of
the heat radiator has been hot (it proves that the thermoatat has been opened, and the coolant has
begun to flow through the system).
3) Stop the engine and drain the coolant.
4) Add water to the system until the system is full, and operate the engine until the upper hose of the
heat radiator has been hot again. Warning:
5) Repeat the third and forth procedures until the color of the In order to avoid the danger of being
drained fluid is close to be colorless. scalded, when the engine and the heat
6) Seal the connecting line of the cooling system after
radiator are still hot, the cover of the water
draining it.
storage bottle shall not be disassembled. The
7)Disassemble the water storage bottle, open the cover of the boiling fluid or vapor may be sprayed
water storage bottle, take down the water storage bottle, pour outwards under the effect of the pressure,
out the fluid, clean the inside of the water storage bottle with because the cover of the water storage bottle
the soapy water, flush thoroughly with the clean water and is opened early.
drain completely, and well install the water storage bottle
and the hose.
8)Add the mixed coolant of high-quality ethylene glycol and water with a 50/50 proportion into the
water storage bottle and the heat radiator.
9）After the engine operates for a period of time, the coolant does not decrease. The cover of the water
storage bottle shall be covered again, and the engine shall operate for two minutes again. Observe the
fluid level of the coolant. If the fluid level is not within the scale scope, the coolant shall be added to
the water storage bottle until the fluid level of the water storage bottle reaches to the Max mark. The
cover of the water storage bottle shall be screwed up.
10)If the air still exists in the cooling system, the ninth
step shall be repeated.
Water Pump Belt Tension
1）Check whether the belt has crack, incised wound, distortion,
abrasion or dirt. If necessary, replace the belt, and see the
Installation and Disassembling of Water Pump Belt.
2) Check the belt tension; if the water pump belt is too loose,
the generator voltage shall be influenced and the belt shall be
too hot and abraded in the early period. When the inspection
is performed, the middle part of the belt is pressed down with
the force of 100 N, and the belt shall be sunk to be 5 to 6mm
deep.
3) Connect the cathode wire to the battery terminal.

长安•奔奔.MINI
301-02-7 Cooling System of Engine 301-02-7

Warning:
● Before the tension of the belt is checked and
adjusted, the cathode electric wire shall be cut off.
● Read Warning of the Servicing of the Cooling System

On-vehicle Maintenance
Draining of Cooling System
1) Disassemble the cover of the water storage bottle.
2) Loosen the draining plug on the heat radiator, so as to drain the coolant.
3) Make sure every part is at where it was after draining the coolant.
4) Fill the cooling system. (See the part Coolant in Maintenance.)

Cooling Water Pipe or Hose Warnings:

Disassembly
1) Empty the cooling system.
2) In order to disassemble the cooling water pipe
or hose, the pipe clip bolts of each water pipe or
hose shall be loosened, and the hose shall be
drawn out.
● Before any part of the cooling system is disassembled,
check and ensure that the coolant has been cooled.
● Ensure that the cathode wire is disconnected from the
battery terminal before any part of the engine is
disassembled.

Installation
The installation shall be performed according the sequence opposite to the disassembly sequence, and includes the
following points:
1) The pipe clip bolts shall be tightened.
2) Fill the cooling system with the correct coolant, and see Section Maintenance for the instruction related to the
coolant.
3) The water pipe shall be installed on the water pump, and the new O-shaped ring shall be used.

Thermosistor
Disassembly
1) Disassemble the cathode conduction wire of the battery.
2) Empty the coolant and screw up the draining plug.
3) Disassemble the thermosistor cover from the thermosistor
seat.
4) Take out the thermosistor.

Inspection
1) Check whether the air exhaust valve of the thermosistor is
complete. If the valve is blocked, the overheating phenomenon
of the engine can be caused.
2) Check whether the valve seat has foreign matters; ensure that
the valve seat shall have no foreign matter; otherwise, the
installation of the valve can not be tight.
3) Check whether the sealing part of the thermosistor has the
长安•奔奔.MINI
 301-02-8 Cooling System of Engine 301-02-8

breakage, distortion and other damages.

4) Check the constant temperature motion of the wax ball
according to the following steps:
a) Immerge the thermosistor in water, and heat the water
gradually.
b) Check whether the temperature when the valve is opened
the specified temperature.
c) If the temperature when the valve is opened is lower than
or higher than the specified temperature obviously, a new
thermoatat shall be used for replacement. The super-cold or
super-heat trend can be caused by using the thermoatat with
the temperature which does not comply with the specified
temperature.

sembly Function Specifications of Thermosistor

1）Assemble the thermosister into it’s base.

2）Assemble the thermosister cover. Temperature when the valve is
3）Fill coolant into the cooling system. 88℃±2℃
opened
4）Connect the cathode line of the storage battery.
5）Check the leaking of every part after assembly.
Temperature when the valve is
95℃
Water Pump Belt completely opened
Disassembly
1) Disconnect the cathode electric wire from the battery.
2) Loosen the tightening nuts of the water pump belt.
3) Take down the front-end belt.
Installation

1) The water pump belt is sleeved on the water pump pulley,

the generator belt pulley and the crankshaft belt pulley, and
the surface of the water pump belt with the words is rightly
arranged towards the inside, that is, the character heads of the
words face the engine.
Water pump belt pulley 2) Screw up the bolts of the generator belt adjusting block by
a wrench, to ensure that the water pump belt is tightened.
Water pump
Bolt of the belt
water pump belt When the pressing force of 100 N is exerted on the water
pump pulley and the crankshaft pulley, the flexibility is 5 mm
to 6 mm.
3) Connect the cathode electric wire of the battery well.
Torque of the water pump pulley: 9-12 N.m

长安•奔奔.MINI
301-02-9 Cooling System of Engine 301-02-9

Heat radiator
Disassembly
1) Disconnect the electric wire of the negative electrode wire of the battery.
2) Disconnect the adapter of the cooling fan motor.
3) Disconnect the water inlet and outlet hoses of the heat radiator and the hose of the water storage bottle.
4）Remove the fan motor from the heat radiator.

Inspection
Check whether the heat radiator has leakage or
Notice：
●Fill the coolant in the cooling system according
damage, and straighten any bent blade.
to the asking of cooling system in the part of
Cleaning
maintenance
Clean the front area of the core of the heat radiator.
● Check the leaking of every connector after
Installation
assembly.

The installation is performed according to the procedures

opposite to those disassembly ones.

Disassembly
1) Disconnect the cathode electric wire of the battery.
2) Empty the cooling system.
3) Remove the timing belt, the tensioning wheel and the
timing wheel.
4) Take out the water pump assembly.

Inspection

1) Rotate the water pump by hand, to observe whether the

operation is flexible. If the rotation of the water pump is
not flexible or generates noise, the water pump shall be
Notes: replaced.
Do not disintegrate the water pump 2) Check whether the impeller of the water pump is
assembly. damaged. If necessary, replace the impeller of the water
If the water pump needs repairing, the pump.
assembly shall be replaced.
Notes:
Do not disintegrate the water pump assembly.

Installation
1) Install the new water pump on the cylinder body.
2) Install the water pump on the cylinder body.

长安•奔奔.MINI
301-02-10 Cooling System of Engine 301-02-1
0

Screwing torque: 9-12 N.m

3) After the water pump is installed well, install the

crankshaft timing belt pulley, the camshaft timing belt
pulley, the tensioning wheel, the timing belt and the outer
cover for the timing belt.
4) Install the crankshaft belt pulley, the water pump belt
pulley, and the transmission belt for the water pump.
5）Adjust the tightness of the water pump belt according to
the method mentioned above.
6) Connect the cathode electric wire of the battery.
7) Fill the cooling system.
8) After the installation is finished, check whether each
part has leakage.

Required Maintaining Material

Material Using
Fill the cooling system of the engine, to strengthen the
Ethylene-glycol coolant (anti-freezing/anti-rust coolant)
cooling effect and to avoid the corrosion.

长安•奔奔.MINI
 301-03-1 Manual Transmission 301-03-1

301-03 Section Manual Transmission

Applicable vehicle model: Changan.Benni.MINI

Catalogue
Maintenance of transmission....................................................................................................................... 301-03-2
Structure of transmission............................................................................................................................. 301-03-2
Maintenance and instructions of transmission........................................................................................... 301-03-10
Assembly and disassembly of transmission .............................................................................................. 301-03-12
Malfunction diagnosis and handling method ............................................................................................. 301-03-19

Changan·Benni MINI
 301-03-2 Manual Transmission 301-03-2
Transmission Maintenance
Structure of transmission
MF508C01 is a new type of mechanical transmission with high technology. The
transmission is manual synchronal mechanical transmission with five advancing gears and
one reverse gear. The gearshift mechanism is portable and it has no impact noise. The
maximum input torque is 85Nm. The driving efficiency, synchronizer lifespan, fatigue lifespan,
noise and cleanliness reached the advanced level in domestic market. This series have
structure of left and right housing model with high rigidity and easy to manufacture, facilitated
to disassemble and assemble. The synchronizer is adopted in the transmission and the
gearshift is reliable, stable and flexible.

This series of transmission apply in FF vehicles, this series get strong adaptability,
which can match various engine types with displacement below 1.6L, comparing with other
transmission types in domestic market, their cost performance is better and market prospect
is wider.
1 Function and working principal
1.1 Function
a、Enlarge the changing range of torque and rotating speed of engine to meet various
power needs under different conditions.
b、Realize reverse driving without changing the rotating direction of camshaft.
C、Cut off the power transfer to meet the needs of short drive and sliding , etc.

1.2 Working Principal

Transmission can change speed, torque and rotating direction by shifting various gears.
The particular transfer routine is illustrated in section 1.4.2

1.3 Main technical parameters

Transmission Max input Max output rotating

Type torque speed transmission ratio
(N.m) （rpm）
1st 2nd 3rd 4th 5th Reverse
MF508C01 85 3500±500 3.417 1.905 1.28 0.967 0.818 3.583

1.4 Structure of Transmission MF508C01

It mainly consists of the following parts: right housing, left housing, input shaft
groupware, countershaft groupware, main shaft groupware, differential groupware, gearshift
and transposition groupware(see chart 1).
The transmission has two shafts: input shaft is parallel to countershaft and reverse gear
shaft. The power is input from the input shaft, then to countershaft and output from differential.
The gearshift is realized by cooperation of gearshift arm groupware and transposition arm
groupware, the inertia synchronizer helps to make smooth gearshift.

1.5 Power transfer routine of transmission

Transmission MF508C01 depends on gears and synchronizer to realize the transfer
and switch of power. The transfer route of each gear is as follows:

Changan·Benni MINI
301-03-3 Manual Transmission 301-03-3

Illustrative structure figure of Transmission MF508C01

1st gear: input shaft→input shaft 1st drive gear→countershaft 1st drive gear→low speed
synchronizer→countershaft→countershaft drive gear→ differential
2nd gear: input shaft→input shaft 2nd drive gear→ countershaft 2nd drive gear→low speed
synchronizer→countershaft→countershaft drive gear→differential
3rd gear: input shaft→input shaft 3rd drive gear→countershaft 3rd drive gear→ high speed
synchronizer →countershaft→countershaft drive gear→differential
4th gear: input shaft→input shaft 4th drive gear→countershaft 4th drive gear→high speed
synchronizer →countershaft→countershaft drive gear→differential
5th gear: input shaft→input shaft 5th drive gear→countershaft 5th drive gear→5th gear
synchronizer→countershaft→countershaft drive gear→differential
Reverse gear: input shaft→input shaft reverse drive gear→reverse idle
gear→countershaft reverse drive gear (low speed synchronizer sleeve)
→countershaft→countershaft drive gear→differential

Changan·Benni MINI
301-03-4 Manual Transmission 301-03-4
1.6 Parts list
Parts of transmission box and housing

Changan·Benni MINI
 301-03-5 Manual Transmission 301-03-5
Parts of transmission box and housing
No. Parts name Parts code Quantity No. Parts name Parts code Quantity
Transmission
NO.1 stud bolt Differential right 1709161-MF5
1 0912100042 1 2 1
M10×1.25-M10 fluid seal 10A
×1.25×42
3 Right body 1701711-MF5 1 4 Bolts of oil-leading
06D01 plate M6×12-B 0905060012B 3
5 Oil-leading 1701814-MF 1 6 Left body 1701721-MF5 1
plate 508A01 10D2
7 换档止动螺栓 1709326-MF 1 8 Gearshift catch 0927100 1
510D02 gasket 10
9 Junction bolt 0904080040 13 10 Fluid inlet plug 1709905-MR4 1
M8×40 06A01
11 Fluid drain plug 1709904-MR 1 12 Differential left 1709162-MF5 1
508A01 fluid seal 10A
13 Locking bolts 0927100 1 14 Gearshift locking 1709323-MF5 1
gasket 10 bolts 10A01
15 Left box cover 1701730-MF 1 16 Left box cover 0905060012C 8
assembly 508A01 bolts M6×12-C
17 Reverse lamp 3729610-MF 1 18 Bolts of clutch 0904080016 2
switch 506A01 cable support
assembly M8X16
19 Clutch cable 1706250-MF 1 20 Gasket of reverse 1709202-MR5 1
support 506D01 gear shaft bolts 10A01
assembly
21 Bolts of reverse 1709351-MR 1 22 Oil-transporting 1701810-MF5 1
gear shaft 510A01 groove assembly 08A01
23 Bolts of 0905060012 1 24 Bolts of gearshift 0904080025 4
oil-transporting B and transposition
groove support M8X25
M6×12-B
25 Transposition 1706242-MF 1 26 Gearshift cable 1706241-MF5 1
cable support 506A01 support 06A01
27 Clutch release 1706265-MF 1 28 Clutch rotating arm 1706266-MF5 1
bearing 506D01 06D01
29 Nuts of clutch 1709304-MR 1 30 Bolts of clutch 0904080040 1
rotating arm M8 508A01 rotating arm
M8×40
31 Seal circle of 1709170-MF 1 32 Clutch fork shaft 1709706-MF5 1
clutch fork shaft 508A01 No.2 sleeve 08A01
33 Returning 1706269-MF 1 34 Clutch shift fork 1706210-MF5 1
spring of clutch 506D01 assembly 06D01
shift fork
Transmission
Clutch fork
1709705-MF NO.2 stud bolt
35 shaft No.1 1 36 0912100050 1
508A01 M10×1.25-M10×1.
sleeve
25×50

Changan·Benni MINI
301-03-6 Manual Transmission 301-03-6

Parts of transmission gears

Parts of transmission gears

No. Parts name Parts code Qu No. Parts name Parts code Qua
ant ntity
ity
1 Input shaft 1700401-MF 1 2 Input shaft 1701111-MF 1
groupware 508C01 508C01
3 Input shaft 1709401-MF 1 4 Input shaft 3rd 1709455-MR 1
right bearing 510A01 gear roller 510A01
bearing
5 Input shaft 3rd 1701231-MF 1 6 Input shaft 3rd 1701232-MR 1
gear 510A01 gear ring 510A01
7 High speed 1701432-MF 2 8 High speed 1701442-MR 2
synchronizer 510D02 synchronizer 510A01
ring spring

Changan·Benni MINI
301-03-7 Manual Transmission 301-03-7
9 Gear shell of 1701412-MR 1 10 High speed 1701472-MR 3
high speed 510A synchronizer 510A01
synchronizer slider
11 Gear cover of 1701422- 1 12 High speed 1709522-MR 1
high speed MF510D02 synchronizer 510A01
synchronizer circlip
13 Input shaft 4th 1701242-MF 1 14 Input shaft 4th 0934253022 1
gear ring 510A01 gear roller 1
bearing
15 Input shaft 4th 1701241-MF 1 16 Input shaft left 1709402-MF 1
gear 506E01 bearing 510A01
17 Left body 1701751- 1 18 Bolts of left GB819-85 6
bearing press MF508A01 body bearing
plate press plate
19 Input shaft 5th 1709721-MF 1 20 Input shaft 5th 1701250- 1
gear shaft 510A01 gear assembly MF508C01
cover
21 Input shaft 5th GB5846-86 1 22 5th gear 1701434-MR 1
gear roller synchronizer 510A01
bearing ring
23 5th gear 1701474-MF 3 24 Geer shell of 1701414-MF 1
synchronizer 510A01 5th 510A01
slider synchronizer
25 5th 1701424-MF 1 26 5th gear 1701443-MR 3
synchronizer 510A01 synchronizer 510A01
sleeve spring
27 5th gear 1709524-MF 1 28 5th gear 1701484-MF 1
synchronizer 510A01 synchronizer 510A01
circlip press plate
29 Reverse idle 1701560-MF 1 30 Reverse idle 1701512-MF 1
gear assembly 508A01 gear shaft 510A01
sleeve
31 Reverse gear 1701511-MF 1 32 Countershaft 1700502- 1
shaft 508A01 groupware MF508C01
33 Countershaft 1701131- 1 34 2nd gear 1701439-MF 1
MF508C01 synchronizer 510D02
ring
35 Low speed 1709521-MR 1 36 Low speed 1701441-MR 2
synchronizer 510A synchronizer 510A01
circlip spring
37 Low speed 1701421-MF 1 38 Gear shell of 1701411-MR 1
synchronizer 506D01 low speed 510A01
sleeve synchronizer
39 Low speed 1701471-MR 3 40 1st gear 1701431-MF 1
synchronizer 510A01 synchronizer 510D02
slider ring
41 Countershaft 1709452-MR 1 42 Countershaft 1701311-MF 1
1st gear roller 510A01 1st gear 510A01
bearing
43 Outer circle of 1709422-MF 1 44 Countershaft 1701321-MF 1

Changan·Benni MINI
301-03-8 Manual Transmission 301-03-8
countershaft 510A01 2nd gear 508C01
right bearing
45 Countershaft 1709453-MR 1 46 Countershaft 1701331-MF 1
2nd gear roller 510A01 3rd gear 510A01
bearing
47 Third-fourth 1709707-MF 1 48 Countershaft 1701341-MF 1
gear spacer 510A01 4th gear 510A01
cover

49 Countershaft 1709430-MF510 1 50 Countershaft 1709208/1-16-MF510 1

left bearing A01 adjusting A01
assembly gasket
51 Countershaft 1701351- 1 52 Countershaft 1709302-MF510A01 1
5th gear MF508C01 nut
53 Differential 2303300- 1 54 Differential 09306207P53 1
groupware MF508C01 left bearing
6207
55 Differential 0905100021A 8 56 Final drive 2303511-MF510J01 1
bolt gear
57 Gasket of 1709218/1-7-MF 2 58 Differential 2303341-MF510A01 2
differential 510A01 axle
axle
59 Planet gear 2303331-MF510 2 60 Planet gear 2303351-MF510A01 1
A01 shaft
61 Gasket of 1709228-MF510 1 62 Differential 2303411-MF510A01 1
planet gear A01 case
63 Pin of planet 0903053030 1 64 Signal plate 1703121-MF506D01 1
gear shaft
65 Right 09306007P53 1
bearing of
differential
6007

Changan·Benni MINI
301-03-9 Manual Transmission 301-03-9

Parts of transmission gearshift mechanism

N Parts name Parts code Qua No. Parts name Parts code Quan
o. ntity tity
1 first-second 1 2 gearshift locking 5
1702411-MF510A01 0932007938
shift lever steel ball
3 gearshift 3 4 gasket of locking 0927100 3
1702415-MF506D01
spring bolts10
5 gearshift 1709323-MF510A01 3 6 first-second shift 0903045020 6
locking bolts fork pin 4.5X20
7 first-second 1702271-MF508A01 1 8 first-second shift 1702211-MF508A 1
fork fork 01
9 Third-fourth 1702221-MF508A01 1 10 Third-fourth fork 1702281-MF508A 1
shift fork 01
11 Third-fourth 1702421-MF508A01 1 12 Fifth-reverse 1702451-MF508A 1
shift lever shift lever 01
13 fifth-reverse 1702452-MF508A01 1 14 reverse shift 1702241-MF508A 1
shift guiding cantilever 01
lever
15 Reverse shift 1702290-MF508A01 1 16 reverse shift 1702242-MF510A 1
fork cantilever spring 01
17 Reverse shift 0945080020 2 18 Fifth-reverse fork 1702261-MF508A 1
fork bolts 01
M8×20
19 Bolts of 5th 1709909-MF510A01 1 20 Fifth shift fork 1702231-MF508A 1

Changan·Benni MINI
 301-03-10 Manual Transmission 301-03-10
shift fork 01

No. Parts name Parts code Qua No. Parts name Parts code Quantit
ntity y
1 Transposition 1700531-MF510D02 1 2 Transposition 1709211-MR510A 3
shaft groupware shaft ‘E’ shaped 01
circlip
3 Gasket of low 1702579-MF510D02 2 4 Low speed 1702576-MF510D 1
speed returning returning spring 02
spring
5 Gasket of 1709209-MR510A01 1 6 Transposition 1702531-MF510D 2
transposition shaft 02
shaft
7 Gearshift 1702611-MF510D02 1 8 Steel ball of 0932005556 2
rotating arm gearshift rotating
arm
9 Gearshift 1702613-MF510D02 1 10 Spring of 1702575-MF510D 1
interlocking plate gearshift rotating 02
arm
11 High speed 1702577-MF510D02 1 12 Gasket of high 1702578-MF510D 1
returning spring speed returning 02
spring
13 Bolts of gearshift 0905060012B 2 14 Gearshift guiding 1702562-MF508A 1
guiding case case press plate 01

Changan·Benni MINI
 301-03-11 Manual Transmission 301-03-11
press plate
15 Reverse lock 1709809-MR510A01 1 16 Reverse lock 1702582-MR510A 1
cam seat pin cam seat
17 Reverse lock 1702583-MF508A 1 18 Reverse lock 090305020 1
returning spring cam pin 5×20
19 Reverse lock 1702581-MF508A 1 20 Gearshift guiding 0928060012 2
cam case locating pin
M6×12
21 Fifth-reverse 1709334-MF510A01 1 22 Reverse guiding 1702572-MF508A 1
interlocking bolts case 01
23 Gearshift guiding 3 24 Gearshift and 1
1709120-MF508A
case bolts 0904080025 transposition
01
M8×25 shaft oil seal
25 Transposition 1 26 Gearshift tumbler 1702640-MF506A 1
1702651-MR510A01
shaft dust guard assembly 01
27 Gearshift 1709806-MR510A01 1 28 Gearshift tumbler 1709803-MR510A 1
tumbler outer pin inner pin
29 Gearshift guiding 1 30 1
Transposition arm 1702630-MF508A
case bolts 0904080075
support assembly 01
M8×75
31 Transposition 1 32 1
Guiding shaft 1702624-MF508A
tumbler support 0904080025
inner dust guard 01
bolts M8×25
33 Transposition 1 34 Transposition arm 1702559-MF508A 2
1702559-MF508A01
arm pin roll lining pin roll lining 01
35 Transposition 2 36 gasket of guide 1709203-MF508A 1
1702620 MF508A01
arm assembly shaft 01
37 Guiding shaft 1 38 Nuts of guide 1
1706226-MF508A01 GB6170-86
gasket shaft M8-6H
39 Guiding shaft 1 40 Transposition 1700601-MF508A 1
1702625-MF508A01
outer dust guard groupware 01
41 Gearshift catch 1 42 Gearshift catch 1
1709326-MF510D02 0927100
bolts gasket10
43 Inner pin of 1 44 Outer pin of 1
1709806-MR510A
gearshift rotating 1709803-MR510A01 gearshift rotating
01
arm arm

Use and Maintenance Method

Use of Transmission
1）. Appropriate speed for each forward gear
Gear 1st 2nd 3rd 4th 5th
Speed(km/h) 5 ～ 20 ～ 30 ～ 40 ～ 50 ～
20 50 70 100 130
Attention:
1 The shift operation should be carried out within the above speed ranges.
2 The appropriate speed ranges vary with the vehicle model.

2）．Shift principal

Changan·Benni MINI
301-03-12 Manual Transmission 301-03-12
As the vehicle is moving forward, you should shift as follows: the accelerating shift should
be from 1st gear to 5th gear gradually, while decelerating shift should be from 5th gear to 1st
gear gradually; it’s forbidden to shift into reverse gear when moving forward. In order to
prevent shifting from 5th gear to reverse gear directly, the transmission is equipped with
locking device.

In principal, only when the vehicle is still can the gear be shifted to reverse gear. Do not
shift to reverse gear when the vehicle is moving forward and do not shift to forward gear when
the vehicle is reversing.
Attention: in emergency, the gear shifting principal can be ignored.

3）.Transmission Maintenance
The transmission oil recommended is GL-4 75W-85 gear oil, and the oil capacity is 2.1L.

4）.The transmission oil we use is lifelong maintenance-free oil. Therefore, the transmission oil
does not need to be replaced in initial maintenance. We suggest that it can be replaced
according to customer’s desire after 10000km.
5）.Regular maintenance interval is given in the following table:

Km 1×104 2×104 3×104 4×104 5×104 6×104 7×104 8×104

Month 6 12 18 24 30 36 42 48
Item B H B H B H B H

Notes: 1. The maintenance intervals should be judged by mileage or month, whichever

4
comes first. The table above shows the regular maintenance within 8×10 kilometers, and if
4
it exceeds 8×10 kilometers, please maintain the transmission as the same interval.
2．The maintenance interval is suitable for various road conditions (repeated short
journey; rough or muddy road; dusty road; extremely cold season; saline and alkaline road;
repeated short journey in extremely cold season)
3. B: during check and maintenance, replace the transmission oil if necessary; H:
replace the transmission oil
4 .Even not for replacing the gear oil but for other work, you should also check the
transmission for oil leak when lifting the vehicle

Maintenance and trouble-shooting

7）. During maintenance, the check method of transmission oil is as follows:
（1） Make sure the vehicle is in level state for oil level check.
（2） Inspect whether the transmission has oil leak. If there is, please repair the leaking
part. The repairing method is illustrated in chapter 3 Assembly and disassembly of
transmission.
（3） Remove the fluid inlet plug;
（4） Check the oil level. Through the fluid inlet hole, we can roughly inspect the oil level:
remove the fluid inlet plug, if the transmission oil is flowing out from the hole, or you can see
the oil level has reached the hole, it means the oil level is normal. Otherwise, we should add
the specified oil until it reaches the fluid inlet hole.
8） The method of replacing transmission oil is as follows:
1 Before replacing the oil, shut off the engine and then lift the vehicle flatly.
2 After lifting the vehicle, check the oil level and oil leak. If there is oil leak, repair it.

Changan·Benni MINI
301-03-13 Manual Transmission 301-03-13
3 Remove the fluid drain plug to drain out the used oil, and then fill in specified oil with
specified oil capacity (fill to the fluid inlet hole).
4 Smear sealant on the fluid drain plug and tighten it to the specified torque
5 Remove the fluid inlet plug
6 Fill in specified oil with specified oil capacity (fill to the fluid inlet hole).
7 Smear sealant on the fluid inlet plug and tighten it to the specified torque

◆During maintenance, if it is found that the oil seal of input shaft has oil leak, please
replace the oil seal according to chapter 3 Assembly and disassembly of transmission.
◆During maintenance, if it is found that the oil seal of output shaft has oil leak, please
repair it. The method of replacing the oil seal is as follows:
1 Hoist the vehicle and drain out the used oil
2 Remove the bolts and stopper gasket，use a screwdriver to prize the drive shaft, and
remove it from the drive axle
3 Push back the drive shaft to break off the spline of half axle and the spline of drive shaft,
and then take off the drive shaft;
4 After taking off the oil seal, smear lubricating grease on the new oil seal. Install the new
oil seal with special tools and hammer.
5 Insert the drive shaft to the spline of half axle and install to the original position, and
make sure the drive shaft rotates well
6 Tighten the bolts of drive shaft to the specified torque, and install a catch gasket
7 Fill the transmission fluid to the specified capacity and check whether the oil seal
Attention：The drive shaft should not damage the lip part of the oil seal.

Assembly and disassembly of transmission

3.1 Disassembly of transmission

3.1.1 Drain out the oil
Use a wrench to remove the fluid drain plug, and drain out the oil. It’s not allowed to drain
out the oil from other position.
3.1.2 Remove the gearshift lever cable support

Changan·Benni MINI
301-03-14 Manual Transmission 301-03-14

Use a ratchet wrench to remove the bolts of cable support.

3.1.3 Remove the junction bolts on the clutch side

3.1.4 Remove the bolts of left case

Use a ratchet wrench to remove the bolts of left case and take out the countershaft 5th gear
and input shaft 5th gear

3.1.5 Remove the locking nuts of countershaft

3.1.6 Remove the bolts of 5th synchronizer shift fork

Changan·Benni MINI
301-03-15 Manual Transmission 301-03-15

Take out the 5th synchronize and the 5th shift fork

3.1.7 Remove the nuts of input shaft

Use pliers to remove the outer circlip of countershaft rear bearing
3.1.8 Remove the bolts of interlocking plate

3.1.9 Remove bolts 1 of bearing press plate

Remove bolts 2 of bearing press plate

Changan·Benni MINI
301-03-16 Manual Transmission 301-03-16
Take off the bearing press plate

3.1.10 Remove the countershaft left bearing circlip.

Remove the input shaft left bearing circlip

3.1.11 Remove the junction bolts 1

Take off the left case

Changan·Benni MINI
301-03-17 Manual Transmission 301-03-17

3.1.12 Remove the bolts of reverse shift lever

Take out the reverse shift fork

Remove the reverse gear idler shaft and the reverse gear idler.

3.1.13 Take out the countershaft and input shaft groupware

Attention: Take the countershaft groupware, input shaft groupware, first-second shift fork
assembly, fifth-reverse shift lever assembly and third-fourth shift fork together.

3.1.14 Remove the differential.

Changan·Benni MINI
301-03-18 Manual Transmission 301-03-18

3.2 Check significant parts

3.2.1 Check the input shaft groupware
Check the gears of input shaft whether they are broken, corroded, worn or veneered, if
they are, replace the input shaft
Check the spline of input shaft if it is worn or damaged, if it is, replace the input shaft
To feel whether the bearing rotates well or it is stagnant. If it doesn’t rotate well or it is
stagnant, replace the bearing.

3.2.2 Check the countershaft groupware

Check the gears of countershaft whether they are broken, corroded, worn or veneered, if they
are, replace the countershaft
To feel whether the bearing rotates well or it is stagnant. If it doesn’t rotate well or it is
stagnant, replace the bearing.
3.2.3 Check the differential groupware
Check the gears of main gearbox whether they are broken, corroded, worn or veneered, if
they are, replace the output shaft
Check the planet gear and half axle gear and spline whether it is seriously worn or
damaged, if there is, replace it.
Check the condition of bearing outer circle and roller, if they are badly worn, please
replace the bearing.
3.2.4 Check the gear and synchronizer gear ring
Join the synchronizer gear ring to the matching gear conical surface and check the
clearance of the joining surface. The specific standard is as following chart. If the clearance
reaches or exceeds the limit, then the parts must be replaced.

Clearance of gear and the gear Theoretical Limited

ring surface clearance(mm) clearance(mm)

0.8～1.2 0.5

3.2.5 Check the synchronizer groupware

Changan·Benni MINI
301-03-19 Manual Transmission 301-03-19
Check the sliding flexibility of the synchronizer groupware, if there is stagnancy, replace
or repair it.

Attention：
1、 Clean all the parts
2、 Pour gear oil on the parts having relative
moving
3、 Swear lubricating grease on the circle
surface of roller bearing before
assembly
3.3 Main procedures of transmission
4、 Swear lubricating grease on the outer
assembly
circle and inner circle of deep ball
3.3.1 Install the differential groupware
bearing before assembly
5、 Swear lubricating grease on the lip of oil
seal before assembly
6、When press mounting the synchronizer
groupware, fist aim the slider to the slider groove
in the synchronizer gear ring and then press
mount the groupware

3.3.2 Install input shaft, countershaft and gear shift fork assembly

3.3.3 Install reverse gear and reverse gear shaft

Changan·Benni MINI
301-03-20 Manual Transmission 301-03-20

Attention:
1.The fork should be inserted into
the groove of synchronizer gear
cover
3.3.4 Install reverse gear shift fork 2、The three gearshift lever should
be enclosed to corresponding
hole
3、Do not injure the input shaft oil
seal when assembling input
shaft groupware

3.3.5 Join the two cases

Install the joining bolts

Changan·Benni MINI
301-03-21 Manual Transmission 301-03-21

3.3.6 Install the bolts of reverse gear shaft

3.3.7 Install the self-locking mechanism of transmission

Pay attention to the assembly procedures: Install the steel ball, spring and bolts

3.3.8 Install the gearshift housing

Changan·Benni MINI
301-03-22 Manual Transmission 301-03-22

3.3.9 Install the fifth-reverse interlocking bolts and gearshift limiting bolts

3.3.10 Install the circlip of input shaft left bearing and countershaft left bearing
3.3.11 Install the bearing press plate

Install the press plate bolts 1

Changan·Benni MINI
301-03-23 Manual Transmission 301-03-23

Install the press plate bolts 2

Attention:
1.the gum should be applied
evenly, not allowed for
degumming or off-gum
2.After applying the gum,
combine the housing in 15
minutes

3.3.12 Install the input shaft nuts

Install the input shaft 5th gear, please be attention that the surface with circle groove should
be downside.

Changan·Benni MINI
301-03-24 Manual Transmission 301-03-24

3.3.13 Install countershaft 5th gear roller pin, gear and gear ring

3.3.14 Install 5th synchronizer and shift fork

Install the bolts of 5th shift fork

Install the countershaft nuts

3.3.15 Install the interlocking press plate

Changan·Benni MINI
301-03-25 Manual Transmission 301-03-25

Attention: First install the interlocking pin, and then install the interlocking plate
Install the bolts

3.3.16 Install the left case cover

Changan·Benni MINI
301-03-26 Manual Transmission 301-03-26
Attention:
1.the gum should be applied
evenly, not allowed for
degumming or off-gum
2.After applying the gum,
combine the housing in 15
minutes

3.3.17 Install the cable support and bolts

3.3.18 Install the joining bolts 2

Changan·Benni MINI
301-03-27 Manual Transmission 301-03-27

Malfunction Diagnosis and Handling Method of Transmission

Malfunction Cause Handling method

y gearshift shaft wear Replace

y gearshift fork or synchronizer sliding Replace

sleeve wear Replace

Slips and out
y gearshift shaft location spring weaken Replace synchronizer
of gear
or damaged gear sleeve or gear

y synchronizer gear sleeve and

chamfer gear wear

y insufficient lubricant Add

y free travel of clutch pedal is wrong Adjustment

y clutch friction disc is deformed or Replace

damaged Replace pressure plate

Hard shifting y clutch pressure plate is damaged Replace

y synchronizer gear ring wear Replace synchronizer

y synchronizer gear sleeve or chamfer gear sleeve or gear

gear wear Replace

y gearshift shaft is deformed

y insufficient lubricant Add

y bearing damaged or wear Replace

Noise
y gear damaged or wear Replace

y synchronizer parts damaged or wear Replace

y input shaft oil seal wear or damaged Replace

y extension housing oil seal damaged Replace

Oil leak
or wear(oil seal damaged due to bad

quality of transmission shaft surface) Replace

Changan·Benni MINI
301-03-28 Manual Transmission 301-03-28

y oil leak at oil plug

1.1 Attention tips of using transmission
1.1.1 Please strictly conform to the requirements and specifications in this manual
1.1.2 Before using, fill in the lubricating oil as follows
The oil capacity of transmission MF508C01 is 1.8~2.0L, the oil type is Gear Oil
SAE75W-90.To assure the cleanliness and oil capacity of transmission oil, please clean
the vehicle and replace the oil when the vehicle has traveled for the first 1 month or
1000km; Afterwards, check the oil half a year and replace every two years; In the form of
mileage, check the oil every 10000km and replace it every 40000km
1.1.3 It is not allowed to make the transmission work when the lubricating oil is insufficient
and there is abnormal sound.
1.1.4 The stock period of transmission MF508C01 should not exceed 3 years and it
should be stored in storeroom which is clean, dry, and ventilative and without corrosive
gas.
1.2 Main malfunction and handling method of transmission
1.2.1 Out of gear
The causes for this problem are:
a. The gearshift shaft is seriously worn or deformed;
If the gearshift shaft is bent, deformed or seriously worn or the hole is worn, the
self-lock function of gearshift shaft will be unreliable, if there is vibration, the gearshift
shaft will be out. For the malfunction of gearshift shaft bent or worn seriously, it should be
aligned.
The solution is to replace the gearshift shaft timely.
b． The gearshift rocker is seriously worn or deformed;
If the gearshift rocker is seriously worn or deformed, it will cause the inefficiency of
travel, and results in the problem of out of gear. The solution is to replace the gearshift
rocker timely.
c. The steel ball of the third-fourth locking bolts or the third-fourth shift fork is worn
seriously
The steel ball of the third-fourth locking bolts or the third-fourth shift fork is worn
seriously, it will cause the inefficiency of travel, and
The solution is to replace the third-fourth locking bolts and third-fourth shift fork
timely.
d． Elasticity of the locking spring of third-fourth locking bolts is weakened;
If the elasticity of the locking spring of third-fourth locking bolts is weakened, the locking
force will decline and then will result in the problem of out of gear. The solution is to
replace the third-fourth locking bolts assembly timely.

e．Elasticity of the locking spring of first-second or fifth-reverse locking bolts is weakened;

If the elasticity of the locking spring of first-second or fifth-reverse locking bolts is
weakened, the locking force will decline and then will result in the problem of out of gear.
The solution is to replace the spring of first-second or fifth-reverse locking bolts timely.

Changan·Benni MINI
301-03-29 Manual Transmission 301-03-29

f. The first-second or fifth-reverse locking steel ball or the gearshift lever groove is
seriously worn
If the first-second or fifth-reverse locking steel ball or the gearshift lever groove is
seriously worn, it will result in the efficiency of engaging travel or make the problem of out
of gear. The solution is to replace the first-second or fifth-reverse locking steel ball or the
gearshift lever timely.

g． The axial clearance of gear is over big, which is mainly because the gear circlip is
seriously worn
If the gear circlip is worn, it will make the gear shaft move axially, and the
synchronizer can’t engage the gear completely and also will make the problem of out of
gear.
The solution is to replace the gear circlip
If the input shaft, countershaft bearing is badly worn, it will also make the gear shaft
move axially, and result in the problem of out of gear.
The solution is to replace the bearing
h．The shift fork is worn or deformed
If the shift fork is worn or deformed, the synchronizer will not engage well, the spline
of gear will be worn cone-shaped if it is worn for a long time, when the axial force is bigger
than the locking force, it will make the gear out
The solution is to align the bent fork or replace it
i. The synchronizer gear shell, cover or ring is worn
If the synchronizer gear shell, cover or ring is worn, it will make the axial force bigger
than the locking force, and then make the gear out

The solution is to replace the worn parts

j． After adjustment, the transmission gear is not in ‘N’ position, or the adjusting
mechanism is loosen
If the he transmission gear is not in ‘N’ position, or the adjusting mechanism is
loosening, the gearshift shaft can’t be pushed in place.
The solution is to put the gear in ‘N’ position or adjust the clearance.
k． The connection between engine, transmission and the vehicle is loose, or the
clearance is improper
If the connection between engine, transmission and the vehicle is loose, or the
clearance is improper, it will make the travel of gearshift shaft too big and make the
problem of out of gear
The solution is to adjust the clearance
1.2.2 Transmission big noise or abnormal sound
The causes and solution:
a． The oil capacity in transmission is insufficient or not clear
If the oil is not sufficient, the gears can not be lubricated sufficiently, and this will

Changan·Benni MINI
301-03-30 Manual Transmission 301-03-30
aggravate the wear, even erosion. Besides, if the oil is not clean and has particles, it will
influence the transfer of gears and make noise or abnormal sound.
The solution is to add oil and replace clean transmission oil
b. The axial clearance of gear is over big
If the axial clearance of gear is over big, it will make the transfer unstable, and make the
knock noise
The solution is to replace the gear or the gear circlip
c. The gear is worn or the gear tooth is broke.
。If the gear is worn badly or the gear tooth is broken, it will make abnormally big noise,
even make the parts broken. Besides, if the side clearance of gear exceeds the specified
range, the gear should also be replaced. The standard side clearance of gear of
MF514Ais 01.mm, the using limit is 0.3mm
d. The synchronizer gear ring is worn or the gear tooth is broken
If the synchronizer gear ring is worn or the gear tooth is broken, it will make abnormal
sound
The solution is to replace the gear ring
e. The bearing is damaged or worn
If the bearing is damaged or worn, the gear shaft will has unsmooth running and make
friction or knock noise
f． The bearing circlip is damaged or worn
If the bearing circlip is damaged or worn, it will make unstable transfer and make
noise or abnormal sound
The solution is to replace the bearing circlip.
1.2.3 Hard shifting
The causes and solution of hard shifting:
a. The gearshift lever or the shift fork is deformed or worn.
。If the gearshift lever or the shift fork is deformed or worn, the shift block may slip
from the groove and make the gear engagement and gear shift difficult.
The solution is to replace the parts
b． The locking steel ball and the gearshift shaft groove is worn
If the locking steel ball and the gearshift shaft groove is worn, the self-locking force
will weaken and the gearshift is not reliable
The solution is to replace the parts
c. The synchronizer gear ring gets stuck in the gear pyramid
If in this situation, the gear ring can also transmit the power to the shaft, but it can not
shift the gear smoothly.
The solution is to replace the gear ring.
The solution is to replace the parts
1.2.4 Oil leak
a. Oil leak of the oil drain plug
The causes of the oil leak of the oil drain plug may be as follows: one is the tightening
torque of the bolts is less than the specified torque. Please check the torque, if it not big

Changan·Benni MINI
301-03-31 Manual Transmission 301-03-31
enough, tighten it; Second is the offset of matching or the damage of screw thread, if there
is, we should replace corresponding parts
b. Oil leak of sealed parts
It’s mainly resulted from damage of parts caused by improper assembly or use
The solution is to replace the sealed parts and pay attention to the standard of
operation
c. Oil leak of the joining surface of the cases.
It should be noted to smear glue on the joining surface and tighten the bolts to the
specified torque
d. Oil leak of input shaft oil seal
First check whether the oil seal is broken, if it is, replace the oil seal; Then check the
matching hole of right body is worn badly, if it is, replace the oil seal; Check the body
whether t is cracked, if it is, replace the right body
1.3 Maintenance of transmission
1.3.1 If not using the transmission, the sump oil in the transmission should be drained out.
1.3.2 If the transmission has to be stored for more than half a year, anti-rust measures
should be taken to protect the outer metal parts
1.3.3 It is not allowed to pile up the transmission one on top of another.

Changan·Benni MINI
302-01-1 Clutch –General Description 302-01-1

302-00 Clutch – General Description

Applicable Vehicle Model:Changan.Benni.MINI

Contents
Specifications

Specifications.................................................................................................................................................... 302-00-2

Instruction and Operation

Clutch................................................................................................................................................................ 302-00-2

Diagnosis and Test

Clutch................................................................................................................................................................ 302-00-2
Clutch................................................................................................................................................................ 302-00-2
Failure Phenomenon Table ............................................................................................................................... 302-00-3
Fixed Point Inspection ...................................................................................................................................... 302-00-4

General Procedures

Inspection of the Clutch Friction Disc .................................................................................................... 302-00-11

Changan·Benni MINI
302-01-2 Clutch –General Description 302-01-2

Clutch
Description mm
The abrasion limit of the clutch friction disc 1.5

Torque Specifications for Installation

Description N·M Pound-Foot Pound-Inch

The fixing bolts of the clutch platen 21～25 -------- --------

Clutch
See Section Clutch for relevant information.
Controlling components of the clutch
See Section Controlling Components of Clutch for relevant information.
Clutch

Inspection and Conformation--Clutch

1. Identify the faults put forward by the Customer.
2. Check the obvious mechanical failure visually.
3. If the cause of the obvious problem is found, it should be solved before the next operation.
4. If no obvious failure cause is found, see Failure Phenomenon Table for the identification of the failure.
5. The operation of clutch inspection: Place a wood block with 25 mm thickness under the clutch pedal and step on
the clutch pedal completely. If the Gear I and the Gear II can be put into normally under the conditions that the
engine is running and the parking brake is applied, the operation of the clutch is normal. Otherwise, the clutch needs
repairing.

Changan·Benni MINI
302-01-3
Failure Phenomenon Table
Failure Description
• Clutch skidding.
• The clutch has the noise of click or • The engine bracket
shakes.
• The clutch is procrastinated.
• The clutch pedal is pulsed.
• The clutch is shaking.
• The gearshift is difficult.
• The noise is over high.
Clutch –General Description 302-01-3
Possibe Causes Maintenance Action
• Turn to the fixed point inspection
• The free travel of the clutch pedal. A
• The clutch pedal is bonded.
• The diaphragm spring
• The clutch platen
• The surface of the clutch friction
disc.
• The surface of the clutch friction
disc is excessively hardened or has
oil stains.
• The flywheel
• Turn to the fixed point inspection
• The surface of the clutch friction B
disc has oil stains
• The diaphragm spring
• The clutch platen
• The surface of the clutch friction
disc
• The flywheel
• Air is in the hydraulic system. • Turn to the fixed point inspection
• The free travel of the clutch pedal. C
• The diaphragm spring
• The clutch friction disc
• The spline of the clutch friction disc
• The surface of the clutch friction
disc has oil stains.
•The clutch and the pivot axle of the • Turn to the fixed point inspection
brake pedal can not be lubricated D
sufficiently.
• The flywheel
• The spring of the clutch plate is
fatigued.
• The engine components are • Turn to the fixed point inspection
contacted with the vehicle frame. E
• The driving belt
• The flywheel bolt.
• The flywheel
• The clutch platen is imbalance.
• The free travel of the clutch pedal • Turn to the fixed point inspection
• The manual transaxle has failure. F
• The free travel of the clutch pedal • Turn to the fixed point inspection
• The release bearing of the clutch G
• The release bearing of the clutch
can not be lubricated sufficiently.
• The guiding bearing.
• The axial clearance of the
crankshaft is overlarge.
Changan·Benni MINI
302-01-4 Clutch –General Description 302-01-4

Fixed point inspection A: Clutch skidding

Inspection Items Concrete Procedures/ Results/ Measures

A1: Inspection of Clutch Skidding
1 Inspect the wheels and apply the parking brake.
2 Turn the ignition switch to the START position.
3 Start the engine, and put into the 4th gear.
4 Run the engine at the rotating speed of 2000 rpm.
5 Slowly release the clutch pedal.
• Is the engine flamed out when the clutch pedal is
completely released?
　 Yes
The clutch is normal.
　 No
Turn to A2
A2: Inspection of the Free Travel of the Clutch Pedal
1 Press the clutch pedal by hand and release it when
you feel the resistance.
2 Check the free travel of the clutch pedal.
• The clutch pedal should have 5 to 10 mm free travel
when using normally
　 Yes
Turn to A3
　 No
Turn to B3
A3: Controllability of the Clutch Pedal
1 Checked the lubrication condition.
• Is the clutch pedal axle lubricated well?
　 Yes
Turn to B3
　 No
Lubricate the clutch pedal axle

Fixed point inspection B: The clutch has the noise of click or shakes
Inspection Items Concrete Procedures/ Results/ Measures
B1: Inspection of the Noise of Click or the Shaking of the Clutch
1 Turn the ignition switch to the START position.
2 Start the engine, and put into the 1st gear.
3 Make the engine rotate within the speed of
1200-1500 rpm.
4 Release the clutch pedal slowly.
• Does the vehicle shake during start-up?

Changan·Benni MINI
302-01-5 Clutch –General Description 302-01-5

Inspection Items Concrete Procedures/ Results/ Measures

　 Yes
Turn to B2
　 No
The clutch is normal.
B2: Inspection of the Engine/ Isolating Gasket of the Transaxle and the Anti-Rolling Frame
1 Check the damage of the engine/ the installation
isolating gasket of the transaxle/ the anti-rolling
frame or the loosening of the bolts.
• Is the engine/ the isolating gasket of the transaxle/
the anti-rolling frame loosen or damaged?
　 Yes
Screw up the bolts or replace them if necessary.
Does the testing system work normally?
　 No
Turn to B3
B3: Inspection of the Clutch Platen
1 Remove the clutch platen.
•Does the clutch platen have the abrasion sign?
　 Yes
Install a new clutch platen.
　 No
Turn to B4
B4: Inspection of the Clutch Friction Disc
1 Checked the clutch friction disc visually.
•Does the clutch friction disc have oily or burnt sign?
　 Yes
Install a new clutch friction disc. Test whether
the system can be operated normally.
　 No
Check the flywheel. See this section Flywheel
part.

Fixed point inspection C: the clutch is dragging

Inspection Items Concrete Procedures/ Results/ Measures
C1: Inspection of the Free Travel of the Clutch
Pedal
1 Press the clutch pedal by hand and release it when
you feel the resistance.

Changan·Benni MINI
302-00-9 Clutch–General Description
302-00- 9

Inspection Items Concrete Procedures/ Results/ Measures

2 Check the free travel of the clutch pedal.
• The clutch pedal should have 5 to 10 mm free travel
when using normally.
　 Yes
Turn toC2
　 No
Turn to B3
C2:Inspection of the Supporting Spacer of the Diaphragm Spring of the Clutch Platen
1 Remove the transaxle.
•Does the clutch platen or the supporting spacer of the
diaphragm spring have the abrasion sign?
　 Yes
Replace with a new clutch platen. Test whether
the system works normally.
　 No
Turn to B4

Fixed point inspection D : the pulsing of the clutch

pedal
Inspection Items Concrete Procedures/ Results/ Measures
D1: Inspection of the Clutch Pedal
1 Check the lubrication of the clutch pedal
mechanism.
• Is the clutch pedal axle well lubricated?
　 Yes
Check the flywheel. See the Flywheel part in this
Section.
　 No
Lubricate the clutch pedal axle. Test whether the system
works normally.
 302-00-9 Clutch–General Description
302-00- 9

Inspection Items Concrete Procedures/ Results/ Measures

2 Release the accessory driving belt to check the
vibration.
• Does the vibration stop when the accessory driving
belt is removed?
　 Yes
Maintain the accessory driving belt or replace
with a new accessory driving belt.
　 No
Turn to E3
E3: Inspection of the Noise of the Release Bearing
1 Turn the ignition switch to the START position.
2 Step on the clutch pedal and hold on
• Does the harsh friction sound occur?
　 Yes
Replace the clutch sub-pump. Test whether the
system works normally.
　 No
Turn to E4
E4: Inspection of the Flywheel
1 Remove the transmission driving axle.
2 Check whether the flywheel bolt is loosened.
3 Check the radial and the axial roundness of the
flywheel.
• Is the flywheel normal?（non-roundness in axial or
radial direction exceeds 0.25mm will be considered to
be over high, exceeding 0.1mm will cause vibration）
　 Yes
Diagnose the engine vibration failure.
　 No
Tighten the flywheel or replace with a new
flywheel, and test whether the system works
normally.
302-00-9 Clutch–General Description
302-00- 9

Fixed Point Inspection F: Difficult Gear Shifting

Inspection Items Concrete Procedures/ Results/ Measures
Fill in braking fluid and check whether the clutch
and braking system has leakage. Test whether the
system works normally
F1: Inspection of the Free Travel of the Clutch Pedal
1 Press the clutch pedal gently by hand
2 Measure the free travel of the clutch pedal.
• Is the free travel of the clutch pedal between 10 to 15
mm?
　 Yes
Diagnose the failure of gear switching difficulty.
　 No
Check whether the clutch platen is damaged. See
the part of the Platen in the Clutch in this Section.

Fixed point inspection G: The noise is over high

Inspection Items Concrete Procedures/ Results/ Measures
G1: Inspection of the Neutral Gear Position Of the Transmission Driving Axle
1 Turn the ignition switch to the START position
2 Start the engine at the natural gear.
3 Tread on the clutch pedal fully.
• Does the clutch have noise?
　 Yes
Turn to G2
　 No
For the failure of the transmission driving axle,
see the Failure Phenomenon Table.
G2: Inspection of the Free Travel of the Clutch Pedal
1 Press the clutch pedal by hand and release it when
you feel the resistance.
2 Measure the pedal travel.
• Is the travel less than 120 mm?
　 Yes
Turn to G3
　 No
See the General Procedures of the Master Pump
of the Clutch in this Section.
G3: Inspection of the Clutch Sub-Pump and the Release bearing
1 Remove the transaxle.
2 Check the bolts of the clutch sub-pump.
3 Check whether the release bearing is abraded or
corroded.
• Does the bolts have the phenomena of loosening or
abrasion or corrosion?
　 Yes
302-00-9 Clutch–General Description
302-00- 9

Inspection Items Concrete Procedures/ Results/ Measures

Tighten the bolts or replace a new clutch

sub-pump and install a release bearing. Test
whether the system works normally.
　 No
Turn to G4
G4: Inspection of the Torsion Spring of the Clutch Friction Disc

1 Check whether the torsion spring is abraded.

• Does the abrasion phenomenon exist?
　 Yes
Install a new clutch friction disc. Test whether the
system works normally.
　 No
Check the axial clearance of the crankshaft.

2．Clutch System Failure

Problems Causes Treatment Methods

Clutch Skidding ．The free travel of the clutch pedal is improper.
．The friction disc assembly is abraded or has oil Replace the friction disc
stains.
．The clutch platen assembly or the flywheel Replace the clutch platen
surface is deformed.
．The diaphragm spring is deformed.
．The dragline of the clutch is corroded.
Difficult Clutch
Release ．The free travel of the clutch pedal is improper.
． The diaphragm spring is deformed or the
spring part is abraded.
The input axle spline has pitting.
The input axle spline of the transmission gear is
damaged or abraded.
The swinging of the clutch plate is serious.
The clutch plate is damaged or has oil stains.
Clutch
Vibration
．The clutch plate is brightened.
The clutch plate has oil stains.
．The release bearing can not smoothly slide on
the bearing protective ring of the input axle
．The clutch plate swings or has bad contact.
． The torsion spring in the clutch plate is
deformed.
．The rivets of the clutch cover are loosened.
．The platen or the flywheel surface is deformed.
Adjust the free travel to 10-15
mm.
assembly.
assembly of the flywheel.
Replace the clutch cover.
Replace.
The travel is adjusted to 10-15
mm.
Replace the clutch plate.
Lubricate.
Replace the input axle.
Replace the input axle.
Replace the input axle.
Repair or replace the input axle.
Replace the clutch plate.
Lubricate or replace the guard
ring of the input axle bearing.
Replace the clutch.
Replace the clutch plate.
Replace the clutch cover.
Replace the clutch plate or the
302-00-9 Clutch–General Description
302-00- 9

Problems Causes Treatment Methods

flywheel.
．The installing gasket of the engine becomes
Screw up the installation gasket
weak or the installation bolts and nuts are again or replace it.
loosened.
Clutch Sounding ．The release bearing is abraded or damaged. Replace the release bearing.
The flywheel bearing is abraded. Replace the input axle bearing.
．The clutch plate hub is too loose. Replace the clutch plate.
．The clutch plate has cracks. Replace the clutch plate.
． The platen and the diaphragm spring are
Replace the clutch cover.
loosened.

Clutch Seizing ．The clutch plate is soaked with oil. Replace the clutch plate.
．The clutch plate is seriously abraded. Replace the clutch plate.
．The rivets are exposed out of the plate surface. Replace the clutch plate.
．The torsion spring becomes weak. Replace the clutch plate.

Inspection of the Clutch Friction Disc

1. Warning: it is forbidden to use the wax based cleaning agent and melting agent to clean the clutch
friction disc.
Check whether the clutch friction disc has:
Oil stains
Burnt marks
Thickness (abrasion limit: 1.7 mm)
Check spring
Replace the clutch friction disc if necessary.
302-03-1 Starter motor 302-03-1

302-03 Section Starter motor

Applicable vehicle model: Changan.Benni.MINI
General Description
Starting Circuit
A starting circuit consists of battery, starter motor, ignition switch and relevant harness.
Starter motor will be described in this section.

Starter motor Circuit

z When opening the ignition switch, magnetic switch coil create a magnetic filed.
z The plunger drive pinion rod to engage pinion with engine flywheel and cause main contact
of magnetic switch to be closed, the engine begin to start up
z When the engine has started up, pinion overspeed clutch protect armature from overspeed till
the switch is opened, at this point, the return spring pull pinion and make pinion out of
engaged state.

Starter motor
Starter motor includes the stator assembly, armature assembly, overspeed clutch
assembly, solenoid switch assembly, the front/rear cover, brush holder and the drive
rod. The solenoid switch assembly and its components have been enclosed inside the
cover to keep from being damaged by dirt and water.
Note：

故障诊断 malfunction diagnose

由于起动系统故障而出现的情况如下:because of the start system’s fault ,some thing occurs as
below:
z 起动机不转（或运转慢）starter does not rotate
z 起动机运转但不能起动发动机 starter rotates but can’t start the engine
z 异常噪声 abnormal noise

Changan•Benni•MINI
302-03-2 Starter motor 302-03-2

必须进行适当的诊断以确定每个故障产生的地方（如：蓄电池、线束、起动电机开关、起动
电机或发动机。
In order to confirm the malfunction point, those things must be diagnosed such as
battery, harness, starter switch, starter or engine
不要因为起动电机不运转而拆卸电机，检查下表列出的各项并逐渐排查故障原因。
Don’t disassemble the motor due to the motor does not rotate, check the items as below:
1） 故障情况 malfunction situation
2） 电池接线柱（包括发电机侧的搭铁线接头）和起动机接线柱 battery connect column and
starter connect column
3） 电池放电 discharge the battery
4） 起动电机安装 install starter
Condition Possible cause Handling method
Motor not No operating sound of magnetic switch:
running Recharge battery
·Battery run down
Replace battery
·Battery voltage too low due to battery Retighten or replace
deterioration Retighten
·Poor contact in battery terminal connection Retighten or replace

·Loose grounding cable connection

Replace
·Fuse set loose or blown off Retighten
· Poor contacting action of ignition switch Repair
and magnetic switch Replace magnetic switch
Repair or replace
·Lead wire coupler loose in place
Repair
·Open-circuit between ignition switch and
magnetic switch Recharge battery
·Open-circuit in pull-in coil Replace battery
·Brushes are seating poorly or worn down Retighten
·Poor sliding of plunger and/or pinion Replace magnetic switch
Repair or replace
Operating sound of magnetic switch
Replace
heard
Replace armature
·Battery run down Replace
·Battery voltage too low due to battery Repair
deterioration
·Loose battery cable connections

· Burnt main contact point, or poor

contacting action of magnetic switch
·Brushes are seating poorly or worn down

　·Weakened brush spring

Changan•Benni•MINI
302-03-3 Starter motor 302-03-3

·Burnt commutator

·Layer short-circuit of armature

·Crankshaft rotation obstructed

Changan•Benni•MINI
302-03-4 Starter motor 302-03-4

Condition Possible cause Handling method

Starting motor If the battery and the wires are all OK, then check Replace magnetic
running but too the starter motor. switch.
slow (small ·Poor contact of magnetic switch main contacts
Replace.
torque) ·Layer open-circuit of armature
Repair or replace
·Disconnected, burnt or worn commutator armature
·Poor grounding of coil Repair
·Worn brushes Replace brush.
·Weakened brush springs Replace spring
·Burnt or abnormally worn end bush Replace bush.
Starting motor ·Worn pinion tip Replace overspeed
running, but not ·Poor sliding of overspeed clutch clutch.
engine Repair
·Overspeed clutch skidding
·Worn teeth of ring gear Repair
Replace flywheel
Noise ·Abnormally worn bush Replace
·Worn pinion or worn teeth of ring gear Replace
·Poor sliding of pinion (failure in return over-running clutch
movement) or flywheel
·Lack of lubricating oil in each part Repair or replace
Replace.
Fill lubricating oil
Starting motor ·Fused contact points of magnetic switch Replace magnetic
does not stop · Short-circuit between turns of magnetic switch
running switch coil (layer short-circuit) Replace magnetic
·Failure of returning action in ignition switch switch
Replace

Changan•Benni•MINI
 302-03-5 Starter motor 302-03-5

大修 Overhaul
拆卸与安装 Disassembly and Installation
1） 拆下蓄电池负极导线 Disconnect the 6） 用卡环钳子和起子拆下电枢压紧，然后
negative (-) cable of battery. 拉出小齿轮止动环和超速离合器。
2） 从起动电机接线柱上拆下电磁开关导线
合 电 池 导 线 Disconnect magnetic
switch lead wire and battery cable
from starting motor terminals.
3） 拆下两颗安装螺钉 Remove the two
starting motor mounting bolts.
4） 拆下起动机 Remove starting motor
5） 重装则按相反顺序进行 Reverse the
removal procedure for installation

拆卸 Removal
1） 从电磁开关上拆下螺母并断开导线。
Disassemble the bolts and disconnect the
wire from the electromagnetic switch.
2） 拆下两颗螺母，然后通过拉动电磁开关
后面部分来取出电磁开关，以便内钩从
传动杆上脱开。Disassemble two bolts
then pull out electromagnetic switch ,in
order to help the inside clasp get off from
the transmission rod.

Attention
Forbidden to disassemble the electromagnetic
switch ,replace it when installation if it needed
3） 拆卸外壳螺栓然后拉出整流子端盖。
Disassemble cover bolts then pull out the end
cover.
4） 拆下绝缘体和电刷弹簧，然后拆卸电刷
架。
Disassemble the insulator and electronic
bush spring then disassemble the bush bracket.

5） 拆下定子，电枢和传动杆。Disassemble
the stator ,armature and transmission rod

Changan•Benni•MINI
1）
302-03-6 Starter motor 302-03-6

重装 Installation
1） 检查零件（参见检查部分）必要并更换。
Check the components (refer to the Check
section) and change if necessary.
2） 装超速离合器之前，必须加润滑脂，然
后用卡环固紧止动环。
Before installing the overspeed clutch, first to
fill lubricating grease, and then tighten the
stopper ring by snap ring
3） 在传动杆上加润滑脂并与电枢装在一 装配完成后，进行性能测试
起，然后与驱动端盖装在一起。
Swear lubricating grease on the driving lever 检查 check the plunger
and install it together with armature, and then 柱塞
install the assembly together with driving end 检查柱塞磨损情况，如有必要则更换。
cap. Check the plunger wear condition, replace it if
4） 安装定子和电刷架，然后将四个带有弹 necessary.
簧的电刷固定，再安装绝缘体。
Install the stator and brush holder, and then fix
the four brushes with spring, and then install
the insulator

Attention:
z 安装电刷时，必须保证将电刷和整流子上的润滑脂彻底去除。
z Make sure get rid of the brush’s lubricant when installation
z 确保电刷零件与其它部件无不必要的接触。
z Make sure don’t contact other component with brush

5） 在衬套内部加润滑脂，后安装后壳。
Before install the rear cover, add lubricant in
the bushing
6） 更换新的电磁开关或及其罩套。如必要，
加润滑脂于柱塞之上。
Replace a new electromagnetic switch or its
cover, add lubricant in the plunger if
necessary.
7） 回传动杆钩住电磁开关柱塞然后用螺帽
固紧电磁开关总成。
Fix the electromagnetic switch with bolts.
8） 连接导线到位然后检查电磁开关工作情 Attention:
况。Check the electromagnetic working z 安装螺母之前，必须保证柱塞与传动杆连
condition 好。
Make sure connect plunger and transmission
before install the bolts.
z 使罩套通气孔朝下。Make sure air vent are
down

Changan•Benni•MINI
302-03-7 Starter motor 302-03-7

电磁开关 electromagnetic switch z 接地试验

将柱塞推进并放松，该柱塞应迅速回到原来 整流子片和电枢芯间绝缘。应欧姆表检查。
的位置，如有必要则更换。
Pull in the plunger and loose it, it will back to
place quickly. replace it if necessary
吸合线圈断路试验 coil open circuit test
检查电磁开关“S”接线柱和“M”接线柱
是否导通，如不导通，则表明线圈断路，应
更 换 。 Check whether the electromagnetic
switch “S” column and “M” column are
passing, if not, then the coil open
circuit ,should be replaced.

检查电磁开关“S”接线柱和线圈壳是否导
通，如不导通，则线圈断路，应更换。
Check whether the electromagnetic switch “S”
column and coil cover are passing ,if not,
then the coil open circuit ,should be replaced.

电刷 electronic brush
测量电刷长度，如有并作必要应更换。
Measure the brush’s length, replace it if
necessary
电刷长度限定：6mm
Brush length limited:6mm

电刷架 electronic brush bracket

检查电刷弹簧是否腐蚀或断裂，检查电刷架
是否腐蚀和绝缘，如需要，则在安装时更换。
Check whether the brush spring are corrosion
or fracture ,check whether the brush bracket
are corrosion and insulate ,replace it if
necessary.

电枢 armature

Changan•Benni•MINI
302-03-8 Starter motor 302-03-8

z 断路试验 abruption circuit test

检查整注解子片间的导通性，如任何测
试点皆无导通，则表明电路断开，必须
更换电枢。
Check whether the rectification is passing ,if
none of them passing, it indicates abruption
circuit, must replace the armature.

z 将电枢支在 V 形块上，检查整流子是否
偏心。如有问题则用车床校正。
Put the armature in the V pad, check whether
the rectification is bias. adjust it with lathe if
had problem.
椭圆整流子限定（最大值）值：0.4mm
Ellipse rectification limited(maximum):0.4mm

如果直径低于限定值，则检查磨损情况并更
换电枢。

If the diameter lower than limited ,then check

the wear condition and replace armature
整流子外径限定值（最小值）：27mm

Rectification outside diameter

limited(minimum):27mm

用＃400 金刚砂布打磨表面并检查云母深
度。Polish the surface with emery cloth(#400)
and check the mica depth.

整流子绝缘体深度“a”限定值（最小值）：
0.2mm
Rectification Insulation body
limited(minimum) :0.2mm

Changan•Benni•MINI
302-03-9 Starter motor 302-03-9

定子 stator
检查励磁线圈是否导通。接线柱间应导通。
Check whether the urge magnetic coil are
passing, the connect column should passing
z A 接线柱间。Connect column A
z B 接线柱间。Connect column B
z B 接线柱和 C 接线柱间（定子体的金属
件表面）Connect column B and C(stator
metal surface)
z

超速离合器 overspeed clutch

检查小齿轮是否磨损,损坏或其他异常情况..
当按驱动方向转动离合器时,检查离合器是
否锁止并能反向顺利转动.如有必要,则更换.
Check whether the little gear is wear, damaged
or other abnormal situation,rotate the clutch
according to the drive way, check whether the
clutch is locked and rotate in the opposite way.
replace it if necessary.

性能测试 performance test

Attention:
To avoid buring the coil, every test must
within 3-5 seconds

吸合测试 meshing test

如图连好导线并检查小齿轮(超速离合器)是
否向外转动,如不移动,则更换电磁开关.
Connect electrode and check little gear
whether are rotate to outside, if not, replace
the electromagnetic switch.
Attention:
测试前必须将历次线圈与接线柱’M’断开.
The connect between second coil and
colum”M” must be disconnected before test. Changan•Benni•MINI
302-03-10 Starter motor
302-03-10
保持测试 maintenance test
如上所述的那样连好导线小齿轮朝外转,然
后拆下’M’接线柱负极导线,检查小齿轮是
否朝外转,否则应更换电磁开关
Rotate the little gear to outside then
disassemble the negative electrode of M
column, check whether the little gear is
rotating to outside, if not, then replace the
electromagnetic switch.

小 齿 轮 ( 柱 塞 ) 回 位 测 试 little gear
(plunger)returning test
接上一步,拆下负极导线并检查,保证小齿轮
往里迅速回位..
Attach to last step, disassemble the negative
electrode and check, make sure the little gear
return to place quickly.

无负载性能测试 no loading performance test

如图所示连接试验导线,检查电机是否无故
障运转并且小齿轮应朝外转.还要检查电枢
是否显示了规定电流量.
Connect the electrode ,check whether the
motor is working normally and whether the
little gear is rotating to outside, besides that,
check whether the armature indicates
provision electric current.

Changan•Benni•MINI
 302-03-1 Generator 302-03-1

302-03 Section Generator

Applicable vehicle model :Changan.Benni MINI

General Description
The main charging system is the integrated circuit regulator charging system, and the
electrical connections of all the components in the charging system are shown in Figure 1.The
generator has the characteristics that a solid regulator is installed inside the generator. All the parts
of the adjuster are installed in an airtight case. The adjuster and the electric brush bracket
assembly are installed on the sliding ring and the frame, and the preset voltage of the generator
can not be adjusted.
The rotor bearing of the generator has adequate lubricating grease, therefore the regular
lubrication is not required. Two electrical brushes can ensure that the current flows to the magnet
exciting coil on the rotor through two sliding rings. Under the normal circumstances, the electrical
brushes require no maintenance for a long term.
The stator coil is installed inside the laminated membrane type iron core, and the iron core is
the generator frame element. The rectifier connected onto the stator coil is composed of six diodes
and converts the alternating current voltage on the stator into the direct current voltage on the
generator output binding post. The central pivot diode is used to convert the fluctuation of the
voltage of the neutral point into the direct current to increase the output of the generator.
The capacitor installed on the adjuster assembly can protect the voltage of the diodes and
restrain the interference of the radio wave.

Figure 1 Structure of generator

1、Socket cross screws in the belt pulley 6、Magnet exciting coil
2、Belt pulley 7、Adjuster
3、Rotor fan 8、Electrical brush
4、Stator coil 9、Rear end cover
5、Stator iron core 10、Driving end cover

Changan·Benni MINI
 302-03-2 Generator 302-03-2

1、Generator provided with an adjuster assembly 6、Charging indicating lamp

2、Integrated circuit regulator 7、Ignition switch
3、Stator coil 8、Battery
4、Rectifying diode 9、Load
5、Magnet exciting coil (rotor coil)

Figure 2 Generator performance test circle

Changan·Benni MINI
 302-03-3 Generator 302-03-3

Failure Diagnosis
For fear of the damage of the generator, please observe the following items:

Notes:
z The polarities of the ignition binding post and the indicating lamp binding post can
never be mistaken.
z Short circuit can not happen between the ignition binding post and the indicating
lamp binding post, the two binding posts should be connected through the charging
indicating lamp.
z No load can be connected between the indicating lamp binding post and the
grounding.
z If a charger or an auxiliary storage battery is required to be connected to the
vehicle, see this Chapter Storage Battery.

When one or many of the following circumstances happens, it is shown that the charging system is
out of order.
1. The failure indication lamp is on.
2. The starting is slow or the indicating lamp is not bright, which indicates the insufficient
charging of the accumulator.
3. The electrolyte is excessive and is seeped out of the ventilation hole, which indicates the
overfull charging of the accumulator.
The noises of the engine generated due to the following causes: the positive belt pulley or
the installing bolt is loosened, the bearing is abraded or has dirt or the diode or the stator is out of
condition.

Failure Indication Lamp Light

Failure Phenomenon
The charging indicating lamp
is off when the ignition switch
is switched on and the engine
is stopped to run.
The charging indicating lamp
is not turned off when the
engine runs (the accumulator
requires frequent charging)
Possible Causes
z The safety fuse is broken
z The lamp bulb is burnt
z The binding post is
loosened and dropped.
z The integrated circuit
regulator is failed.
z The electrical brush and
the sliding ring are not
well connected.
z The transmission belt gets
loose or is abraded
z The integrated circuit
regulator or the generator
is out of condition.
z The circuit is failed.
Elimination Methods
Check the safety fuse
Replace the indicating lamp.
Tighten the loose connection.
Replace the integrated circuit
regulator.
Maintain or replace
Adjust or replace the
transmission belt.
Check the charging system.
Repair the circuit.

Changan·Benni MINI
 302-03-4 Generator 302-03-4

Insufficient charging of the accumulator

The slow starting is caused by the following one or several conditions, even the indicating lamp
works normally, it is also the same condition. Use a voltage gauge and an ampere meter to carry
out the following procedures on the vehicle.
1. Make sure that the insufficient charging of the accumulator does not result from the fact that the
auxiliary device is switched on.
2. Check whether the tightness degree of the transmission belt is normal.
3. If the failure of the accumulator there is doubted, see the instruction in Section Accumulator.
4. Check whether the circuit has fault and whether the connection is fastened and is clean. Check
the connection status of the cable on the storage batter.
5. As shown in the Figure, the voltage gauge and the ampere meter are connected.

Voltage Gauge
The voltage gauge is connected between the B binding post of the generator and the grounding.

Ampere Meter
The ampere meter is connected between the B binding post of the generator and the positive
electrode binding post of the battery.

6. Measure the voltage and the current under the following conditions.

Unloaded Inspection
The reading is read out on the instrument when the engine runs from the idle speed to 2000r/min.

Changan·Benni MINI
 302-03-5 Generator 302-03-5

Notes:
z It should be taken into consideration that the difference of the voltage can be generated along
with the difference of the temperature of the adjuster box.
z The test can not be performed on the discharged accumulator. Before the test, the
accumulator must be fully charged.

Notes:
When the engine runs, the binding
posts of the accumulator can not be
disconnected, otherwise, the electronic
parts may be damaged.

The standard current: 10 A（maximum）

The standard voltage: 14.2-14.8 V when the temperature is 25℃.

Changan·Benni MINI
 302-03-6 Generator 302-03-6

The voltage is higher.

If the voltage is higher than the standard value, replace the integrated circuit regulator.

The voltage is lower.

If the voltage is lower than the standard value, the following inspection should be carried out.

The binding post of the magnetic field coil (F) is grounded, and the engine is started. Then, as
shown in the Figure, the voltage is measured at the binding post B.

If the voltage is higher than the standard value

It is believed that the generator is good, but the integrated circuit regulator is damaged.

If the voltage is lower than the standard value

The generator has fault itself and should be inspected.

Load Inspection
The engine rotates at the rotating speed of 2000 r/min, the headlights and the heating and
ventilation motor are switched on. The current is measured, if it is lower than 20 A, the generator
should be repaired or replaced.

The excess charging of the accumulator

1. If the electrolyte seeps excessively, it is proved that the charging is over, the generator should be
disassembled to check whether the magnetic field armature is grounded or short-circuited. If
the problem still exists, the rotor should be replaced.
2. The voltage is measured under the condition that the generator runs at 2000 r/min.
3. If the measured voltage is not within the standard range, the grounding of the electric brush or
the integrated circuit regulator should be checked.

Changan·Benni MINI
 302-03-7 Generator 302-03-7

Assembly Disintegration Inspection

1-pulley 10-threaded stud 19-glue cover

2-front housing 11-gasket 20-screw
3-front bearing 12-regulator 21-screw
4-cap 13-M5 nut 22-cover
5-bolt 14-M8 nut 23-conductive element
6-stator 15-insulative cover 24-M5 nut
7-rotor 16-rectifier 25-M5 nut
8-rear bearing 17-brush
9-rear housing 18-M4 bolt

Disassembly and Reinstallation

1. Remove the negative pole cable from the accumulator.
2. Remove the B binding post conduction wire and the differential.
3. Remove the bolts of the generator cover.
4. Remove the adjusting bolts of the generator transmission belt.
5. Remove the bolts of the generator cover, and then remove the cover.
6. Remove the installing bolts, and take out the belt. Take out the generator assembly downwardly.
7. The reinstallation is performed according to the procedure reverse to the procedure for
disassembling the components, and the transmission belt is adjusted to the specified output
tension.

Changan·Benni MINI
 302-03-8 Generator 302-03-8

Disassembly
If the wiring of the generator is correct and has no other affects, the failure of the generator can be
judged, please replace it directly, the inspection can be carried out without disassembling.

Installation
Because the silicon semiconductor element and the IC circuit are adopted in the generator,
cautious handling should be observed during carrying and installation, to avoid the damage of the
electronic devices. During the installation, the following items should be paid attention to:
a. Don’t knock the one-way belt pulley;
b. The belt tension is appropriate at about 450 N;
c. The tightening torque of the B pole wire fixing nut at the output end of the generator is
appropriate at about 7-10 N·m;
d. Seen from one side of the belt pulley, the generator should be ensured to rotate in the
clockwise direction;
e. The generator can work after being connected with the battery in series;
f. The IG end and the L end can not be connected wrongly, the charging indicating lamp
(the component 5 in Figure 1) can not be short-circuited.
g. If the engine does not work, the ignition switch (the component 6 in Figure 1) can not be
kept at the ON position for a long time.
h. The generator and the automobile are connected through wiring

Changan·Benni MINI
 302-03-9 Generator 302-03-9

Failure Analysis and Elimination

Failure Analysis and Elimination

Failure Potential Failure Factors Elimination Methods

Phenomenon
Belt pulley skidding Adjust the belt tension.
The rotating speed of the Make the rotating speed of the
generator is too low. generator larger than 1250 r/min
The external conducting wire of Reconnect the wire.
the generator is not well
contacted.
The electric appliance is failed. Replace the electric appliance.
The vehicle body wiring hardness Eliminate the fault.
Electric power
is broken and short-circuited.
can not be
The accumulator is failed, and the Replace the accumulator.
generated or the
inner resistance is over large.
output voltage is
The voltage regulator is damaged. Replace the voltage regulator.
too low
The rectifier diode is damaged. Replace the rectifier.
The magnet exciting coil is Replace the rotor.
disconnected or short-circuited.
The electrical brush is completely Replace the electrical brush.
or excessively abraded.

Screw gets loose Screw up the screw.

The voltage regulator is damaged. Replace the voltage regulator.

Short circuit occurs in the generator, Eliminate the short circuit source.
such as iron chips.
The stator coil has the phenomenon of Replace the stator.
The output voltage short circuit.
is not steady The rotor coil has the phenomenon of Replace the rotor.
short circuit.
The electrical brush has excessive Replace the electrical brush.
abrasion.
The electric appliance is failed. Replace the electric appliance.
The accumulator is failed. Replace the accumulator.
The charging The charging indicating lamp is failed. Replace the charging indicating lamp.
indicating lamp is
not on.
The loop of the charging indicating Reconnect the wire.
lamp is obstructed

Changan·Benni MINI
302-03-10 Generator
The voltage regulator is damaged.
The belt pulley skids
The charging The rotating speed of the generator is
indicating lamp can too low.
not be turned off The external conducting wire of the
generator is not well contacted.
The electric appliance is failed.
The vehicle body wiring hardness is
broken and short-circuited.
The accumulator is failed, and the inner
resistance is over large.
The charging The voltage regulator is damaged
indicating lamp can The rectifier diode is failed.
not be turned off The magnet exciting coil is
disconnected or short-circuited.
The electrical brush is completely or
over abraded.
The screw gets loose.
The noise gets There is foreign matter in the generator.
louder The bearing is damaged.
Generator Output Characteristic Curve
302-03-10
Replace the voltage regulator.
Adjust the belt tension.
Make the rotating speed of the
generator larger than 1250 r/min
Reconnect the wire.
Replace the electric appliance.
Eliminate the fault.
The accumulator is changed
Replace the voltage regulator.
Replace the rectifier.
Replace the rotor.
Replace the electrical brush.
Fasten the screw.
Remove the foreign matter.
Replace the bearing.
Changan·Benni MINI
 302-03-11 Generator 302-03-11

Rated Parameters
r/min 6000 r/min 18000
Rated Working Maximum
Rotation Speed Rotating Speed
r/min r/min
A 70 V 14
Rated Current A Voltage
Specifications V
Unloaded Maximum
Rotating Speed Output
Permissible -40℃～105℃ Polarity Cathode
Ambient Grounding
Temperature
Rotation Clockwise Weight 6.8kg
Direction direction seen
from the
driving end

The cold state working performance

The cold state working performance of the generator under the normal temperature should
conform to the following specifications.
Code State Working Performance

r/min A V
Rotating Speed Output Current Test Voltage
r/min A V
1900 ≥50
2500 ≥60 13.5±0.1
5000 ≥80

The hot state working performance

The hot state working performance of the generator should conform to the following
specifications.
Hot State Working Performance

r/min A V
Rotating Speed Output Current Test Voltage
r/min A V
1900 ≥40
2500 ≥50 13.5±0.1
6000 ≥70

The voltage adjustment performance

Changan·Benni MINI
 302-03-12 Generator 302-03-12

The voltage adjustment performance under the normal temperature should conform to the
following specifications.
Normal Temperature Voltage Adjusting Performance

V
Performance Voltage Adjustment or Adjustment of the
Difference Value of Voltage
Voltage Adjustment 14.55±0.25
Load Characteristics │ΔU│≤0.5
Rotating Speed Characteristics │ΔU│≤0.3

The high temperature voltage adjusting performance of the generator should conform to the
following specifications.
High Temperature Voltage Adjusting Performance

Adjusting voltage Adjuster temperature compensation ratio

V mV/℃
≥13 0～-7

Changan·Benni MINI
 304-00-1 Fuel System 304-00-1

Section 304-00 General Description of Fuel

System

Applicable Vehicle Model: CHANA.BENNI-MINI

Contents Page
General ..............................................................................................................
Fuel system……………………………………………………………………………………… 304-00-02
Fuel pump assembly………………………………………………………………………………… 304-00-03
Disassembly and Installation
Fuel pump assembly………………………………………………………………………………… 304-00-04
Fuel filter……………………………………………………………………………………… 304-00-05

CHANA.BENNI-
MINI
304-00-2 Fuel System 304-00-2

General

Fuel system

The main parts and components of the fuel system comprises a fuel tank assembly, a fuel
pump assembly, a fuel filter, a fuel pipe assembly, a carbon can assembly with accessories, a fuel
feeding pipeline and a fuel vapor pipeline.

1. Fuel tank assembly

2. Fuel pump assembly
3. Carbon cans
assembly with accessories
4. Filling pipe
5. Filling cover
6. Fuel filter
7. Fuel pipeline
8. Vapor pipeline

CHANA.BENNI-
MINI
304-00-3 Fuel System 304-00-3

Fuel pump assembly

1. Flange component
2. Sealing ring
3. Fluid level sensor
4. Float rod components
5. Spring
6. Fuel outlet pipe
7. Pressure adjusting valve
8. Wiring harness
9. Fuel returning pipe
10. Electric fuel pump
11. Bracket of the oil pump
12. Fuel roughing filter

CHANA.BENNI-
MINI
304-00-4 Fuel System 304-00-4

Disassemble and installation of fuel 4 Disassemble and discard the sealing ring
system Installation
fuel pump assembly Install the O-shaped sealing ring of the new
1、 Screw off the bolts installed on the flange fuel pump model
pressing plate install the flange pressure plate

2 Take down the flange pressing plate Finally screw on the bolts.

3 Move upwards the fuel pump assembly

carefully

CHANA.BENNI-
MINI
304-00-5 Fuel System 304-00-5

Notes: Except float rod component of the fluid level sensor, other parts of the bracket of the oil
pump can not be separately disassembled
The procedures of disassembling the fluid level sensor are as follows:
1. Press inwards the two clipping buckle of the fluid level sensor.

2 Move upward the fluid level sensor and the float rod component carefully.

Therein, the fuel pump and the flanges are connected through the fuel returning pipes, and can not
be separately disassembled. If the tools are used to lacerate the fuel returning pipe, the fuel outlet
pipe opening of the fuel pump can simultaneously be damaged, which influences the sealing and
results in the leakage.

Notes: When it is found that the fuel pump assembly has damaged, replace the entire fuel pump
assembly. The parts and components of the fuel pump assembly can not be separately replaced for
fear of influencing the sealing.
Fuel filter
The fuel filter is located under the right side of the fuel tank, just as the photo below, it
function is to filter the fuel that pass through the fuel pump
The fuel filter can not be decomposition, it must be replaced if it has problem

CHANA.BENNI-
MINI
304-00-6 Fuel System 304-00-6

CHANA.BENNI-
MINI
304-01-1 Fuel Tank and Fuel Pipeline 304-01-1

Section 304-01 Fuel tank and Fuel Pipeline

Applicable Vehicle Model: CHANA. BENNI-MINI

Contents Pages
Specifications

Specifications .................................................................................................................................... 304-01-2

Instruction and Operation

Fuel Tank and Fuel Pipe ...................................................................................................................................304-01-3

All vehicles.......................................................................................................................................................304-01-4

Diagnosis and Test

Fuel Tank and Fuel Pipe ...................................................................................................................................304-01-5

Inspection and Conformation ...........................................................................................................................304-01-5

Disassembly and Installation

Fuel Tank ......................................................................................................................................................... 304-01-6

Fuel Pump Module....................................................................................................................................... 304-01-8
Fuel Filter................................................................................................................................……………… 304-01-10
Pipeline from Fuel Pump to Filter...........................................................................................……………… 304-01-11
Pipeline from Fuel Filter to Fuel Rail ............................................................................................................ 304-01-12
Fuel Returning Pipeline ................................................................................................................................. 304-01-14

CHANA.BENNI-MINI
304-01-2 Fuel Tank and Fuel Pipeline 304-01-2

Specifications

Torque Specifications
Description Nm lb-ft lb-in
Fixing bolt of the fuel tank 28 -
Bolts of the heat isolating space 10 -
Bolts of the fuel filter 10 -
Bracket bolts of the fuel filter 10 -
Flange screw of the fuel transferring pump 10 -

CHANA.BENNI-MINI
304-01-3 Fuel Tank and Fuel Pipeline 304-01-3

Instruction and Operation

DESCRIPTION AND OPERATION

Fuel Tank and Fuel Pipeline

Serial Parts Names

Number Number
1 Gasoline filter and its
bracket
2 Fuel pipe of the fuel tank
3 Oil returning pipe of the
fuel tank
4 Safety valve
5 Heat isolating plate of the
fuel tank
6 Fuel tank assembly
7 Fuel pump and fuel amount
sensor assembly

CHANA.BENNI-MINI
304-01-4 Fuel Tank and Fuel Pipeline 304-01-4

Instruction and Operation

All vehicles
Fuel filling pipe of the fuel tank
The fuel tank is equipped with a metal fuel filling pipe,
and the filling cover has the ventilation function.
Safety Valve
The safety valve is positioned at the top part of the
fuel tank. The ventilation of the fuel tank can reach to
the recovering carbon can through the safety valve.
The valve is sealed through a rubber spacer.
Fuel Tank
The fuel tank is made of metal and is fixed at the
lower part through bolts, The ventilation of the fuel
tank is realized through the safety valve.
Fuel pipeline
The fuel supplying pipeline and the fuel returning
pipeline are the combination of the nylon product, the
rubber product and the metal product. The pipeline is
installed at the bottom part of the vehicle body
through the fixing clip. The nylon pipeline and the
rubber pipeline can be used to connect the fuel tank,
the fuel filter and the components in the fuel system of
the engine .

Fuel Amount Sensor

The fuel amount sensor is a conventional float
metering type, the variable resistance type is installed
in the fuel tank, which is installed by a plastic locking
ring and sealed through the rubber spacer.

Gasoline Vehicle
Fuel Pump Module
The fuel pump is installed in the fuel tank, and the fuel
pump and the fuel amount sensor are connected as a
whole. The fuel pump is installed through a plastic
locking ring and sealed through the rubber spacer.
Gasoline Filter
The gasoline filter has a can-shaped structure, and
installed at the lower part of the vehicle body and
adjacent to the fuel tank through a bolt.

CHANA.BENNI-MINI
304-01-5 Furl Tank and Fuel Pipeline 304-01-4

Diagnosis and Test

Fuel Tank and Fuel Pipeline

General Equipment
WDS

Inspection and Conformation

1. Check the failure complained about by the
customer.
2. Inspect the obvious mechanical or electrical damage
visually.

Visual Inspection Table

Mechanical Part Electrical Part
– The fuel pipeline is – The connector is
damaged loosened or abraded.
– The quick connector
is damaged
– The fuel leakage
occurs
– The fuel filling cover
of the fuel tank is
damaged.
– The fuel filling pipe
of the fuel tank is
damaged
– The installation of the
gasoline filter is
wrong.
3. If the failure is obvious, before the following
maintenance or diagnosis is performed, the failure
shall be repaired.
4. If the obvious failure reasons are not found, the
diagnosis is performed with WDS.

CHANA.BENNI-MINI
304-01-6 Fuel Tank and Fuel Pipeline 304-01-6

Disassembly and Installation

Fuel Tank

Disassembly 5 Warnings: The appropriate material

should be used at the bottom part of the
Warnings: The procedures comprise the fuel fuel tank to perform the supporting
treatment. Pay attention to the overflowing function, to avoid the damages.
of the fuel at any time and the precautions 6. Support the fuel tank.
for the treatment of the fuel; otherwise, the
bodily injury may be caused.
Warnings: When the operation related to the
fuel components is performed, any form of
open flame must be forbidden. The high
inflammability gas mixture caused in the
operation may be ignited. The wrong
operation may cause the bodily injury
accident.
1. Remove the grounding wire of the battery.
Please see section 407-00 for the relevant
information.
2. Empty the fuel tank, Please see Section 304-00
for relevant information.
3. Hoist the vehicle. Please see Section 100-01 for 7. Remove the installing bolt for the fuel tank.
the relevant information.
4. Remove the fuel filling pipe and the ventilation
pipe of the fuel tank.

8. Warnings: When the fuel tank is taken

down, the fuel pipeline should be confirmed that no
oversized tightening force is applied on.
Lower the fuel tank partially.

CHANA.BENNI-MINI
304-01-7 Fuel Tank and Fuel Pipeline 304-01-7

Disassembly and Installation (Continued)

9. Remove the fuel pipeline and the electric

appliance connector.

10. Disassemble the fuel tank.

Installation
Warnings: The procedures comprise the fuel
treatment. Pay attention to the overflowing
of the fuel at any time and the precautions
for the treatment of the fuel; otherwise, the
bodily injury may be caused.
Warnings: When the operation related to the
fuel components is performed, any form of
open flame must be forbidden. The high
inflammability gas mixture caused in the
operation may be ignited. The wrong
operation may cause the bodily injury
accident.
1. The installation process is opposite to the
disassembly process.

CHANA.BENNI-MINI
304-01-8 Fuel Tank and Fuel Pipeline 304-01-8

Disassembly and Installation

Fuel Pump Module

Disassembly 4. Remove and discard the O-shaped sealing ring.

Warnings: The procedures comprise the fuel

treatment. Pay attention to the overflowing
of the fuel at any time and the precautions
for the treatment of the fuel; otherwise, the
bodily injury may be caused.
Warnings: When the operation related to the
fuel components is performed, any form of
open flame must be forbidden. The high
inflammability gas mixture caused in the
operation may be ignited. The wrong
operation may cause the bodily injury
accident.
1. Remove the fuel tank, and please see the Fuel
Tank part in the section for relevant
information. Installation
2. Remove the flange of the fuel pump module by
using a tool. Warnings: The procedures comprise the fuel
treatment. Pay attention to the overflowing
of the fuel at any time and the precautions
for the treatment of the fuel; otherwise, the
bodily injury may be caused.
Warnings: When the operation related to the
fuel components is performed, any form of
open flame must be forbidden. The high
inflammability gas mixture caused in the
operation may be ignited. The wrong
operation may cause the bodily injury
accident.

3. Remove the fuel pump module.

CHANA.BENNI-MINI
304-01-9 Fuel Tank and Fuel Pipeline 304-01-9

Disassembly and Installation (Continued)

1. Installation: install the new O-shaped sealing

ring for the fuel pump module.
Notes: The arrow mark on the fuel pump module
must be ensured to be aligned with the concave groove
on the fuel tank.
The installation process is opposite to the
disassembly process.

CHANA.BENNI-MINI
304-01-10 Fuel Tank and Fuel Pipeline 304-01-10

Disassembly and Installation

Gasoline Filter

Disassembly 6. Remove the filter.

Warnings: When the operation related to

the fuel components is performed, any
form of open flame must be forbidden.
The high inflammability gas mixture
caused in the operation may be ignited.
The wrong operation may cause the
bodily injury accident.
1. Disassemble the grounding wire of the battery.
2. Release the pressure of the fuel system.
3. Hoist the vehicle, and please see Section
100-01 for relevant information.
4. Remove the fuel intake pipe of the filter from
the fuel filter.

Installation
1. Warnings: When the operation related to
the fuel components is performed, any
form of open flame must be forbidden.
The high inflammability gas mixture
caused in the operation may be ignited.
The wrong operation may cause the
bodily injury accident.

Notes: Pay attention to the arrow of the fuel

flowing direction.
The installation process is opposite to the
disassembly process.
5. Remove the bolts of the fixing clips of the fuel
filter.

CHANA.BENNI-MINI
304-01-11 Fuel Tank and Fuel Pipeline 304-01-11

Disassembly and Installation

Pipeline from the fuel pump to the fuel filter

Disassembly
Installation
Warnings: When the operation relating to the
fuel components is performed, any form of Warnings: When the operation related to the
open flame must be forbidden. The high fuel components is performed, any form of
inflammability gas mixture caused in the open flame must be forbidden. The high
operation may be ignited. The wrong inflammability gas mixture caused in the
operation may cause the bodily injury operation may be ignited. The wrong
accident. operation may cause the bodily injury
accident.
1. Release the pressure of the fuel system. The installation process is opposite to the
2. Remove the fuel tank, and please the Fuel Tank disassembly process.
part in the section.
3. Remove the oil intake pipe of the fuel filter.

4. Remove the oil intake pipe of the fuel filter from

the fuel tank.

CHANA.BENNI-MINI
304-01-12 Fuel Tank and Fuel Pipeline 304-01-12

Disassembly and Installation

Oil Channel between Fuel Filter and Fuel Rail

Disassembling 7. Remove the fuel supplying pipeline from the fuel

Warnings: When the operation related to the filter.
fuel components is performed, any form of
open flame must be forbidden. The high
inflammability gas mixture caused in the
operation may be ignited. The wrong
operation may cause the bodily injury
accident.
Notes: When the operation is performed, the
vehicle is required to be hoisted.
1. Disassemble the cathode connecting line of the
accumulator cell.
2. Release the pressure of the fuel system.
3. Remove the engine.
4 Remove the fuel supplying pipeline from the oil
intake pipe of the fuel rail. 8. Remove the fuel supplying pipeline.

5. Take down the fuel supplying pipeline from the

fixing clip.

6. Separating the fuel supplying pipeline.

CHANA.BENNI-MINI
304-01-13 Fuel Tank and Fuel Pipeline 304-01-13

Disassembly and Installation (Continued)

Installation
Warnings: When the operation related to the
fuel components is performed, any form of
open flame must be forbidden. The high
inflammability gas mixture caused in the
operation may be ignited. The wrong
operation may cause the bodily injury
accident.
The installation process is opposite to the
disassembly process.

CHANA.BENNI-MINI
304-01-14 Fuel Tank and Fuel Pipeline 304-01-14

REMOVAL AND INSTALLATION (Continued)

Fuel Returning Pipeline

Disassembly
Warnings: When the operation
related to the fuel components is
performed, any form of open flame
must be forbidden. The high
inflammability gas mixture caused
in the operation may be ignited.
The wrong operation may cause the
bodily injury accident.
Remove the fuel returning pipe from the
fuel pump.

The installation process is opposite to

the disassembly process.

G32571 en 09/2002 2003.50 Gala

402-00-1 Electric Vehicle Window Controller and Switch 402-00-1

Section 402-00 Electric Vehicle Window Switch

DESCRIPTION AND OPERATION

Applicable Vehicle Model: U-Shine

Electric Vehicle Window Switch

Instruction and Operation

All the vehicle window glass of this vehicle

adopt the electric elevation type, when the
vehicle door glass is required to be elevated,
only the button of the glass lifter is required to
be pressed. The front vehicle door glass lifter
buttons are installed behind the gearshift handle,
the buttons for rear door are installed behind the
brake handle.

Button 1 is the riser button of the left front vehicle

door glass
Button 2 is the riser button of the right front vehicle
door glass
Button 3 is the riser button of the left rear vehicle
door glass.
Button 4 is the riser button of the right rear vehicle
door glass.

The door glass lifter button, the button is pressed, the

vehicle door glass will be descended by hand.
the button is lifted, the vehicle door glass will be
rised
when pressed the left front door glass lifter button
more than 300 ms, the vehicle door glass will be
descended by hand. when pressed the left front door
glass lifter button less than 300 m,the vehicle door
glass will be automatically descended.

DIAGNOSIS AND TESTING

REMOVAL AND INSTALLATION

U-Shine
402-00-2 Electric Vehicle Window Controller and Switch 402-00-2

Electric Vehicle Window Switch

Disassembly and Installation

4 Screws

2 clips on
two sides

Disassembling Method:
As shown in the Figure, all the switches adopt on the switch board., when the front electric vehicle window
switch are dismounted, firstly, press the wiring harness clip. and plucked out the plug , then the screws are removed,
the switch can be taken out.. when the rear electric vehicle window switch are dismounted, firstly, press the wiring
harness clip. and plucked out the plug, then pry the clip between the switch and board, the switch can be taken out.

U-Shine
402-00-3 Electric Vehicle Window Controller and Switch 402-00-3

Electric Vehicle Window Switch

Circuit Schematic Diagram of the Main Electric Vehicle Window Switch

Circuit Schematic Diagram of the Auxiliary Electric Vehicle Window Switch, the Left Rear
Door Electric Vehicle Window Switch and the Right Rear Door Electric Vehicle Window
Switch

U-Shine
402-00-4 Electric Vehicle Window Controller and Switch 402-00-4

Electric Vehicle Window Switch

Table of Main Electric Vehicle Window Switch Gear Position

Gear Position Table of the Auxiliary Electric Vehicle Window Switch, the Left Rear Door
Electric Vehicle Window Switch and the Right Rear Door Electric Vehicle Window Switch

U-Shine
402-00-5 Electric Vehicle Window Controller and Switch 402-00-5

Electric Vehicle Window Switch

Inspection and Maintenance
First step: check whether the ignition switch is turned on the Gear ON,
If no, please switch the ignition switch on the Gear ON
If yes, turn to the second step.
Second step: check whether the safety fuse used for controlling the vehicle window motor in the
instrument panel central control box assembly is melted,
If yes, the safety fuse is changed
If no, the universal meter measuring switch is used.
b. Check the electric vehicle window switch are communicated or not according gear position.
c. After the above check is completed, if the door locking switch is still failed, please check the motor of lifter
and connecting wiring harness.

U-Shine
403-02-1 Emergency Alarming Switch 403-02-1

Section 403-02 Emergency Alarming Switch

Applicable Vehicle Model: Benni Mini

Contents
Instruction and Operation Pages
…………………………………………………………………………………………………… 403-02-2

Disassembly and installation

…………………………………………………………………………………………………… 403-02-3

Circuit Schematic Diagram

…………………………………………………………………………………………………… 403-02-3

Pin Definition 、Gear Position Table of Emergency Alarming Switch

…………………………………………………………………………………………………… 403-02-3

Inspection and Maintenance

…………………………………………………………………………………………………… 403-02-4

U-Shine
403-02-2 403-02-2

DESCRIPTION AND OPERATION

Emergency alarming switch

Instruction and Operation

Press the switch once, the complete vehicle position lamp flashes; press the switch again, the complete vehicle
position lamp shall stop flashing.

Clip

U-Shine
403-02-3 Emergency Alarming Switch 403-02-3

Emergency Alarming Switch

Disassembly and installation

The emergency alarming switch is installed on the instrument panel. The CD is disassembled before emergency
alarming switch disassembly, Press the clip and the switch can be taken out.

U-Shine
403-02-4 Emergency Alarming Switch 403-02-4

Circuit Schematic Diagram

Gear Position Table of Emergency Alarming Switch

Pin Definition

Inspection and Maintenance

a. The emergency alarming switch does not work.
Step 1: inspect whether the lamp is damaged.

U-Shine
403-02-5 403-02-5

Step 2: inspect whether the BCM is damaged.

b. In contrast with the gear position table, inspect the on-off states of the emergency alarming switch.
c. After the above inspections are completed and the normal condition is restored, if the emergency alarming
switch does not work normally, please inspect the connecting wiring harness.

U-Shine
403-02-1 403-02-1

Section 403-02 Front Fog Lamp Switch

Applicable Vehicle Model: Benni Mini

Contents
Instruction and Operation Pages
Front Fog Lamp Switch…………………………………………………………………………………… 403-02-2

Disassembly and installation

Front Fog Lamp Switch…………………………………………………………………………………… 403-02-3

Circuit Schematic Diagram

Front Fog Lamp Switch…………………………………………………………………………………… 403-02-4

Rear vision mirror switch PIN DEFINITION

Front Fog Lamp Switch………………………………………………………………………………… 403-02-4

Inspection and Maintenance

Front Fog Lamp Switch……………………………………………………………………………… 403-02-5

U-Shine
403-02-2 403-02-2

DESCRIPTION AND OPERATION

Front Fog Lamp Switch

Instruction and Operation

Press the switch once, the front fog lamp works, and the work indication lamp is light. Press the switch again,
the front fog lamp shall be turned off, and the work indication lamp is out.

U-Shine
403-02-3 Rear View Mirrors 403-02-3

DESCRIPTION AND OPERATION (Continued)

Rear Fog Lamp Switch

Disassembly and installation
The front fog lamp switch is installed on the instrument panel. Pry the clip 1 by tool before get out the switch
installation box. Press the clip 2 and the switch can be taken out.

Clip2
Clip1

Z-Shine
403-02-4 403-02-4

Rear Fog Lamp Switch

Circuit Schematic Diagram

Gear Position Table of Rear Fog Lamp Switch

Pin definition

Rear Fog Lamp Switch

Inspection and Maintenance
a. The front fog lamp switch does not work
Step Ⅰ: Inspect the position lamp is at the ON position.
No: Please turn on the high beam
Yes: Switch to Step 2

U-Shine
403-02-5 Rear Fog Lamp Switch 403-02-5

Step Ⅱ: Inspect whether the headlight is turned on or not

No: Turn on the headlight or the high beam
Yes: Switch to Step 3
Step Ⅲ: Inspect whether the front fog lamp turn on or not
No: Please turn on the front fog lamp
Yes: Inspect according to the following methord
b. I contrast with the gear position table, inspect the on-off states of the front fog lamp
switch
c. After the above inspection is completed and the normal condition is restored, if the front
fog lamp switch still does not work normally, please inspect the front fog lamp and the
connecting wiring harness.

U-Shine
406-00-1 Illumination System 406-00-1

Section 406-00 Illumination System

Applicable Vehicle Model: Benni Mini

Contents
Disassembly and Installation Pages

Installation Position of Complete Vehicle Lamp …………………………………………………………… 406-00-2

Installation Method of Complete Vehicle Lamp……………………………………………………………… 406-00-3

Electric Appliance Principle

Reversing Lamp……………………………… 406-00-7

Internal Roof lamp………………………………………………..…………… 406-00-7
Brake Lamp……………………………………… 406-00-7
The head Lamp adjust switch 406-00-7
The front small lamp 406-00-8
The head lamp and the fog lamp 406-00-8
The Fuse and relay distribution of engine compartment 406-00-9
The Fuse and relay Distribution of Instrument Panel
The Fuse and relay container cover
Instruction and Operation………………………………………………………………………………… 406-00-10

Diagnosis and Maintenance

Dipped Headlight Failure………………………………………………………………………………… 406-00-19

High Beam Failure………………………………………………………………………………………… 406-00-26
Turning Lamp/ Warning Lamp Failure…………………………………………………………………… 406-00-39
Position Lamp Failure……………………………………………………………………………………… 406-00-57
Registration Plate Lamp Failure………………………………………………………………………… 406-00-64
Brake Lamp Failure……………………………………………………………………………………… 406-00-65
Reversing Lamp Failure……………………………………………………………………………………… 406-00-67
Front Fog Lamp Failure……………………………………………………………………………………… 406-00-70
Rear Fog Lamp Failure……………………………………………………………………………………… 406-00-71
Reading Lamp Failure……………………………………………………………………………………… 406-00-81
Front Roof Lamp Failure (part one)…………………………… 406-00-86
Front Roof Lamp Failure (part two)………………………………………… 406-00-89
406-00-91

Element Test……………………………………………………………………………………………………… 406-00-93

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406-00-2 Illumination System 406-00-2

I. Installation Position of Complete Vehicle Lamp

1. The installation positions of the external illuminating lamps on the vehicle are shown as follows:

Headlight Roof lamp

Front fog lamp

High position brake lamp

Rear brake lamp

Registration plate lamp rear Combined lamp

Reflector

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406-00-3 Illumination System 406-00-3

II. Installation Method

1. Headlight
Cross recessed pan
head screw
09116-06004

．Front Fog Lamp

2．

Cross recessed pan

head self-tapping
screw Q2714816

3. Rear combined Lamp

Cross recessed pan
head screw
Clipper
09128-06003
09409-10401

Clipper
09409-08406
Crushion pad
6303300-K01

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406-00-4 Illumination System 406-00-4
4. Rear brake Lamp

Cross recessed pan

head screw
09128-06003

5. Registration plate lamp

Nuts 09148-05001
Q2714816 cross recessed pan
head self-tapping screw
6. High position brake lamp

Nuts 09148-04002
3716013-k01 high position
braking screw
7. Roof Lamp

Cross recessed pan

head screw
Q2140512

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406-00-5 Illumination System 406-00-5
8. Reflector
Cross recessed pan
head self-tapping
screw Q2714816

Ⅰ Electric Appliance Principle

1. Principles of the reversing lamp (Schematic Diagram I)

2. Schematic diagram of the internal lamp (Schematic Diagram II)
3. Principles of the brake lamp (Schematic Diagram III)
4. Principles of the headlamp adjust switch (Schematic Diagram IV)
5. Principles of the front lamps (Schematic Diagram V)
6. Principles of the front headlamp and the front fog lamp (Schematic Diagram VI)

Reversing lamp
switch
Right head lamp

Schematic Diagram I

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406-00-6 Illumination System 406-00-6
Schematic diagram of the internal lamp

Schematic diagram of the internal lamp Schematic Diagram Ⅱ

Principles of the brake lamp (Schematic Diagram III)

Principles of the headlamp adjust switch (Schematic Diagram IV)

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406-00-7 Illumination System 406-00-7

Principles of the front lamps (Schematic Diagram V)

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406-00-8 Illumination System 406-00-8
Principles of the front headlamp and the front fog lamp (Schematic Diagram VI)

Schematic Diagram VI

．Distribution diagram of components in safety fuse box

4．

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406-00-9 Illumination System 406-00-9

Arrangement of components in the electric appliance box of the engine compartment:

MS02 MS03 MS05

3.0 3.0 3.0
RW RB RG
15A 10A 15A 10A 7.5A 7.5A 7.5A 7.5A 15A 25A 20A
CG01 FW07 FW01 AL11 BU01 EU17 AB01 AC06 DF01 PW01 PW02
1.25 0.85 1.25 0.85 0.5 0.5 0.5 0.5 1.25 2.0 2.0
VB UR WY WG YG WR R WU SR G P
f12 f13 f14 f15 f16 f17 f18 f19 f20 f21 f22

f1 f2 f3 f4 f5 f6 f7 f8 f9 f10 f11
SL01 DM01 HO01 BM05 EU16 IL01 PF01 AC01 FF01 2D136 EU08
0.5 0.5 0.5 2.00 0.5 0.85 1.25 0.85 1.25 1.25 2.0
GY N NY WY W YR RY OB PG R WN
10A 10A 10A 20A 10A 10A 15A 10A 15A 15A 15A
AG01 MA01
5.0 2.0
WG RU

The arrangement of the components in the electric appliance box of the instrument panel is shown

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406-00-10 Illumination System 406-00-10

as follows:

15A 10A 15A 10A 7.5A 7.5A 7.5A 7.5A 15A 25A 20A

ABS/EPS/仪表

鼓风机继电器
倒车灯/BCM
CD/点烟器

前后洗涤

安全气囊

主电动窗

副电动窗
A/C开关

后除霜
后雨刮

前雨刮

ECU
f12 f13 f14 f15 f16 f17 f18 f19 f20 f21 f22

f1 f2 f3 f4 f5 f6 f7 f8 f9 f10 f11
10A 10A 10A 20A 10A 10A 15A 10A 15A 15A 15A

/氧传感器等
ECU/喷油嘴
顶灯/仪表

ECU/诊断

点火线圈
制动灯

电喇叭

压缩机

前雾灯
油泵
小灯
BCM
/CD

IV. Instruction and Operation

1. Headlight

Element Type

Headlight Reflecting mirror which can be regulated to realize the alignment adjustment of beams

Headlight Adjustment

X value

Headlight To be confirmed after the test

2. If the lamps have the problems such as cracks and water leakage in their lamp bodies, matched mirrors, reflecting
mirrors, installation supporting legs, replace the lamps.
Notes: Instruction on the water leakage: after the lamps are lighted for ten minutes, no water drop can appear on the
lamp covers, and the water mist is allowed at the place without the irradiation of the sunlight. If the above situations
are satisfied, it is proved that the lamps are in the normal state.
3. Specifications of lamp bulbs and models of inserting parts
The headlight of the integrated headlight is respectively composed of dipped headlight and high
beam. The used lamp bulb is a single beam halogen lamp bulb. The models of the lamps bulb are
respectively H4, the incandescent lamp is used as the front position lamp, and the model of the lamp
bulb is W5W. The lamp bulb used in the front turning lamp is the white halogen lamp bulb, and its
model is PY21W. The size and the photoelectric performances of all lamp bulbs in the integrated
headlight shall conform to GB/T 15766.1-2000.

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406-00-11 Illumination System 406-00-11

Model of the high beam, the dipped headlight, the position lamp and the turning lamp inserting parts: HONGQIANG
DJD031A-1/TAIKE 0-1813029-1 HONGQIANG/:DJ7021-2.2-21/YUYAO DJ7037Y-2.2-21
(2) Front Fog Lamp
The lamp bulb used in the front fog lamp is the single beam halogen lamp bulb, its model is H3,
and the model of the lamp base is PK22S. The size and the photoelectric performances of the lamp bulb
shall conform to relevant regulations in GB/T 15766.1-2000.
Model of the inserting parts: DJ7021-2-21
(3) Combined Rear Lamp (including the tail decorative lamp)
The rear fog lamp in the combined rear lamp adopts the single beam halogen lamp bulb, its model is
W21W. The model of the lamp bulb in the reversing lamp is W21W. The brake lamp and the rear position
lamp adopt the double-beam incandescent lamp, and the model is P21W. The rear turning signal lamp
(hereafter rear turning lamp for short) adopts the single beam incandescent lamp, and its model is
W16W.The sizes and the photoelectric performances of all lamp bulbs in the combined rear lamp shall
conform to the relevant regulations in GB/T 15766.1-2000.
Model of the inserting parts of Lamp A: Henan Tianhai TDCY-4FS
Model of the inserting parts of the tail decorative lamp: DJY7021-2-21
(4) High Position Lamp
The high position lamp adopts 5 W5W lamp bulbs, and the size and the photoelectric performance
of the lamp bulb shall conform to the relevant regulations in GB/T 15766.1-2000.
Model of the inserting parts: DJY7021-2-21
(5) Registration Plate Lamp
The lamp bulb used in the registration plate lamp is a single beam wedge-shaped incandescent bulb,
its model is C5W.
Model of the inserting parts: DJ7031-2.8-21
V. Diagnosis and Maintenance
1. Inspection and Confirmation
Confirm the problem of the customer.
Inspect whether the obvious failure in the aspect of the machinery or electric appliance visually, and eliminate the
damaged lamp bulb.
If the obvious failure is found, before the next step is performed, solve the failure.
If the failure inspection items are not obvious, confirm the failure.
Notes: Before the lamp bulb is replaced, confirm that the lamp switch is turned off. The model and the wattage of the
new lamp bulb must be same with that of the old lamp bulb.

2. Instruction and Operation

Schematic Diagram of Central Control Safety Fuses and Relays in Engine Compartment
序号 Relays and Fuses
DF1 Main relay
DF2 Blower relay
DF3 Compressor relay
DF4 Radiator relay(low speed)
DF5 Front fog lamp relay
DF6 horn relay
DF7 Oil pump relay

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406-00-12 Illumination System 406-00-12

DF8 Radiator relay(high speed)

F1 AG01
F1-1 AGA1
F2 MS01
F3 ET01
F4 RD01
F5 AL01
F6 AG01-HF03
F7 AG01-HL01
F9 AG01-HL02
f32 Empty
f33 Empty

Schematic Diagram of Central Control Box Safety Fuse and Relay of Instrument Panel

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406-00-13 Illumination System 406-00-13

MS02 MS03 MS05

3.0 3.0 3.0
RW RB RG
15A 10A 15A 10A 7.5A 7.5A 7.5A 7.5A 15A 25A 20A
CG01 FW07 FW01 AL11 BU01 EU17 AB01 AC06 DF01 PW01 PW02
1.25 0.85 1.25 0.85 0.5 0.5 0.5 0.5 1.25 2.0 2.0
VB UR WY WG YG WR R WU SR G P
f12 f13 f14 f15 f16 f17 f18 f19 f20 f21 f22

f1 f2 f3 f4 f5 f6 f7 f8 f9 f10 f11
SL01 DM01 HO01 BM05 EU16 IL01 PF01 AC01 FF01 2D136 EU08
0.5 0.5 0.5 2.00 0.5 0.85 1.25 0.85 1.25 1.25 2.0
GY N NY WY W YR RY OB PG R WN
10A 10A 10A 20A 10A 10A 15A 10A 15A 15A 15A
AG01 MA01
5.0 2.0
WG RU

15A 10A 15A 10A 7.5A 7.5A 7.5A 7.5A 15A 25A 20A
ABS/EPS/仪表

鼓风机继电器
倒车灯/BCM
CD/点烟器

前后洗涤

安全气囊

主电动窗

副电动窗
A/C开关

后除霜
后雨刮

前雨刮

ECU

f12 f13 f14 f15 f16 f17 f18 f19 f20 f21 f22

f1 f2 f3 f4 f5 f6 f7 f8 f9 f10 f11
10A 10A 10A 20A 10A 10A 15A 10A 15A 15A 15A
/氧传感器等
ECU/喷油嘴
顶灯/仪表

ECU/诊断

点火线圈
制动灯

电喇叭

压缩机

前雾灯
油泵
小灯
BCM
/CD

Instrusment electric box cover

序号 fuse instruction
f1 Brake lamp
f2 roof lamp/instrument/CD
f3 horn
f4 BCM
f5 ECU/diagnosic
f6 Small lamp

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406-00-14 Illumination System 406-00-14
f7 Fuel pump
f8 Compressor
f9 Front fog lamp
f10 Ignition coil
f11 ECU/injector/oxygen sensor
f12 Vehicle window motor(assistant)
f13 Vehicle window motor(driver)
f14 blower relay/ Rear defroster
f15 A/C switch
f16 Safety airbag
f17 ECU
f18 Reversing lamp/BCM
f19 ABS/EPS/instrument
f20 Front wiper
f21 Frontand rear washing/rear wiper
f22 CD/ Cigarette lighter

3. Fixed Point Inspection

Inspection Items Possible Failure Measures

• Dipped headlight failure • Safety fuse • Turning to the Fixed Point

• Circuit Inspection A
• Lamp bulb
• Combined switch
• Dim light relay
• High beam malfunction • Safety fuse • Turning to the Fixed Point
• Circuit Inspection B
• Lamp bulb
• Combined switch
• High beam relay

• Non-serviceable turning lamp • Safety fuse • Turning to the Fixed Point

malfunction • Circuit Inspection C
• Lamp bulb
•BCM
• Position lamp malfunction • Safety fuse • Turning to the Fixed Point
• Circuit Inspection D
• Lamp bulb
• Combined switch
• Registration plate lamp • Safety fuse • Turning to the Fixed Point
malfunction • Circuit Inspection E
• Combined switch
• Brake lamp malfunction • Safety fuse • Turning to the Fixed Point
• Circuit Inspection F
• Lamp bulb
• Brake lamp switch

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406-00-15 Illumination System 406-00-15

Inspection Items Possible Failure Measures

• Reversing lamp malfunction • Safety fuse • Turning to the Fixed Point

• Circuit Inspection G
• Lamp bulb
• Reversing lamp switch
• Ignition switch
• Front fog lamp malfunction • Safety fuse • Turning to the Fixed Point
• Circuit Inspection K
• Lamp bulb
• Front fog lamp relay
• Front fog lamp switch
• Rear fog lamp malfunction • Safety fuse • Turning to the Fixed Point
• Circuit Inspection N
• Lamp bulb
• Front fog lamp relay
• Rear fog lamp relay
• Front fog lamp switch
• Rear fog lamp switch
• Front roof lamp malfunction • Safety fuse • Turning to the Fixed Point
• Circuit Inspection Q
• Lamp bulb

Fixed point inspection A: Dipped Headlight Failure

Inspection Items Concrete Procedures/Result/Measures

、F2.F7
A1: Check safety fuses F1、

F1

1 Turn the ignition switch to the OFF position

2 Check the safety fuse F1

3 Check the safety fuse F2

4 Check the safety fuse F7

5 Check the safety fuse f7

• Are the safety fuses intact?
  Yes
Turn to A2
→ NO
、F2.F7. If the safety
Replace the safety fuse F1、
fuse is fused continuously, the short circuit
should be found and repaired according to the
circuit diagram. Test and operate the system to
see if it is normal.
A2: Power source supply at the end socket connector of the engine compartment wiring harness
1 Turn the ignition switch to the OFF position
2 Disconnect the inserting pins HL02 of the wiring
hardness end socket connector of the engine
compartment

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406-00-16 Illumination System 406-00-16
Inspection Items Concrete Procedures/Result/Measures

3 Measure the voltage between the inserting pins

HL02，HL01 (circled by red color)of the wiring
hardness end socket connector of the engine
compartment and the grounding position of the
vehicle body

• Is the voltage display equal to the battery voltage?

→ YES
Turn toA3 3
→ NO
According to the circuit diagram, find and repair
the lines between the safety fuse F7,F9 and the
inserting pins HL01,HL02 (circled by red
color)of the wiring hardness end socket
connector of the engine compartment. Test and
operate the system to see if it is normal.
A3: Power source supply at the input end of the dipped headlight relay

1 Turn the ignition switch to the OFF position

2 Pull out the dipped headlight relay
3 Measure the voltage between the inserting pins
HL08 of the wiring hardness end socket connector
butted with the lamp light controller and the
grounding position.

• Is the voltage display equal to the battery voltage?

→ YES
Turn to A4 4
→ NO
According to the circuit diagram, find and repair
the lines between the inserting pins of the wiring
hardness end socket connector of the safety fuse
F9 butted with the lamp light relay. Test and
operate the system to see if it is normal.
A4: Check the grounding position of the inserting pin of the inserting parts for the lamp light switch
1 Turn the ignition switch to the OFF position

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406-00-17 Illumination System 406-00-17
Inspection Items Concrete Procedures/Result/Measures

2 Measure the resistance between the inserting pins

TL03,PA01 and of the wiring hardness end socket
connector butted with the lamp light switch and the
grounding position of the vehicle body.

• Is the resistance less than 0.05 ohm?

→ YES
Turn to A5 5
→ NO
According to the circuit diagram, find and repair
the open circuit between the conducting wire bus
and the grounding position. Test and operate the
system to see if it is normal.
A5: Check the output end of the lamp light switch

1 Turn the ignition switch to the OFF position

2 Disconnect the inserting pin HL10 and HL10/1of
the lamp light controller.
3 Turn the lamp light controller to the dipped
headlight position
4 Measure the resistance between the inserting pin
HL10 and HL10/1 on the lamp light controller and
the grounding position

• Is the resistance less than 0.05 ohm?

Yes
Switch to A6
No
If the inner circuit of the lamp light controller
has problems, replace it. Test and operate the
system to see if it is normal.
A6: Inspect the left headlight dipped headlight relay output
1. Switch the ignition switch to the ON position.

2. Remove the dipped headlight relay

3. Turn the lamp light controller to the dipped

headlight position

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406-00-18 Illumination System 406-00-18
Inspection Items Concrete Procedures/Result/Measures

4. Measure the voltage between the inserting pin HL09

of the dipped headlight relay and the grounding
position.

• Is the voltage display equal to the battery voltage?

Yes
Switch to A7
No
Replace the dipped headlight relay
A7: Inspect the power source supply of the dipped headlight relay inserting parts of the left headlight
1. Switch the ignition switch to the ON position
2. Turn on the dipped headlight switch

3. Measure the voltage between the inserting pin

HL02 of the engine compartment wiring harness
end socket connector and the grounding position

• Is the voltage display equal to the battery voltage?

Yes
Switch to A8
→ NO
Find and repair the circuit between the inserting
pin HL06 of the instrument panel wiring harness
end socket connector and the inserting pin HL06
of the engine compartment wiring harness end
socket connector abutted with the right high
beam and the grounding circuit according to the
circuit diagram. Test and operate the system to
see if it is normal.
A8: Inspect the power source supply of the dipped headlight relay inserting parts of the right headlight
1. Switch the ignition switch to the ON position

2. Turn on the dipped headlight switch

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406-00-19 Illumination System 406-00-19
Inspection Items Concrete Procedures/Result/Measures

3 Measure the voltage between the inserting pin HL01

of the wiring harness end socket connector abutted
with the right headlight and the grounding position

• Is the voltage display equal to the battery voltage?

Yes
Inspect the left and right high beam and replace
the left and right high beam when necessary.
No
Find and repair the circuit between the inserting
pin HL05 of the instrument panel wiring harness
end socket connector and the inserting pin HL01
of the engine compartment wiring harness end
socket connector abutted with the right high beam
and the grounding circuit according to the circuit
diagram. Test and operate the system to see if it is
normal.

Fixed Point Inspection B: High Beam Malfunction

Inspection Items Concrete Procedures/Result/Measures

B1: Inspect the safety fuses F1,F7,F9

1. Switch the ignition switch to the OFF position

2. Inspect the safety fuse f1
3. Inspect the safety fuse f7
4. Inspect the safety fuse f9

• Are the safety fuses in good condition?

Yes
Switch to B2
No
1. Switch the ignition switch to the OFF position
Replace the safety fuses F1,F7,F9, If the safety
fuse continues fusing, find and repair the short
circuit according to the circuit diagram. Test and
operate the system to see if it is normal.
B2: Inspect the control output of the combined switch
1. Switch the ignition switch to the OFF position
2. Disconnect the inserting pin HL01 of the combined
switch inserting parts

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406-00-20 Illumination System 406-00-20
Inspection Items Concrete Procedures/Result/Measures

3 Turn the combined switch to the overtaking high

beam position
4 Measure the resistance between the inserting pin
HL01 of the inserting parts abutted with the
combined switch and the grounding position

• Is the resistance less than 0.05 ohm?

Yes
Switch to B3
No
Find and replace the combined switch according
to the circuit diagram. Test and operate the
system to see if it is normal.
B3: Inspect the control voltage of the high beam relay
1 Switch the ignition switch to the OFF position
2 Turn the combined switch to the overtaking high
beam position
3 Measure the voltage between the inserting HL04 of
the socket of the high beam relay and the grounding
position.

Is the voltage display equal to the battery voltage?

Yes
Switch to B4
No
Find and repair the circuit between the inserting
pin HL03 of the instrument panel wiring harness
end socket connector and the inserting pin HL04
of the engine compartment wiring harness end
socket connector abutted with the right headlamp
and the grounding circuit according to the circuit
diagram. Test and operate the system to see if it
is normal.
B4: Inspect the power source supply of the dipped light inserting parts of the right headlight
1. Switch the ignition switch to the OFF position

2. Turn the combined switch to the overtaking high

beam position

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406-00-21 Illumination System 406-00-21
Inspection Items Concrete Procedures/Result/Measures

3 Measure the voltage between the inserting pin HL03

of the engine compartment wiring harness end
socket connector abutted with the left headlight and
the grounding position

• Is the voltage display equal to the battery voltage?

Yes
Switch to B9
No
Find and repair the circuit between the inserting
pin HL03 of the instrument panel wiring harness
end socket connector and the inserting pin HL03
of the engine compartment wiring harness end
socket connector abutted with the right high
beam and the grounding circuit according to the
circuit diagram. Test and operate the system to
see if it is normal.
B5: Inspect the control output of the combined switch
1. Switch the ignition switch to the OFF position
2. Disconnect the inserting pin HL02 of the combined
switch inserting parts
3. Turn the combined switch to the overtaking high
beam position
4 Measure the resistance between the inserting pin
HL01 of the inserting parts abutted with the
grounding position of the vehicle body.

• Is the resistance less than 0.05 ohm?

Yes
Switch to B10
No
Find and replace the combined switch according to
the circuit diagram. Test and operate the system to
see if it is normal.
（Warning Lamp Circuit）
Fixed Point Inspection C: Turning Lamp/Warning Lamp（ ）
Inspection Items Concrete Procedures/Result/Measures

C: Inspect the combined switch input

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406-00-22 Illumination System 406-00-22
Inspection Items Concrete Procedures/Result/Measures

1Switch the ignition switch to the OFF position

2Disconnect the inserting pin TL01,TR01 of the
inserting parts abutted with the combined switch

2Turn the combined switch to left and right turning

positition

3Measure the voltage between the inserting pin

TL01.TR01 and the grounding position of the
vehicle body
• Is the voltage display equal to the battery voltage?
Yes
Switch to C2
No
Find and replace the malfunction according to the
circuit diagram. Test and operate the system to see if
it is normal.
C2: Inspect the HAZARD switch output 根
插
接
并
1 Switch the ignition switch to the On position

2 Disconnect the inserting pin BM14 of the inserting

parts abutted with the HAZARD switch
3 Press the HAZARD switch
4 Measure the resistance between the inserting pin
BM14 of the inserting parts abutted with the HAZARD
switch and the grounding position of the vehicle body

• Is the voltage display equal to the battery voltage?

Yes
Switch to C3
No
Find and replace the HAZARD switch
according to the circuit diagram. Test and
operate the system to see if it is normal.
C3: Inspect the BCM output

1 Switch the ignition switch to the On position

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406-00-23 Illumination System 406-00-23
Inspection Items Concrete Procedures/Result/Measures

2 Press the HAZARD switch and the left and right

turning switch of the combined switch
3 Measure the voltage between the BCM wiring
harness inserting part TL05,TR05 and the
grounding position

• Is the voltage display equal to the battery voltage?

Yes
Switch to C4
No
Find and repair the ECU system according to the
circuit diagram. Test and operate the system to
see if it is normal.
C4: Inspect the power source supply at the end inserting parts of the floor and the engine compartment
wiring harness

1 Switch the ignition switch to the On position

2 Press the HAZARD switch and the left and right
turning switch of the combined switch respectively

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406-00-24 Illumination System 406-00-24
Inspection Items Concrete Procedures/Result/Measures

3 Measure the voltage between the inserting pins TL06

and TR06 of the Floor wiring harness end socket
connector (the red circled position) and the grounding
position of the vehicle body
4 Measure the voltage between the inserting pins TL05
and TR05 of the engine compartment wiring harness
end socket connector (the red circled position) and the
grounding position of the vehicle body
5 Measure the voltage between the inserting pins
TL10/TR10 of the front door(left and right) wiring
harness end socket connector (the red circled position)
and the grounding position of the vehicle body

• Is the voltage display equal to the battery voltage?

Yes
Replace the lamp
No
Find and repair the wiring malfunction according to
the circuit diagram. Test and operate the system to
see if it is normal.

Fixed Point Inspection D: Position Lamp Malfunction

，f6
D1: Inspecting the safety fuses F1，

1 Turn the ignition switch at the OFF position

2 Inspect the safety fuse F1
3 Inspect the safety fuse f6

• Are the safety fuses in good condition?

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406-00-25 Illumination System 406-00-25
Yes
Switch to D2
No

Replace the safety fuse F1, F6. If the safety fuse

continues fusing, find and repair the short circuit
according to the circuit diagram. Test and
operate the system to see if it is normal.
D2: Grounding position of the inserting parts of the inserting pin of the combined switch
1 Turn the ignition switch at the OFF position
2 Measure the resistance between the inserting pins
TL03 and PA01of the wiring harness end socket
connector abutted with the lamp light controller and
grounding position of the vehicle body.

• Is the resistance less than 0.05 ohm?

Yes
Switch to D3
No
Find and repair the circuit between the conducting
wire bus and the grounding position. Test and
operate the system to see if it is normal.
D3: Inspecting the output end supply of the combined switch
1 Turn the ignition switch at the OFF position
2 Disconnect the inserting pin IL02 of the combined
switch
3 Turn the lamp light controller to the position lamp
position
4 Measure the resistance between the inserting pin
IL02on the lamp light controller and inserting pins
of the grounding position.

• Is the resistance less than 0.05 ohm?

Yes
Switch to D4
No
Replace the combined switch. Test and operate
the system to see if it is normal.
D7: Inspecting the power source supply of the position lamp in the headlight
1 Turn the ignition switch at the OFF position

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406-00-26 Illumination System 406-00-26

2 Disconnect the inserting pins TL01/1 and TL02/1

of the engine compartment wiring harness end
socket connector abutted with the headlight.
3 Turn on the position lamp switch

4 Measure the voltage between the inserting pins

IL02 、 IL04 of the engine compartment wiring
harness end socket connector abutted with the
headlight and the grounding position of the vehicle
body.

Is the voltage display equal to the battery voltage?

Yes
Switch to D8
No
Find and repair the circuit among the inserting
pins of the engine compartment wiring harness
end socket connector according to the circuit
diagram. Test and operate the system to see if it is
normal.
D8: Inspecting the power source supply of the position lamp in the combined rear lamp
1 Turn the ignition switch at the OFF position
2 . Disconnect the inserting pins TL01/2 and TL02/3
of the floor wiring harness end socket connector
abutted with the combined rear lamp.
3 Turn to the position lamp position

Benni MINI
406-00-27 Illumination System 406-00-27

4 Measure the voltage between the inserting pins

IL03、IL05 of the floor wiring harness end socket
connector abutted with the combined rear lamp and
grounding position of the vehicle body.

Is the voltage display equal to the battery voltage?

Yes
•Replace the lamps
No
Find and repair the circuit among the floor wiring
harness according to the circuit diagram. Test and
operate the system to see if it is normal.

Fixed Point Inspection E: Registration Plate Lamp Malfunction

E1: Inspecting the power source supply of the floor wiring harness
1 Turn the ignition switch at the OFF position
2 Disconnect the inserting pins IL06,IL07 of the floor
wiring harness end socket connector.

3 Turn to the position lamp position

Benni MINI
406-00-28 Illumination System 406-00-28

4 Measure the voltage between the inserting pins

IL06,IL07 of the floor wiring harness end socket
connector and the grounding position of the vehicle
body.

• Is the voltage display equal to the battery voltage?

Yes
Replace the lamp
No
Find and repair the circuit among the inserting
pins IL03 and IL06, IL0 of the floor wiring
harness end socket connector according to the
circuit diagram. Test and operate the system to
see if it is normal.

Fixed Point Inspection F: Brake Lamp Malfunction

F1: Inspecting the safety fuse f1

1. Turn the ignition switch at the OFF position

2. Inspect the safety fuse F1

• Is the safety fuse in good condition?

Yes
Switch to F2
No
Replace the safety fuse F1. If the safety fuse
continues fusing, find and repair the short circuit
according to the circuit diagram. Test and
operate the system to see if it is normal.
F2: Inspecting the power source supply at the end socket connector of the engine compartment wiring
harness
1 Inspecting the power source supply at the end
socket connector of the engine compartment
wiring harness
2 . Disconnect the inserting pin AG01 of the engine
compartment wiring harness end socket connector.

Benni MINI
406-00-29 Illumination System 406-00-29
3. Measure the voltage between the inserting pins
AG01 of the engine compartment wiring harness
end socket connector (the red circled position) and
the grounding position of the vehicle body.

Is the voltage display equal to the battery voltage?

Yes
Switch to D3
No
Find and repair the circuit between safety fuse
F1 and the inserting pins AG01 of the engine
compartment wiring harness end socket
connector according to the circuit diagram. Test
and operate the system to see if it is normal.
F3: Inspecting the power source supply of the brake lamp switch
1 Turn the ignition switch at the OFF position

2 Disconnect the instrument panel wiring harness

end inserting parts SL01 abutted with the brake
lamp switch.
3 Measure the voltage between the front
compartment wiring harness end socket connector
SL01 abutted with the brake lamp switch and the
grounding position of the vehicle body.

• Is the voltage display equal to the battery voltage?

Yes
Switch to F4
No
Find and repair the circuit between safety fuse F1
and the front compartment wiring harness end
socket connector AG01 according to the circuit
diagram. Test and operate the system to see if it is
normal.
F4: Inspecting the power source supply of the brake lamp and high position brake lamp in the combined
rear lamp
1 Turn the ignition switch at the “OFF” position

Benni MINI
406-00-30 Illumination System 406-00-30

2 Disconnect the inserting pins

AL24/1,AL4/2,AL24/3 of the floor wiring harness
3 Turn on the brake lamp switch

4 Measure the voltage between the inserting pins

AL24/1,AL4/2,AL24/3 of the floor wiring harness
and the grounding position of the vehicle body,

• Is the voltage display equal to the battery voltage?

Yes
• Replace the lamps
No
Find and repair the circuit among the inserting
pins AL24 of the instrument wiring harness end
SL01socket connector according to the circuit
diagram. Test and operate the system to see if it
is normal.
Fixed Point Inspection G: Reversing Lamp Malfunction

G1: Inspecting the safety fuse f16

1 Turn the ignition switch at the OFF position

2 Inspect the safety fuse f16

Is the safety fuse in good condition?

Yes
Switch to G2
No
Replace the safety fuse f16. If the safety fuse
continues fusing, find and repair the short circuit
according to the circuit diagram. Test and
operate the system to see if it is normal.
G2: Inspecting the power source supply of the end socket connector of the engine compartment wiring
harness
1 Turn the ignition switch at the OFF position

Benni MINI
406-00-31 Illumination System 406-00-31

2 Disconnect the pin BU01 at the end socket

connector of the instrument panel wiring harness
3 Measure the voltage between the pin BU01 at the
end socket connector of the instrument panel wiring
harness (in the red circle) and the grounding
position of the vehicle body.

• Is the voltage display equal to the battery voltage?

Yes
Switch to G3.
No
Find and repair the circuit between the safety
fuse f16 and the pin BU01 at the end socket
connector of the instrument panel wiring
harness. Test and operate the system to see if it is
normal.
G4: Inspecting the power source supply of the reversing lamp switch
1 Turn the ignition switch at the OFF position

2 Disconnect the inserting pin BU01 of the wiring

harness end socket connector abutted with the
reversing lamp switch
3 Turn the ignition switch at the ON position

4 Adjust to the reversing gear position

5 Measure the voltage between the inserting pin

BU01 of the wiring harness end socket connector
abutted with the reversing lamp switch and the
grounding position of the vehicle body.

• Is the voltage display equal to the battery voltage?

Benni MINI
406-00-32 Illumination System 406-00-32

Yes
Switch to G5
No
Find and repair the circuit among the inserting
pins of the engine compartment wiring harness
end socket connector according to the circuit
diagram. Test and operate the system to see if it
is normal.
G5: Inspecting the power source supply of the reversing lamp
1 Turn the ignition switch at the OFF position

2 Disconnect the inserting pin BU01 of the floor

wiring harness end socket connector abutted with
the combined rear lamp.
3 Turn the ignition switch at the “ON” position.

4 Turn on the reversing lamp switch.

5 Measure the voltage between the inserting pin

BU01 of the floor wiring harness end socket
connector abutted with the combined rear lamp and
the grounding position of the vehicle body.
• Is the voltage display equal to the battery voltage?

Yes

• Replace the lamps

No

Find and repair the circuit among the inserting

pins of the floor wiring harness end socket
connector according to the circuit diagram. Test
and operate the system to see if it is normal.
Fixed Point Inspection K: Front Fog Lamp Malfunction
Concrete Procedures/Result/Measures
Inspection Items
K1: Front fog lamp signal of the combined switch
1 Turn the ignition switch at the “OFF” position
2 Turn on the front fog lamp switch

Benni MINI
406-00-33 Illumination System 406-00-33

3、Measure the voltage between front fog lamp

switch pins FF02 and the grounding position
HF11/1

HF11/1
Is the voltage display equal to the battery voltage?
2.0
B

Yes
Switch to K2
No
Inspect the combined switch and make sure the
grounding is in good condition, replace the
combined switch when necessary. Test and
operate the system to see if it is normal.

2: Inspect the power source supply of the front fog lamp relay
K2

1 Turn the ignition switch at the OFF position

2 Measure the voltage between the inserting pins
FF01 of the front fog lamp relay and the grounding
position of the vehicle body.

• Is the voltage display equal to the battery voltage?

Yes
Switch to K3
No
Find and repair the circuit between the inserting
pins FF01 and F7 of the front fog lamp relay. Test
and operate the system to see if it is normal.

Benni MINI
406-00-34 Illumination System 406-00-34

K3: Inspect the output voltage of the front fog lamp relay

1 Switch the ignition switch to the ON position

2 Turn on the headlight switch

3 Press the front fog lamp switch

4 Measure the voltage between the inserting socket pin
FF03 of the front fog lamp relay and the grounding
position

• Is the voltage display equal to the battery voltage?

Yes
Turn to K4
→ NO
Inspect the front fog lamp relay, and replace the
front fog lamp relay if necessary. Test and operate
the system to see whether it is normal.

K4: Inspect the power source supply of the front fog lamp
1 Switch the ignition switch to the ON position

2 Disconnect the inserting pins FF03/2 of the engine

compartment wiring harness end socket connector
which connected with the front fog lamp and the
inserting pin FF03/1

3 Press the front fog lamp switch

Benni MINI
406-00-35
Fixed Point Inspection N: Rear Fog Lamp Failure
N1: Inspect the safety fuse
Illumination System 406-00-35
4 Measure the voltage between the inserting pins FF03
of the engine compartment wiring harness end socket
connector which connected with the front fog lamp
and inserting pins FF04 and the grounding position
• Is the voltage display equal to the battery voltage?
Yes
• Inspect lamps, and replace the lamps if necessary
→ NO
Search and repair circuit between the inserting
pins FF03 of the front fog lamp wiring harness
end socket connector and the fog lamp relay
inserting pin FF03 according to the circuit
diagram, and test and operate the system to see
whether it is normal.
Research and repair the circuit between the
inserting parts of the front fog lamp wiring
harness end socket connector FF04 and the fog
lamp relay inserting pin FF03 ,and test and
operate the system to see whether it is normal.
f7
1 Inspect the safety fuse f7
• Are the safety fuses intact?
Yes
Turn to N2
→ no
Replace the safety fuse F7, F1. If the safety fuse
continues to fuse, search and repair the short
circuit according to the circuit diagram. Test and
operate the system to see whether it is normal.
Benni MINI
406-00-36 Illumination System 406-00-36

N2: Inspect the power source supply of the rear fog lamp
1 Turn the ignition switch to the ON position

2 Turn on the headlamp switch,measure the

voltage of the combined switch inserting pin
HL10/1
• Is the voltage display equal to the battery voltage?

→ Yes
Turn to N3
→ No
Inspect the circuit between HL10 and
HL10/1 According to the wiring diagram
N3: the power source supply of the rear fog lamp
1 Turn the ignition switch to the ON position

2 打Turn on the headlamp switch,measure the

voltage of the rear left combined lamp inserting
pin RF01

• Is the voltage display equal to the battery voltage?

→ Yes

Turn to N4
→ No
Inspect the circuit between the rear left
combined lamp inserting pin RF01 and
combined switch inserting pin RF01
According to the wiring diagram
N4: Inspect the grounding signal of the rear fog lamp switch

Disconnect the connector of the rear left combined

lamp, inspect the circuit between GD02/1 and the
grounding GD02 is connected or not? And make
sure the grounding GD02 is in good condition

Benni MINI
406-00-37 Illumination System 406-00-37

→ connect
inspect the fog lamp bulb, replace it when
necessary
→ no
Inspect and repair the circuit between GD02/1
and the grounding GD02
→ YES
inspect the rear fog lamp bulb, replace it
when necessary
The Fixed Point Inspection Q: Front Roof Lamp Failure (circuit I)
Inspection Items Concrete Procedures/ Results/ Measures

、f2
Q1: Inspect the safety fuses F1、

1 Inspect the safety fuse F1

2 Inspect the safety fuse f2

• Are the safety fuses intact?

Yes
Turn to Q2
→ NO
Replace the safety fuse F1. F2 If the safety fuse
continues to fuse, search and repair the short
circuit according to the safety fuse. Test and
operate the system to see whether it is normal.
Q2: Inspect the power source supply of the loof lamp
1、Disconnect the inserting pins of loof lamp inserting
parts, measure the voltage of the inserting pin
DM01 of inserting parts of loof lamp harness

• Is the voltage display equal to the battery voltage?

Yes
Turn to Q3
No

Benni MINI
406-00-38 Illumination System 406-00-38
Search and repair the circuit between the
inserting pins DM01 of the ceiling wiring
harness and DM01 (the red circled place) of
inserting parts of the instrument panel wiring
harness end and the safety fuse f2 according to
the circuit diagram, test and operate the system
to see whether it is normal.
Q3: make the wire of the front roof lamp short to grounding
1、Disconnect the front roof lamp switch

Measure the resistance between the inserting part

DM03 of the front roof lamp switch and the vehicle
body grounding

→ Is the roof lamp is connected to the rounding?

YES,Inspect the lamps, replace the lamps if

necessary
No
Search and repair the circuit between the wiring
harness end DM01 and the vehicle body
grounding PA01,make sure the grounding is
good according to the circuit diagram
Test and operate the system to see whether it is
normal.
Q4: Inspect the grounding wire of the front roof lamp switch

1 Disconnect the front roof lamp switch

2 Measure the resistance between the inserting part

BG13 of the front roof lamp switch and the vehicle
body grounding
The Fixed Point Inspection Q: Front Roof Lamp Failure (circuit II)
1 Disconnect the inserting pins DM01 and DM02 of
the wiring harness end socket connector
2 Open the left front door

3 Measure the voltage between the inserting pins

DM01 and DM02 of the ceiling wiring harness end
socket connector
• Is the voltage display equate to the battery voltage?

→ YES

Benni MINI
406-00-39 Illumination System 406-00-39
• Inspect the lamps, and replace the lamps if
necessary
→ no
Search and repair the circuit between the
instrument panel wiring harness end DM01 and
DM02 and the inserting pins DM01 and DM02
of the ceiling wiring harness end socket
connector according to the circuit diagram

Element Test

Relay
The element test shall be applied in the following relays:
Relay –high beam and fog lamp

1. Inspect the relay contact situation under the normal conditions

Measure the resistance between the inserting pins 3 and 5 (VFE0023129). (Show in the above figure)
Is the resistance value less than 2 ohm?
If so, replace the relay.
Otherwise, continue to perform Step 2.

2. Inspect the relay contact situation under the connection circumstances.

Supply the power to the insetting pins 1 and 2 (VFE0023407).
(as shown in the above figure)
Measure the resistance between the inserting pin 3 and 5 (VFE0023407).

Benni MINI
406-00-40 Illumination System 406-00-40
Is the resistance value less than 2 ohm?
If so, the electric appliance is intact.
Otherwise, replace the relay.

Headlight Adjustment

General Tool

Headlight Detector

Adjustment
1. Preparation Work:
• The vehicle is positioned on the horizontal surface.
• Inspect whether the headlight work normally works. Replace the damaged components if necessary.
• Inspect the wheel air pressure.
• Inspect the load (the oil load of the fuel tank can surpass the half.)
• Adjust the horizontal system of the headlight for several times, in order to inspect the function, and
turn the switch to the position 0.
• If the vehicle has the air suspension, make sure the switch is at the ON position.
• The lamp light test display is set up to the following headlight adjustment value
(X): X=17 cm/10 m=0 degree 59 minute=1.7%.（left）；
X=35 cm/10 m=2 degree 0 minute=3.5%.（right）.
2. Adjust the dim light.
• Open the dipped headlight.
1. Vertically adjust the screw.
2. Horizontally adjust the screw.

Benni MINI
406-00-41 Illumination System 406-00-41
The following figure Dipped and high
presents the left lamp Headlight

Verticality
Adjusting Point

Horizontal Adjusting Point

3. Vertical Adjustment.
•Adjust the dim light and enable the cut-off line produced by the dim light in the scope of the shade area, as
shown in the following figure.

Benni MINI
406-00-42 Illumination System 406-00-42
4. Notes: Some astigmatism of the dipped headlight may be above the 15-degree line.
Notes: It is possible to perform vertical adjustment again after the horizontal adjustment.
Horizontal Adjustment (as shown in the left figure).
• Adjust the dim light and enable the cut-off line produced by the dim light in the scope of the shade area, as
shown in the following figure.

Benni MINI
 407-00-1 Accumulator System 407-00-1

Section 407-00 Accumulator System

Applicable Vehicle Model: Benni Mini

Contents
Installation and Disassembly Page

Accumulator system……………………………………………………………… 407-00-02

Accumulator electric appliance connection diagram

Accumulator system……………………………………………………………… 407-00-02

Inspection servicing and Charging maintenance

Accumulator system……………………………………………………………… 407-00-03

Benni Mini
 407-00-2 Accumulator System 407-00-2

Accumulator System
I. Installation and Disassembly
The accumulator system is installed at the left side of the engine compartment.

Where:
1. Accumulator assembly
2. Accumulator tray
3. Accumulator fixing pressing plate
4. Accumulator fixing screw rods

II. Accumulator Electric Appliance Connection Diagram

Benni Mini
 407-00-3 Accumulator System 407-00-3

The basic parameters of the accumulator are as follows:

a. Specification: the exhaust type (be commonly called as maintenance free type)
b. Nominal voltage: D.C. 12 v
c. 20 hours rated capacity: 45 AH
d. Idle capacity: above 94min
e. Charging acceptance capacity: above 9 A
f. Quality (with electrolyte): 13.2Kg

III. Inspection Servicing and Charging Maintenance

1. Self discharging of the accumulator
Theoretically, the self discharging of the accumulator can not be avoided, although the self discharging of the
maintenance-free accumulator is far lower than the common accumulator, a certain degree of self discharging still
exists, even if the accumulator is laid in open circuit, if the laying time is too long, the electric charge quantity of
the accumulator can still be obviously consumed. The self discharging of the accumulator is mainly affected by
the following factors:
a. The higher the temperature is, the higher the self-discharge rate is, generally, the self-discharge rate can
increase approximately 2.7 times when the temperature increases 10℃, and the accumulator
self-discharging rates have great difference when the vehicle is stored in summer and in winter.
b. The storage site has great influence on the self-discharge of the accumulator which can be aggravated
when the humidity and dust are much.
2. The capacity loss after the accumulator is loaded on the vehicle
After the accumulator is loaded on the vehicle, the electric quantity loss mainly in the following several
aspects:
a. The electric quantity loss during the debugging process;
b. The electric loss of the incessant electric appliance on the vehicle, such as the anti-theft siren;
c. The electric leakage is generated due to the poor insulation performance of the elements on the vehicle;

Benni Mini
 407-00-4 Accumulator System 407-00-4

d. The electric quantity loss generated due to the static current and the leaked current in the circuit when the
cathode wire is not pulled out.
Thus, the standing time of the accumulator is related with many factors. Under normal circumstances,
the fully charged accumulator can still start the vehicle when being positioned under the condition that
the cathode wire is pulled out.
3. Inspection method of the accumulator
a: Inspection with a discharging detector:
The corresponding contactors are pressed on the anode and cathode of the accumulator with force, when the
pointer of the discharging detector is within the green scope and keeps for two seconds, it is shown that the
accumulator capacity can sufficiently meet the starting requirements of the heavy current, when the pointer of the
discharging detector is within the red scope and has no other abnormality, which means that the accumulator
capacity is not enough and the accumulator needs charging.
b: Utilization of the headlight as load and the inspection of voltmeter
The voltmeter is connected to the accumulator according to the method for measuring the voltage of the
accumulator, and the voltage value of the accumulator is read, then, the headlight is turned on, if the accumulator
voltage does not fall quickly and keeps above 10 volts, the accumulator can start the vehicle after being fully
charged. If the headlight is turned on, and the accumulator voltage falls rapidly, the accumulator can be charged
complementarily to let it restore functions, for the accumulator set aside for a long time, the charging time should
be relatively prolonged, charging for many times is required to make it fully activated.
Notes: the accumulator which is charging or has been just the charged is not suitable for the inspection with
the discharging detector. Because the hydrogen and oxygen can be generated during the charging process, sparks
can be generated during the inspection through the discharging detector or the resistance wire to cause the gas
explosion, therefore it will cause personal injury and goods damage.

4. Accumulator Failure Phenomenon, Causes and Remedial Measures

Failure Causes Trouble-shooting Methods Complementary Measures

Phenomenon
The electric 1. The starting is frequent and the The accumulator is timely
power of the continual starting is long, and the charged.
accumulator is accumulator can not be charged in
insufficient, time when in serious shortage of
the starter power
does not run The related circuits on the
or runs 2. The creepage phenomenon exists vehicle is inspected, the
weakly on the vehicle circuit or the lamp creepage phenomenon is
light on the vehicle is forgotten to be eliminated, and the additional
turned off. charging to the accumulator is
performed.

Benni Mini
 407-00-5 Accumulator System 407-00-5

The long-time idling of the

accumulator should be
3. The idling time of the vehicle is avoided, the accumulator
long, and the accumulator is put into should be charged fully before
use without being charged. being set aside and should be
charged one time every month
after the idling.
Under the load condition, the
4. The output voltage of the vehicle
output voltage of the vehicle
generator is too low or the generator
generator is between
is failed.
13.2-14.4 V.
5. The starting current is too large The carbon brush is performed
generated because teh carbon brush inside the engine for
surface of the engine (starting motor) inspection and maintenance.
is abraded (bottoming).
6. The connector at the anode or The connecting end post is
cathode end pole of the accumulator tightened.
is loosened.
Part of the end post is poorly The end pole post is tightened. Avoid the instant startup
connected, which results form the for fear of the damage
The end post
fire striking of the vehicle when it is inside the accumulator.
is burnt.
started (i.e. the heavy current
discharging)
5. Charging Methods:
The voltage inspection should be firstly carried out before departure, if the voltage is lower than 12.6 V, the
accumulator should be charged before the departure, and therefore, the storage time of the stock vehicles in other
places, in which the vehicles can be started, can be greatly prolonged. The charging methods are as follows:
a: Constant voltage charging:
The constant voltage is 14.8 V, when the charging current is reduced to 3 A, the charging should be
continued for another three hours, and the charging is completed. Note that the charging current can not
pass 25 A.
b: Constant current charging:
The accumulator is charged by adopting the 6A current until the accumulator voltage reaches 14.8V, then
the accumulator is charged by using the 3A current, and the charging is completed.

Benni Mini
408-00-1 Wiper and Scrubber 408-00-1

Section 408-00 Wiper and Scrubber

Applicable Vehicle Model: Benni Mini

Contents
Installation and Disassembly Pages

Wiper and Scrubber System 408-00-02

Circuit Schematic Diagram

Wiper and Scrubber System 408-00-04

Failure Judgment and Maintenance

Wiper and Scrubber System 408-00-05

Benni Mini
408-00-2 Wiper and Scrubber 408-00-2

Wiper and Scrubber

I. Installation and Disassembly

The components of the wiper(front and rear) as follows :

Assembly Components Specification Remars

(number and (number and description)
description)
5205010-K01 + 5205110-K01+ Wiper motor
Wiper Motor and
5205210-K01+ Connecting
transmission arm
rod
assembly
5205170-K01+ Main wiper 550mm Shanduoli
5205070-K01+ brush
Main wiper arm and 5205270-K01+ Main wiper arm
wiper brush Different to
Front
assembly 5205071-K01+Decorative cap Benni ,but can be
Wiper
replace with
5205220-K01+ Secondary 300mm Shanduoli
wiper brush
5205120-K01+
5205320-K01+ Secondary
Secondary wiper arm
wiper arm
and wiper brush
The same
assembly 5205071-K01+ Decorative
specification with
cap
Main wiper
3741091-K01+ Decorative
cap
M16×1/subtense
3741092-K01+nuts
22mm hexagonal
3741093-K01+mat Ø40×Ø16×2 Steel mat
3741090-K01+
3741094-K01+rubber cushion Outside
Rear window wiper
I
motor assembly
3741095-K01+rubber cushion Inside
II
Rear
Assemble on the
Wiper 3741096-K01+plastic seat
motor
3741190-K01+ Wiper motor
6310011-K01+Connector
6310010-K01+ cover
Rear window wiper 6310110-K01+ Rear window
arm and wiper brush wiper arm
assembly 300mm The same
6310210-K01+ Rear window
specification with
wiper brush
Benni and Alsvin

Benni Mini
408-00-3 Wiper and Scrubber 408-00-3

2. Installation of front wiper products as follows (the disassembly sequence is opposite to the
installation sequence):
a. Front wiper motor and transmission arm assembly (installed in crossbeam cover board
below the front window , as shown in the following figures):

2 1

Detach the wiper motor and connecting rod from the ball joint between the motor brace and
connecting rod , install the bearing seat of the motor axles 1 and 2 to the upper cover board
through three M6 hexagonal flange nuts respectively.

Remove the end of the connecting rod from the hole of the vehicle body, press the ball head of the
motor brace into the ball groove, fix the motor on the vehicle body through 4 M6×25 flange
bolts, install the motor and the connecting rod, fix the front decorative cover to the vehicle body

Benni Mini
408-00-4 Wiper and Scrubber 408-00-4

and then install the main wiper brush and Secondary wiper brush.

b. Main and auxiliary wiper arms and wiping brush (installed on the wiper motor and the
transmission arm, as shown in the following figures)

5
4

Installation requirements are as follows:

Firstly install the main driving side wiper, and the wiping brush is required to be
approximately parallel with the lower black edge tangent of the glass. The main wiper must
parallel with auxiliary wiper, install the wiper arm to the axles (position 4 and 5 , shown in the
figures)through M8 nuts, after tightening, use the decorative caps to cover.
Installation standards:
There are tapered straight teeth with the proportion of 1:3 on the axles of the wiper motor
and the transmission arm mechanism, and tapered holes with the proportion of 1:3 in the wiping
arm hole. Fix the wiper arm on the axle of the transmission mechanism axle through the M8
flange nut, and the torque is 18N·m to 22N·m.
Installation requirements are as follows:
(1) Firstly install the main driving side wiper, and the wiping brush is required to be
approximately parallel with the lower black edge tangent of the glass.
(2) Then install the assistant driving side wiper, and ensure that the assistant driving side
wiper is connected with the main wiping brush through the connection of the head and the tail
parts. The wiping brush is approximately parallel with the lower black edge tangent of the
glass.

Benni Mini
408-00-5 Wiper and Scrubber 408-00-5

2. Rear wiper device: (installed at the back door and the rear window glass, as shown in the
following figure) (applicable to the Benni Mini super-value type vehicle)

1
3

① Rear window wiper motor assembly

②Rear window wiper arm and wiper brush assembly
③M6 hexagonal flange nuts
④Axle sealing ring of the back door wiper, M16 nut and decorative cap
⑤ M6hexagonal flange bolts (two)
The installation sequence is as follows: (the disassembly sequence is opposite to the
installation sequence)
(1) Make the axle ① of the wiper motor through the glass; install the two rubber cushions to
the lockpin of back door.
(2) Install the ④Axle sealing ring of the back door wiper, M16 nut and decorative cap to the
axles;
(3) Remove the wiper arm cover , fix the tapered holes of the wiper arm to the axle,
horizontally place the wiping brush, fix the wiper arm and axle through ③M6 hexagonal
flange nuts , and cover the wiper cover.
the black edge

Benni Mini
408-00-6 Wiper and Scrubber 408-00-6

3. The scrubbing device is installed as follows:

7
5

4 1

3
6 2

Wherein:
① Windshield cleanser assembly
② Front and rear tank motor
③M6 hexagonal flange bolts
④Front scrubber hose assembly
⑤Cleanser front nozzle assembly
⑥Rear scrubber hose assembly
⑦Cleanser rear nozzle assembly

A .Installation of the scrubbing device: (installing the cleanser assembly at the right side of
the engine compartment)

2 3

4
5
3 3

The sequence is as follows: (the disassembly sequence is opposite to the installation

sequence)

Benni Mini
408-00-7 Wiper and Scrubber 408-00-7

⑴Align the installing hole of the scrubbing tank① with the installation position of the
vehicle body installation position;
⑵Install the scrubbing tank to the vehicle body through ③M6 hexagonal flange
bolts (three);
⑶respectively connect scrubbing hoses ④and ⑤with the scrubbing tank motor (as shown in
the above figure);
Note: The rear scrubbing hose is surrounded with green tape, which is corresponding to the
green pin of scrubbing motor.
⑷ Connecting the scrubbing hoses, pay attention to the rear scrubbing hose is corresponding
to the green pin of scrubbing motor.

B. Installation of the front nozzle, these two front nozzles are installed on the decorative
cover of engine hood, as the following figure shows:

Installation requirements are as follows:

Make these two scrubbing hoses through those two holes of the decorative cover of engine
hood, connect with these two nozzles and then install them to those two holes of the
decorative cover of engine hood.
C. Installation of the rear nozzle (the rear nozzle is supplied with the high position brake lamp
assembly. as the following figure shows:

Installation requirements are as follows:

Connect the rear scrubbing hoses with the rear nozzle, install the high position brake lamp to
the top hole of the vehicle body, Tighten these two screws.

Benni Mini
 408-00-8 Wiper and Scrubber 408-00-8

II. Schematic Diagram of Electric Appliance

1. Schematic Diagram of Front /Rear Wiper and scrubbing System Control

pin

position

Front wiper

Wiper
Front scrubbing

Switch

Front scrubbing

Front
Front Rear Rear
Wiper
Scrubb Scrubb Wiper
Motor
ing ing Motor
Motor Motor

Benni Mini
408-00-9 Wiper and Scrubber 408-00-9

2. Schematic Diagram of Front Wiper System Control

Benni Mini
408-00-10 Wiper and Scrubber 408-00-10

III. Failure Judgment and Maintenance

1. Definition and Basic Parameters of Inserting Parts

a. Front wiper motor socket

High
Low

Blue and Red

Blue and white

Reset

The parameters of the front wiper motor are as follows:

① Nominal voltage: 12V
② Test voltage: 13.5V
③ Braking torque (low speed): ≥20N.m
④ No-load current (low speed): ≤3A
⑤ Braking current: ≤25A
⑥ Motor noise: (≤50dB at low speed; ≤60dB at high speed)
⑦ Rotating speed: under the condition of normal load (the load of 1.9 N.m), the low speed
is 40±4r/min; and the high speed is 60±6r/min;
b. Rear wiper motor socket

Yellow/Blue Blue

Reset

Orange
Black
Work

Benni Mini
408-00-11 Wiper and Scrubber 408-00-11

The parameters of the rear wiper motor are as follows:

1 Rated voltage: 12 V; Test voltage: 13.5 V
○
○
2. Load: load torque of 0.6 N.m; rotating speed of 38±5 rpm; current ≤ 3 A;
○3 No-load: current ≤ 2 A; rotating speed of 38±5 rpm;
○4 Braking: braking torque ≥ 9 N.m; braking current ≤14 A;
○5 Motor noise：≤ 55d.B;
c. The scrubbing motor socket

The parameters of the scrubbing motor parameters are as follows:

○1 Rated voltage：12 v
○2 Test voltage：13.5 v
○3 Working current: below 3.8 A
○4 Maximum current: below 15 A
○5 Rated time：the maximum continuous time under no-load condition is 20s; and the
maximum continuous time in the normal circulation motion is 60s;
○ Spraying pressure：118 Kpa
6

○7 Spraying flow：above 220 ml/10s

○8 Water tank capacity：1.8-2.0 L
○9 Scrubbing fluid：dropping a small amount of household cleaning agent into the water
(appropriately 3-15 ml)

2. Failure Inspection
Wiper:
Failure Phenomenon
Phenomenon 1: The front wiper has failure.
Solution Procedures:
a. Inspect whether the battery voltage is more than 9v. If so, please enter b; otherwise, please
inspect the battery;
b. Inspect whether the front wiper safety fuse F14（15A） in the central control box is broken.
If so, replace the safety fuse; otherwise, please enter c;

Benni Mini
408-00-12 Wiper and Scrubber 408-00-12

c. Inspect whether the end at one end of the engine compartment wiring harness which is
connected with the wiper motor is well grounded. If so, please enter d; otherwise, inspect
the wiring harness;
d. Inspect whether the voltage of the FW03 end at the + end of the engine compartment
wiring harness which is connected with the wiper motor is 12 v in the state with the ON
position. If so, please enter e; otherwise, inspect the wiring harness.
e. Switch the wiper controlling handle of the combined switch at the high speed (HI) position
in the state with the ON position, and inspect whether the wiper works at a high speed. If
so, please enter f; otherwise, inspect the voltage of the engine compartment wiring harness
end FW02 at the +2 end of the wiper motor is 12 v. If so, replace the wiper motor;
otherwise, sequentially inspect whether the port wiring harness is communicated with the
combined switch, and whether the fast gear of the combined switch is connected.
f. Switch the wiper controlling handle of the combined switch at the low speed (LO) position
in the state with the ON position, and inspect whether the wiper works at low speed. If so,
please enter g; otherwise, inspect the voltage of the engine compartment wiring harness
end FW04 at the+1 end of the wiper motor is 12 v. If so, replace the wiper motor;
otherwise, sequentially inspect whether the port wiring harness is communicated with the
combined switch, and whether the fast gear of the combined switch is connected.
g. Switch the wiper controlling handle of the combined switch at the “clearance (INT)”
position in the state with the ON position, and inspect whether the wiper works at the
“clearance (INT)” position. If so, please enter h; otherwise, please replace the combined
switch.
h. Switch the wiper controlling handle of the combined switch at the one-time wiping (MIST)
position in the state with the ON position, If the one-time wiping (MIST) is realized, the
wiper motor works normally; otherwise, please replace the combined switch.

：The rear wiper does not work or can not return.

Phenomenon 2：

Solution Procedures:
a. Inspect whether the battery voltage is more than 9 v. If so, please enter b; otherwise,
please inspect the battery
b. Inspect whether the rear wiper safety fuse F23.1.5（10A） in the central control box is
broken. If so, replace the safety fuse; otherwise, please take the next step;
c. Inspect whether the RW06 end of wiring harness connected with one end of the wiper
motor is in good condition . If so, please take the next step; otherwise, inspect the wiring
hardness;
d. Inspect whether the voltage of the RW02 at the + end of the wiring hardness connected
with the wiper motor is 12 v in the state with the ON position. Inspect whether the end
G15 which is connected with the wiper motor is well grounded. If so, please take the next
step; otherwise, inspect the wiring harness.
e. Switch the wiper controlling handle of the combined switch at the rear wiper and rear
scrubbing position respectively in the state with the ON position:
①the rear wiper is not work:
Inspect whether the voltage of the RW02 end of wiring harness connected with one end of the

Benni Mini
408-00-13 Wiper and Scrubber 408-00-13

combined switch is 12 v?
Yes, inspect the wiring harness between the end and the rear wiper controller and the rear
wiper is in good condition?
No, replace the combined switch.
②the rear scrubbing is not work:
Inspect whether the voltage of the RW03 end of wiring harness connected with one end of the
combined switch is 12 v?
Yes, inspect the wiring harness between the end and the rear wiper controller and the rear
wiper is in good condition?
No, replace the combined switch.
③ Both of the rear wiper and the scrubbing is not work:
Inspect whether the voltage of the FW01/2 end of wiring harness connected with one end of
the combined switch is 12 v?
Yes, please take the next step,
No, inspect the wire harness

Phenomenon 3: The Front wiper can not return automatically.

Solution procedures are as follows:

a. In the state with the ON position, measure whether the voltage of FW03 port at the + end
of engine compartment wiring harness connected with the wiper motor is 12 V. If so,
please come to the next step; otherwise, inspect the circuit;
b. In the state with the ON position, use the universal meter to measure the voltage of the
BB06 port of the wiring harness connected with the S end of the wiper motor connecting.
Firstly open the wiper position of the combined switch, and then return perform the
returning operation. Observe whether the universal meter shows the 12 V power source
output. If so, please replace the combined switch; otherwise, please replace the wiper
motor;
Phenomenon 4: The Rear wiper can not return automatically.
Solution procedures are as follows:
a. In the state with the ON position, measure whether the voltage of RW01 port at the + end
of engine compartment wiring harness connected with the wiper motor is 12 V. If so,
please come to the next step; otherwise, inspect the circuit;
b. In the state with the ON position, use the universal meter to measure the voltage of the
RW05 port of the wiring harness connected with the S end of the wiper motor connecting.
Firstly open the wiper position of the combined switch, and then return perform the
returning operation. Observe whether the universal meter shows the 12 V power source
output. If so, please replace the combined switch; otherwise, please replace the wiper
motor;
c. Inspect the RW05 port of the wiring harness ,which is connect to wiper controller is
connect or not?
Yes, please replace the wiper controller;
No, inspect the circuit;

Benni Mini
408-00-14 Wiper and Scrubber 408-00-14

Phenomenon 5: The wiper can not wipe tidily and shakes.

Solution: (please refer to the following operation and cleanliness standards)
a. Before inspection: ① use the cleaning agent to clean the vehicle windscreen; ② clean
away dust on the rubber strip of the wiper blade and use a wet towel to gently wipe the
cutting edge so as to get rid of foreign matters.
b. Wet the windshield in a spraying way, start the motor, and make the wiper work for one
week (brushing back and forth at a time). Visually inspect the residual drag mark on the
glass immediately, and judge the grade of the wiping cleanliness (see the following table
for standards). During the warranty period, the wiping cleanliness below the fourth grade
indicates that the wiper blade is not qualified, and the wiper blade shall be replaced.
c. On the basis of Item b, continuously move the wiper and use hearing method to inspect
whether the contact between the rubber strip and the glass utters abnormal sound. If there
are abnormal sounds, please make sure that: ① the glass is smooth and without ripple mark;
and ② the glass is cleaned completely. If the two aspects mentioned above are confirmed,
it can be judged that the wiper blade is not qualified. Please replace the wiper blade.
Wiping
Appearance Type Description
Cleanliness Grade

The wiping surface is completely

10
tidy

A continuous line trace with the

maximum width of 1 mm exists in
9
the upper and lower 1/4 area of
the wiping surface respectively
Two continuous line traces with
the maximum width of 1 mm exist
8
in the upper and lower 1/4 area of
the wiping surface respectively
Three continuous line traces with
the maximum width of 1 mm exist
7
in the upper and lower 1/4 area of
the wiping surface respectively
A continuous line trace with the
width of less than 1 mm exists in
2/4 area of the wiping center and
6
four continuous line traces with
the maximum width of 1 mm exist
in the upper and lower 1/4 area

Benni Mini
408-00-15 Wiper and Scrubber 408-00-15

A continuous line trace with the

width of less than 1 mm exists in
2/4 area of the wiping center and
5
six continuous line traces with the
maximum width of 1 mm exist in
the upper and lower 1/4 area

Relatively many continuous

4
stripes

Wiping 3 Continuous foggy phenomena

cleanliness
which does
not suit the
requirements 2 Insufficient wiping

1 Shaking

Scrubbing part:
Failure phenomenon:
Phenomenon 1: The front water spraying is not in the right position.
Solution: use pins or other tools to adjust the nozzle to be at the proper position so as to
ensure that the water spraying area covers 60% of the wiping area of the wiper.

Phenomenon 2: No water is sprayed (in the front part or the rear part).
Solution procedures:
a. Inspect whether the battery voltage is more than 9 V. If so, please enter the next step;
otherwise, please inspect the battery;
b. Inspect whether the central control box safety fuse F23（10A） is broken. If so, please
replace the safety fuse; otherwise, please enter the next step;
c. Disassemble the port of the engine compartment wiring harness connected with the
scrubbing tank motor and inspect whether the FW06 end or RW04 end of the front
scrubbing motor is well grounded. If so, please enter the next step; otherwise, please
inspect the grounding wire;
d. In the state with the ON position, switch to the scrubbing position of the combined switch
and inspect whether the voltage of the FW05 end or RW03 end of the wiring harness is 12
V. If so, please switch to f; otherwise, please enter the next step;
e. Respectively inspect the wiring harness ends: inspect whether the connection from the end
of the engine compartment wiring harness connected with the scrubbing tank motor to the
wiping end (FW05 or RW03) of the combined switch connected with the instrument panel

Benni Mini
408-00-16 Wiper and Scrubber 408-00-16

wiring harness, from the wiping end (RW08) of the combined switch connected with the
instrument panel wiring harness to the RW01/1 end of the wiring harness of the central
control box is broken. If so, please repair or replace the wiring harness; otherwise, please
repair or replace the combined switch;
f. Connect well the wiring harness. In the state with the ON position, switch to the scrubbing
position of the combined switch. Inspect whether the working sound of the motor is normal
or whether water is sprayed out of the scrubbing tube. If so, enter the next step; otherwise,
please replace the scrubbing tank assembly;
g. Respectively inspect the front scrubbing hose or the rear scrubbing hose, and inspect
whether the hoses interfere the vehicle body and whether it is clogged by sundries such as
dust. If so, please reinstall and readjust the scrubbing hoses; otherwise, please reinstall all
scrubbing components and enter the next step;
h. In the state with the ON position, open the scrubbing position of the combined switch and
observe whether water is sprayed. If so, it is indicated that the repair is completed;
otherwise, replace the scrubbing tank and perform the adjustment again. If the failure
phenomenon still exists, please inspect again from Step a.

Benni Mini
 408-01-1 Cigarette Lighter Device 408-01-1

Section 408-01 Cigarette Lighter Device

Applicable Vehicle Model：Benni Mini

Contents
Installation and Disassembling Pages

Cigarette Lighter Device…………………………………………………………… 408-01-02

Circuit Schematic Diagram

Cigarette Lighter Device………………………………………………………… 408-01-02

System Detection and Failure Elimination

Cigarette Lighter Device…………………………………………………………… 408-01-03

Benni Mini
 408-01-2 Cigarette Lighter Device 408-01-2

Cigarette Lighter
Ⅰ. Installation and Disassembling
The cigarette lighter is installed on the control panel of the control box switch

Cigarette Lighter

Control Box Switch Panel

Ⅱ. Electric Appliance Schematic Diagram

Connecting the back light control switch

Cigarette Lighter

Cigarette Lighter Inserting Port

Benni Mini
 408-01-3 Cigarette Lighter Device 408-01-3

Electric appliance parameters of the cigarette lighter

(1) Rated voltage: D.C.12v
(2) Maximum current: 10A
(3) Resetting time: Less than 14±4s
(4) Durability: 5000 times

Ⅲ. Inspection Maintenance
Phenomena a: Cigarette lighter is out of work
Solutions:
1. Inspect whether the battery voltage is normal or not; if affirmative, please move on to the
next step; if negative, please inspect the battery;

2. Confirm that the vehicle key is put into Gears of ACC and ON; if affirmative, please move
on to the next step; if negative, please put the key into the Gears of ACC and ON and re-inspect
the cigarette lighter working state;

3. Inspect whether the safety fuse f13（15A） in the instrument panel safety fuse box is
broken or not; if affirmative, replace the safety fuse; if negative, please move on to the next step;

4. Pull out the cigarette lighter, under the state of Gear ACC or Gear On, respectively inspect
the power source end CG01、and the grounding end G2 of connecting the instrument panel
wiring harness with the cigarette lighter, wherein, the power source end CG01should have at least
9v voltage output, and simultaneously the grounding end G2 should be well-grounded; if
affirmative, please replace the cigarette lighter; if negative, inspect the connecting circuit of the
power source end CG01and the battery and that of the grounding end G2.

Benni Mini
 501-01-1 interior panels and trim 501-01-1

Chapter 501-01 Interior panels and trim

Vehicle applied: Changan·Benni MINI

Contents Page
Standard

Description and operation

Disassembly and Assembly

Front door trim panels .....................................................................................

Rear door trim panels .....................................................................................
Front column trim panels .....................................................................................
Middle column trim panels ...................................................................................
Rear column trim panels .......................................................................................

Changan·Benni MINI
 501-01-2 interior panels and trim 501-01-2

Disassembly and Assembly

Disassembly and Assembly of Front
door trim panels（Symmetrical）

A: Disassembly
1. Remove the front door window frame
trim assembly

3. Disassemble the front door trim panel

assembly
First forced open the cover of screws as
shown

First pry the top, pull out the snap, then

dismantled below.

2.Disassemble the inner handle

assembly.
Remove the screws shown first

Then remove the three screws as

shown, and a screw on the armrest box,
and then forced open from the bottom
up

And then prize open the clip of front

door open hand assembly.

Changan·Benni MINI
 501-01-3 interior panels and trim 501-01-3

Then forced open the rear door inner

handle clips.
B:Assembly

Assembly in accordance with the

opposite of disassembly

Disassembly and Assembly of Rear

door trim panels（Symmetrical）

A. Remove the rear door window frame

trim assembly (similar with the front
door)
1. Forced open the trims of rear door and
window, position of clips as below.
3.Disassenmble the rear door inner
trims.
Then remove the two screws as shown,
and a screw on the armrest box, and
then forced open from the bottom up

2, Disassemble the rear door inner

handle, (same with front door)
First remove the screws as below.

Changan·Benni MINI
 501-01-4 interior panels and trim 501-01-4

B:Assembly

Assembly in accordance with the

opposite of disassembly

3.Disassemble the middle column trim

panels, position of clips as image below
shows：

Disassembly and Assembly of Column

trim panels（Symmetrical）

A：Disassembly
1.Disassemble the front column trim
panels, position of clips as image below
shows：

4. Disassemble the trim assembly on

the middle column
First remove the one screw as shown at
the bottom, and then forced open the
snaps from the bottom up (three)

2.Disassemble rear cover of front

column
First remove a screw at the upper left
corner as shown below, then pry open
the connection clips to the
dashboard.(On the lower right corner of
the figure).

5. Disassemble the rear door trims.

Changan·Benni MINI
 501-01-5 interior panels and trim 501-01-5
First remove a screw at the lower right First remove a screw at the lower right
as shown in the middle and a thread as shown in the middle and a thread
snap at the middle left, and then forced snap at the most left, and then forced
open from the bottom up open from the bottom up

6.Disassemble the rear column trims,

First remove the two screws as shown
at the bottom, and then forced open the
snaps from the bottom up \

B:Assembly

Assembly in accordance with the

7. Disassemble the front door trims. opposite of disassembly

Changan·Benni MINI
501-02-1 Rearview Mirror 501-02-1

Description and operation

Chapter 501-02 Rearview mirror

Vehicle applied: Changan·Benni MINI

Contents 页码
Description and operation
501-02-1
External rearview mirrow……………………………………………………………………………… 501-02-2

Disassembly and Assembly

External rearview mirrow ……………………………………………………………………………… 501-02-3

Changan·Benni MINI
1. 501-02-2 Rearview Mirror 501-02-2
Description

DESCRIPTION AND OPERATION Rearview Mirror

The rearview mirrors of this vehicle is

combined with side turn lamp, and is kind of
manual adjustment mirrors, lens can be
adjusted by adjusting the handle inside the
front door handle to get the desired lens
position.

Changan·Benni MINI
501-02-3 Rearview Mirror 501-02-3

Disassembly and Assembly

2, remove the rear view mirror adjustment

handle rubber sheath;

3 Unscrew the mounting nut;

Disassembly
1, first remove the door panels, detailed steps,
see "501-01 chapter interior panels and trim";
2, unplug the rear view mirror wiring harness
plugs;
3, removed the mirror cover;

4, Remove the the rear-view mirror from the

door panel.

1 Remove the two rear-view mirror mounting

bolts;

Changan·Benni MINI
501-09-4 Rear View Mirrors 501-09-4

Assembly
Assembly steps are in reverse order of
disassembly

Changan·Benni MINI
501-03-1 Seats 501-03-1

Chapter 501-03 Seats

Vehicle applied: Changan·Benni MINI

Contents Page
Description and operation
Seats .................................................................................................................................... 501-03-02

Disassembly and Assembly

Front Seats ....................................................................................................... (40 100 0) 501-03-03

Rear Seats..................................................................................................................... (40 122 0) 501-03-04

Changan·Benni MINI
 501-10-2 Seats 501-03-02

Seats
。
This Vehicle is fitted with two rows of seats,
both front seats of all models can slide front
and rear, and adjust the backrest angle, and
head heightens; rear seats in the practical
models and fashion models are 100% Integral
Backrest, and in the luxury models and
premium models are equipped with 4 / 6 split
backrest. All these backrests can be folded flat
to increase luggage compartment space, and
convenient transportation is convenient travel
items. Specific adjustment method can refer to
"User’s Manual."

Changan·Benni MINI
501-10-3
Disassemble and install
Front seats (40 100 0)
Disassembly
1. Unplug the plastic alarm wiring harness
plugs of seat belt on the frame on the slide
lock, that under the seat, see step ①
2. Pulling the unlock handle in front of the
inferior part of the seat, see step ②, while
sliding the seat to move it to the rear position,
see step ③
3. Remove the front seat mounting bolts, see
step ④
Seats 501-03-03
4. Repeat steps ②, pulling the unlock handle,
slide the seat to move it to the front position,
then remove the rear mounting bolts
Assembly
1. Install seat. Note: Do not fully tighten the
seat bolts.
2. Move the seat toward to the end. Tighten
the front seat mounting bolts.
3. Move the seat toward to the front. Tighten
the rear seat mounting bolts.
4. Plug the alarm wiring harness of seat belt
buckle.
5. Front seat mounting bolt torque value is：40
± 3NM.
Changan·Benni MINI
501-10-4
Disassemble and install
Rear Seat
Disassemble （In case of Integral
Backrest）
1. Lift up the cushion by force, to make it
out of the plastic buckle from the body of
the floor. See Step ①
2. Pull the unlock button at the shoulder
position of backrest, put down the
seatback, in order to remove backrest. See
step ② and ③
(Note: Steps of 4 / 6 split backrest is the
same as above of the Integral Backrest)
3. Remove the seat bolts. See step ④
Integral backrest:
Disassembly of Integral backrest：
Seats 501-03-04
Remove the bolts behind the backrest, one
bolt on left side and one on right. As shown
above.
4 / 6 split backrest:
Disassembly of 4 / 6 split backrest：Remove the
4 bolts behind the backrest, on the left, right
and middle location. As shown above.
Assembly
1. Location the backrest by bolts.
2. Lock the backrest.
3. Put the cushion under the backrest.
4. Fix the cushion fixed to the body buckle.
5. Rear seat mounting bolt torque value: 35
± 3NM.
Changan·Benni MINI
501-04-1 Glass, Window, Frame 501-04-1

501-04 Chapter Glass, Window, Frame

Vehicle model: CHANGAN·Benni MINI

MENU PAGE
Specification

Specification........................................................................ 501-04-2

Specification and Operation

Glass, window, frame ............................................................................................................ 501-04-3

Openable door ....................................................................................................................... 501-04-3
Fiexed door window ............................................................................................................... 501-04-3

Diagosisi and Test

Glass, window, frame ............................................................................................................ 501-04-4

Check and Confirm ................................................................................................................. 501-04-4
Location Test.................................................................................................................................... 501-04-4

Regular Operation

Door window regulator .................................................................................... (42 001 0) 501-04-10

Disassembly and Installation

Front door window glass .................................................................................. (42 314 0) 501-04-12

Rear door window glass ................................................................................... (42 315 0) 501-04-14
Back door window glass ......................................................................................................... 501-04-16
Wind shild screen ........................................................................................... (42 115 0) 501-04-17
Front door window glass trim ......................................................................... (42 333 0) 501-04-20
Rear door window glass trim........................................................................... (42 334 0) 501-04-21

CHANGAN·Benni MINI
501-04-2 Glass, Window, Frame 501-04-2

Specification

Lubricator, fluid, seal, and sealant

ITEMS Specification
Fliter SKM-2G9524-A
Paint SKM-2G9525-A
1K sealant WSKM-2G309-B
2K sealant ESK-M2G369-A1
2K hardener ESK-M2G369-A2

Torque specification
ITEMS Nm lb-ft lb-in
Wiper arm nut 18 13 -
Glass fix plate nut 5 - 44
Window moter fix nut 8 - 71

CHANGAN·Benni MINI
501-04-3 Glass, Window, Frame 501-04-3

Specification and Operation

DESCRIPTION AND OPERATION

Glass, window, frame

Openable door
Door window ususally have certain specification,
market decides specification of electrical power
window. Passanger can control electric power
window by four control switch.

Fixed door window

Wind sheild screen is fixed to window frame by PU
sealant, sealant also have water proof function
around window frame.
It need to good sealant to fix glass directly, PU
sealant need to deal with specially.
Attention: If environmental temperature is below
10°C, warming sealant will be affected by heat
gun. Temperature and moisture affect sealant
working time, the time is short in warm, moist
environment than in cold, dry environment.
Attention: 在The water film of glass or window
frame affect sealant effective.
Before using sealant, clean moisture which near
glass or window frame by heat gun.
It need to two glass cupule when installing glass,
other tolls can be get from tool set.

CHANGAN·Benni MINI
501-04-4 Glass, Window, Frame 501-04-4

Diagnosis and Test

DIAGNOSIS AND TESTING

Glass, window, frame

Please refer to 501-04 chapter for diagram and Mechanic part Electric part
connection.
– Window sealant – Fuse
Universal tool – Window frame –Capacitance
– Connctor box
Multimeter
– Switch
– Circuit
Diagnosis and Test 3. If problem have been found through
inspection or customer report, we should
1. Confirm client problem solve problem before going to nest step.
2. Inspect directly danage of mechanic and 4. If can bnot troubleshoot malfunction directly,
electric part refer to visual inspection sheet.
Visual inpsection sheet
Malfunction description Possible malfunction reason Repair method
• All electric power window failed • Fuse •Steering location test A
• Window glass control switch
• Circuit
• Only one electric power window • Fuse • Steering location test B
failed • Window glass control switch
• Circuit
• Defroster failed • Heat • Steering location test C
• Rear window heat control switch
•Rear window wire
• Circuit
•Defroster can be cut off • Rear window heat relay • Steering location test D
automatically • Reaer window heat control
switch

Location test
Attention: Test all electrics by digital
multimeter
Locaion test A: All electric power window failed
Test item Detail steps/Result/Method
A1: Check fuse f21(30A),f22(30A)
1 Check fuse f21,f22 (30A).
2 Check fusef21,f22 (30A).
• Is fuse normal?
→ Yes
To A2
→ No
Install a new fuse and check sytsyem
operation, if fuse is failed, chck short
ground of circuit.

CHANGAN·Benni MINI
501-04-5 Glass, Window, Frame 501-04-5

Diagnosis and Test

Test item Detail steps/Result/Method

A2: Check instrument fuse f21,f22 (30A).
1 Turn on ignition switch
2 Test voltage between f21(30A) in central fuse
box and PW09 in ground, voltage between
f22(30A) in central fuse box and PW15 in
ground.

• If Voltage big than 10V?

→ Yes
To A3
　 No
Repair PW09, PW15 circuit until system
operation is normal.
A3: Test electric power window control switch
1 Ignition switch is OFF position
2 Turn off
3 Test electric power window control switch, refer
to distribution for relative material.

•Is electric power window control switch normal?

→ Yes
To A4
→ No
Installing a new electric power window
control switch, test system operation is
noraml or not.
A4: Test electri power window control switch voltage
1 Turn on ignition switch
2 Test voltage between plug of electric power
window switch and grounding, test voltage
between PW04(P2.0) and PW01(G2.0) of main
electric power window, test voltage PW03(G2.0)
and PW02(P2.0) of deputy electric power
window.

CHANGAN·Benni MINI
501-04-6 Glass, Window, Frame 501-04-6

Diagnosis and test

Test item Detail steps/Result/Method

• Is voltage big than 10V?

→ Yes
To A5
→ No
Repair circuit, test system operation is
normal.
A5: Test electric power window control switch circuit.
1 Turn off ignition switch
2 Test voltage between plug of electric power
window switch and grounding, test voltage
between PW15(B2.0) and PW09(B2.0) of main
electric power window, test voltage PW16(B2.0)
and PW15(B2.0) of deputy electric power
window.

• Is resistance lee than 5 ohm?

→ Yes
Verify customer problem
→ No
Repair grounding circuit, test system
operation is normal.
Tset B: Only one electric power window failed
Test Item Detail step/Result/Method
B1: Test failed electric power window control switch
1 Disconnect electric power control switch
2 Test deputy electric power control switch, refer
to distribution for relative material.
• Is electric power window control switch normal?
→ Yes
To B3
→ No
Installing a new electric power indow control
switch, test system opeartion is normal.
B2: Test failed electric power window control switch assembly
1 Turn on ignition switch
2 Test voltage between wires and connector of
failed electric power window control switch.
Test voltage between PW04(P2.0) and
PW01(G2.0) of main electric power window
control switch. Test voltage between
PW03(G2.0) and PW02(P2.0) of deputy electric
power window control switch.

CHANGAN·Benni MINI
501-04-7 Glass, Window, Frame 501-04-7

Diagnosis and Test

Test Item Detail step/Result/Method

• Is voltage big than 10V?

→ Yes
To B4
→ No
Repair wires and test system operation is normal.
B3: Check ground connection which control window down function between electric power
window switch assembly and electric power window motor.
1 Turn off ignition switch
2 Test reisistance between plug of electirc
power window and grounding
• Is resistance big than 10000 ohm?
→ Yes
Verify customer problem
→ No
To B5
B4: Check Check ground connection which control window Up function between electric power
window switch assembly and electric power window motor.
1 Test reisistance between plug of electirc power
window and grounding
• Is resistance less than 5 ohm?
→ Yes
Verify customer problem
→ No
To B6
• Is resistance less than 5 ohm?
B5: Check failed electic power window motor
1 Disassemble failed elelctric power window
motor connector
2 Test failed electric power window motor
resistance
• Is resistance less than 5 ohm?
→ Yes
Verify custoner problem
→ No
Replace elelctric power window motor
Location test C: Failed defroster system
Test item Detail step/Result/Method
C1: Test rear window heat voltage

1 Turn off ignition switch

2 Disassemble rear window heater connector
3 Disassemble rear window heater control switch
4 Turn on ignition switch

CHANGAN·Benni MINI
501-04-8 Glass, Window, Frame 501-04-8

Diagnosis and test

5 Test voltage between DF02(R 0.85) of rear

window heater and grounding

• Is voltage big than 10V?

　→Yes
To C2
　→No
To C5
C2: Check rear window heater grounding circuit
1 Test voltage between rear window heater
connector and grounding
• Is resistance less than 5 ohm?
　→Yes
To C3
→ No
Test rear window heater grounding circurt,
check it working state is normal?
C3: Check rear window heater wire is disconnected or not?
1 Test resistance between rear window heater
connector and grounding.

•Is resistance less than 5ohm?

→ Yes
Verify customer problem
→Νο
Replace a now rear window heater and
check system operation is normal.
C4: Check rear window heater control switch LED
1 Connect rear window heat switch
• Dose LED light on?
CHANGAN·Benni MINI
501-04-9 Glass, Window, Frame 501-04-9

Diagnosis and Test

→Yes
To C5
→不No
To C6
C5: Check rear window heat control switch voltage
1 Turn off ignition switch
2 Disconnect rear window heat control switch
3 Turn on ignition switch
4 Test voltage between DF02(R0.85) of rear
window heat control switch connector and
grounding
• Is voltage big than 10V?
→ Yes
To C6
→N
Repair DF02(R 0.85) wire, check system
operation is normal
C6: Test rear window heat control switch grounding circuit
1 Turn off ignition switch
2 Test resistance between DF04(B 0.85) of rear
window heat control switch connector and
grounding
• Is resistance less than 5ohm?
→ Yes
To 7
→ No
Repair wire, check system operation is
normal
C7: Check rear window heat control switch grounding circuit
1 Test resistance between DF04(B 0.85) of rear
window heat control switch connector and
grounding
• Is resistance less than 5ohm?
→ Yes
Repalce a new switch, check system
operation is noraml
→Νο
Repair wires, check system operation is
noraml

CHANGAN·Benni MINI
501-04-10 Glass, window, frame 501-04-10

Regular operation

Front window glass regulator(42 001 0)

Disassembly 4. Divide glass regulator motor and connector
1. Disassemble door trim plate. Refer to
501-05 chapter for relative material
2. Caution: Don’t touch sealant surface
to avoid affect seal effective.
Put off waterproof film from door trim
• Put off waterproof film by plastic knife

3. Down glass as shown in illustrated

position

CHANGAN·Benni MINI
501-04-11 Glass, Window, Frame 501-04-11

Regular operation

5. Disassemble door window fix nut. Rear door window regulator

Disassembly
1. Disassemble door window trim palte, refer t
o 501-05 chapter for relative material.
2. Disassemble door airproof file
• Put off waterproof film by plastic knife
Caution: Don’t touch sealant surface to
avoid affect seal effective.

6．Disassmeble door glass

3. Down door window glass to removable

position
7．Disassemble door window regulator fix nut
(Six on side)

4. Disconnect connector of motor and wire

7

8 8. Remove door window regulator

CHANGAN·Benni MINI
501-04-12 Glass, window, frame 501-04-12

Regular operation

5. Disassemble doorwindow glass fix nut

（Electric power window）
Fix nut in located place

6．Disassemble door glass

7．Disassemble door window glass regulator

fix nut

8. Remove door window glass regulator

CHANGAN·Benni MINI
501-04-13 Glass, Window, Frame 501-04-13

Disassebmbly and Installation

REMOVAL AND INSTALLATION

Front door eindow glass（42 314 0）

Disassebmly
To all vehicles
1. Disassemble front door trim plate, refer to
01-05 chapter for relative material.
2. Caution: Don’t touch sealant surface to
avoid affect seal effective.
Put off waterproof film from door

6. (electric power window)

To electric power window vehicle

3. Down glass to illustrated position

6. Disassemble front dor glass

4. Detach connector of glass motor regulator

and wires
5. Remove frpnt door outside trim

CHANGAN·Benni MINI
501-11-14 Glass, Window, Frame 501-04-14

Disassebmbly and Installation

Installation
To all vehicles

1. Install front door window glass

2. Install front door window glass on regulator

and screw nut tightly.

3. Install front door outside trim

To electric power window vhicle
4. Connect connector of glass regulator and
wires.
To all vehicles
5. Attaching waterproof film on door inner trim
plate.
6. Installing front door trim plate, refer to
501-05 chapter for relative material.

G109245 en CHANGAN·Benni MINI

501-04-15 Glass, Window, Frame 501-04-15

Disassebmbly and Installation

Rear door window glass (42 315 0)

Remove
To all vehicles
1. Renove rear door trim plate, refer to 501-05
6. Remove door window glass fix nut (electric
chapter for relative material
power window)
2. Caution: Don’t touch sealant surface to Fix nut in located place
avoid affect seal effective.
Put off waterproof film from door inner plate

3. Down door window glass to removable.

4. Remove door window glass outside
waterproof trim

7. Remove rear door window glass

5. Detach connector of glass regulator motor

and wires

CHANGAN·Benni MINI
501-04-16 Glass, Window, Frame 501-04-16

Disassebmbly and Installation

Installation To electric power window vehicle

4. Connect connector of window glass
regulator motor and wires
To all vehicles

1. Installing rear door window glass

To all vehicles
5. Attach waterproof film

2. Install window glasstrim 6. Install rear door trim plate, refer to 501-05
3. Install rear door window glass in regualtor chapter for relative material
and screw nut tightly.
• Installing fix nut

To hand window vehicle

7. Install door window regulator handle

CHANGAN·Benni MINI
501-04-17 Glass, Window, Frame 501-04-17

Disassebmbly and Installation

Back door glass

A0 Remove
1. Remove wires(Only for vehicle with electric
power defrost sytem and rear wiper
function)
2. Disassemble bace door assembly, release
install point of back door

3. Hold on back door, remove two install point

of back door hinge.

4. Remove bace door assy

5. Remove back door accessory: hinge, brace
rod install plate, rear wiper assy(Only for
vehicle with electric power defrost sytem
and rear wiper function)
6. Cut off wire trim by plastic knife
7.

Installation
1. Installation steps is reverse for remove

CHANGAN·Benni MINI
501-04-18 Glass, Window, Frame 501-04-18

Disassebmbly and Installation

Fornt wind shield screen (42 115 0)

Usual equiptment
Heat gun
Glass glue cut machine
Sealant gun
6. Remove engine hood trim(left)
DIsassmbly
1. Disconnect negative cable of battery, refer
to 414-01 chapter for relative information
2. Attention: If environmental temperature is less
than 10°C, cartridges should be warm in 15
minutes in oven or warm to 25°C by heat gun
sealant if it’s necessary

8. Remove engine hood trim(right)

3. Remove front wind shield screen wiper

8. Close engine hood

9. Remove inner rearback mirror
10. Remove A-piller trim plate of front wind
shield screen

4. Brace engine hood

5. Remove engine hood trim fix nut

CHANGAN·Benni MINI
501-04-19 Glass, Window, Frame
Disassebmbly and Installation
11. Warning: Glove ane glasses must be
worn when using cut machine,
because of chips happened when
cutting, it will be harmful to human.
Caution: Blade knife should be
changed when cut different degree, to avoid
damage vehciel or trim plate.
12. Remove wind shield screen with other
help of technican
Installation
1. Caution: When using PU sealant, open
door firtsly, to avoid large pressure
when door open or close
Caution: Contact celaned surface will
affect sealant effective.
Cut off exccessful sealant
• Clean sealant in wind shield screen carefully
501-04-19
2. Celan damaged steel plate, iron chip and
irrelative material which easily cause galss
damage.
3. Warning: To ensure sealant effective,
clean moisture on sealant surface
totally.
Control heat gun tepmerature of 25°C,
clean moisture in wind shield screen and
glass sealant.
4. According to specification to prepare wind
shield screen and PU sealant.
5. Attention: 100mm fornt of PU sealant can be
discarded for shorten working time.
Attention: Any leaked area should be put sealant
again to prevent any leakage.
Put on PU sealant along 8-10mm wind
shield screen frame
CHANGAN·Benni MINI
501-11-20 Glass, Window, Frame 501-11-20

Disassebmbly and Installation

6. Attention: Press every parts evenly.

Install wind shield screen with helps from 12. Close engine hood
technician 13. Connect battery negative cable, refer to
414-01 chapter for relative material.

7. If environmental temperature below to 10°C,

warm 50mm by heat gun in 15 minutes.

8. Install A-pillar trim plate in wind shield

screen
9. Install inner rearback mirror
10. Open engine hood
11. Install wind shield screen wiper

CHANGAN·Benni MINI
501-04-21 Glass, Window, Frame 501-04-21

Disassebmbly and Installation

Front door window glass trim (42 333 0)

Remove
Installation
1. Disassemble front door window glass, refer
to window glass chapter for relative
material 1. Installation step is reverse for disassenmbly.
2. Disassemble door rearview mirror handle
(To hand window rearview mirror)

3. Remove window rearview mirror trim cover

4. Remove front window glass frame trim

CHANGAN·Benni MINI
501-04-22 Glass, Window, Frame 501-04-22

Disassebmbly and Installation

Rear door window glass trim(42 334 0)

Remove
1. Remove rear window glass, refer to rear
window glass for relative material
2. Remove rear window glass trim

Installation
1. Installation step is reverse for disassembly

CHANGAN·Benni MINI
501-05-1 Instrument Panel and Control Rack 501-05-1

Section 501-05 Instrument Panel and Control Rack

Applicable Vehicle Model BENNI-MINI

contents page
Specifications

Specifications........................................................................................................................

501-05-2

Disassembly and installation

Instrument panel ................................................................................................. (43 644 0) 501-05-3

CHANGAN-BENNI.MINI
501-05-2 Instrument Panel and Control Rack 501-05-2

Specification

Torque Specifications
Description Nm lb-ft lb-in
Tightening bolt at the upper part of the instrument panel 3 - 27
Tightening bolt on the side surface of the instrument 19 14 -
panel
Tightening bolt at the lower part of the instrument panel 19 14 -

CHANGAN-BENNI.MINI
501-05-3 Instrument Panel and Control Rack 501-05-3

Disassemble and installation

REMOVAL AND INSTALLATION

Instrument Panel (436440)

Disassembly
Warnings: Please remember to wear
protective glasses when operation is
performed on vehicles with safety airbags
or the safety airbag module is moved,
otherwise damage may be caused to human
bodies.

Take down the cigarette lighter assy (refer to

408-01),move ash box, control box screw 1. Disassemble control panel assy and
cover, gearshift cover assy and the rear disconnect the connect switch and the
window panel, then disconnect all the lock of air conditioner (refer to
connection switch 401-00),disassemble the acoustic
unit(refer to 404-00)

Disassemble 5 installation bolts of the central

control box and take down the central control 2. Disassemble the combination meter
box. cover(two fixing bolts ),disassemble the
combination meter (refer to 403-00)

Disassemble the decorative cover plate assembly at

the left /right 3. Disassemble the air bag cover (when
disassemble the co-airbag ,need to
disassemble two fixing screws)

长安·奔奔MINI
501-05-4 Instrument Panel and Control Rack 501-05-4

Disassemble and installation（continued）

8 Disconnect the back connect switch of

emergence alarming lamp switch assy

4 Disassemble the up and down cover of

steering lock (three fixing screws)

Installation
5 Disassemble the kneel protest panel(two
fixing screws),disconnect the connect switch 1. The installation procedures are opposite to the
of switch box installation assy disassembly procedures.

6 Disassemble the steering column( refer

to204-03)
7 Disassemble the glove box (one fixing bolt,
two bottom fixing screws)

CHANGAN-BENNI.MINI
501-06-1 Handle, lock and enter system 501-06-1

501-06 Chapter Handle、Lock and Enter system

Vehicle Model: CHANGAN·Benni MINI

MENU PAGE
Specification

Specification ....................................................................................................................... 501-06-2

Specification and Operation

Handle, lock and enter system ............................................................................................. 501-06-3

Remove and Installation

Front hood lock ............................................................................................................. (41 232 0) 501-06-4

Front door lock.............................................................................................................. (41 351 0) 501-06-5
Rear door lock............................................................................................................... (41 352 0) 501-06-6
Back door lock .............................................................................................................. (41 726 0) 501-06-7
Door outside handle.................................................................................................. (41 333 0) 501-06-8
Door lock remoter............................................................................................................................... 501-06-9
Door lock core ........................................................................................................... (41 336 0) 501-06-10

CHANGAN·Benni MINI
501-06-2 Handle, lock and enter system 501-06-2

Specification

Torque specification
ITEM Nm B-lt B-Inch
Engine hood bolt 10 - 89
Back door bolt
DESCRIPTION AND OPERATION
10 - 89

CHANGAN·Benni MINI
501-06-3 Handle, lock and enter system 501-06-3

Specification and Operation

Handle, lock and enter system

Front door and rear door usually is controlled by

door outside handle and door lock, then front door
Front hood lock is controlled by front control set,
lock and lock core is connected.
back door lock is controlled by back control set.
Lock set have only one control rod which control
close lock, open lock and open door.

CHANGAN·Benni MINI
501-06-4 Handle, lock and enter system 501-06-4

Remove and Installation

DIAGNOSIS AND TESTING

REMOVAL AND INSTALLATION

Front hood lock(41 232 0)

Remove
1. Remove front hood locke tow screws(down).
Then release cable.

2. Remove front hood lock tow screws(up)

Installation
1. Installatin steps is reverse for remove

CHANGAN·Benni MINI
501-06-5 Handle, lock and enter system 501-06-5

Remove and Installation

Front door lock(41 351 0)

Remove
1. Remove front door trim plate, refer to
501-05 chapter for relative information
2. Caution：Don’t touch stick surface to
avoid stickness weaken
Cut off waterproof film

5. Remove lock core cable, outside cable and

wires of door lock.

3. Remove front door inner handle, and

detach inner cable of door bracket.

6. Remove front lock assy (3 install points of

mechanic, 1 install point of latch)

4. Remove rear slide slot of front door

Installation
Installation step is reverse for remove

CHANGAN·Benni MINI
501-06-6 Handle, lock and enter system 501-06-6

Remove and Installation

Rear door lock(41 352 0)

Remove
1. Remove rear door trim plate, refer to 501-05
chapter for relative information.
2. Caution：Don’t touch stick surface to
avoid stickness weaken
Cut off waterproof film

5. Remove outside cable and wires of door

lock.

3. Remove rearhj door inner handle, and

detach inner cable of door bracket.

6. Remove rear door lock assy (3 install

points of mechnic, 1 install point of latch)

4. Remove rear door slide slot assy

CHANGAN·Benni MINI
501-06-7 Handle, lock and enter system 501-06-7

Remove and Installation

Back door lock(41 726 0)

Remove
1. Remove back door lock teo screws, release 3. Remove lock pin two screws, remove
cable and remov back door lock. lock pin.

2. If it equipt wiper, remove trim cover of

Instalation
outside glass and motor nut,
disconnect wire connector, then Installation steps is reverse for remove.
remove install screw in lock pin, remove
wiper motor finally.

CHANGAN·Benni MINI
501-06-8 Handle, lock and enter system 501-06-8

Remove and Installation

Door outside handle (41 333 0)

Remove
Attention：Remove front and rear outside 4. Remvoe door outside handle (two screws)
handle is similar, so it’s discribed in one
chapter, the illustration is only for front
outside handle.

1. Remove inner trim plate, refer to 501-05A

chapter for more information.
2. Warning：Don’t touch stick surface to
avoid stickness weaken
Cut off waterproof film partly
•Cut rubber bandage by plastic knife and off
protective layer

5. Remove door outside handle

3. Release outside rod

Installation

Installation steps is reverse for remove steps

CHANGAN·Benni MINI
501-06-9 Handle, lock and enter system 501-06-9

Remove and Installation

Door lock remoter

Remove
1. Remove door inner trim plate, refer to
501-05A chapter for more information. Installation

2. Warning：Don’t touch stick surface to

avoid stickness weaken Installation steps is reverse for remove steps
Cut off waterproof film partly
• Cut rubber bandage by plastic knife and off
protective layer

3 oOpen clamp, separate control lever and

cable in door.

4. Remove locked cable of electircappliance.

•

CHANGAN·Benni MINI
501-06-10 Handle, lock and enter system 501-06-10

Remove and Installation

Door lock core (41 336 0)

Remove
1. Remove front door trim plate, refer to 4. Remove lock core control lever
501-05 chapter for more information
2. Warning：Don’t touch stick surface to
avoid stickness weaken

Cut off waterproof film

• Cut rubber bandage by plastic knife and off

protective layer

5. Remove lock core ring

3. Remove glass slide slot

6. Remove door lock core

Installation

Installation steps is reverse for remove

DISASSEMBL
Y AND ASSEMBLY

CHANGAN·Benni MINI
501-07-1 Bumper 501-07-1

Chapter 501-07 Bumper

Applicable Vehicle Model: BENNI-MINI

Contents page
Disassembly and Installation 501-07-01

Front 501-07-02
bumper……………………………………………………………………………………………………
Rear 501-07-03
bumper……………………………………………………………………………………………………

CHANGAN-BENNI.MINI
501-19-2 Bumpers 501-19-2

Front bumper
Disassembly
1. Respectively disassemble the screws , bolts and the buckle as shown in the following
diagram. Notes the disassembly is performed from the bottom to the top.

2 Disassemble the bumper side panel from the installation bracket trough
3. Disassemble the socket connector of the tail part of the two front fog lamps connected
with the vehicle body wiring harness, so that the front fog lamp wiring harness is separated
from the vehicle body wiring harness.

4. Carry down the front bumper from the front end of the front bumper, and then the front
bumper is detached from the vehicle body.

Installation

The installation procedures are opposite to the disassembly procedures.

09/2002 2003.50 嘉年华

501-07-3 Bumper 501-07-3

Rear bumper

Disassembly
1. Respectively disassemble the screws as shown in the following diagram from the
bottom to the top.

2 Disassemble the bumper side panel from the installation bracket trough
3、Disassemble the socket connector of the tail part of the rear registration plate lamp
connected with the vehicle body wiring harness,

CHANGAN-BENNI.MIN
I
501-19-4 Bumpers 501-19-4

4. Carry down the rear bumper from the rear end of the rear bumper, and then the rear
bumper is detached from the vehicle body.

Installation

The installation procedures are opposite to the disassembly procedures.

09/2002 2003.50 嘉年华

501-08-1 Passenger’s Safety Belt System 501-08-1

Section 501-08 Passenger’s Safety Belt System

Applicable Vehicle Model: BENNI-MINI

Contents page
Specifications

Specifications .................................................................................................................................. 501-08-2

Safety Belt System

Operation Principle ................................................................................................................... 501-08-3

Inspection and confirmation ........................................................................................................ 501-08-错误！
未定义书签。

Disassembly and Installation

Front row safety belt ........................................................................................... (40 222 0) 501-08-4

Middle row safety belt ......................................................................................... (40 248 0) 501-08-6
Rear row safety belt ............................................................................................ (40 248 0) 501-08-7

CHANGAN-BENNI.MINI
501-08-2 Passenger’s Safety Belt System 501-08-2

Specification

Torque Specifications
Type Nm lb-ft lb-in
Fixing bolt of the retracting device of the safety belt 39±5 - -
Bottom fixing bolt of front safety belt 39±5 - -
Fixing bolt of front safety weaves belt bracket 15±5 - -
Fixing bolt of front safety belt up loop 39±5 - -
Lock buckle fixing bolt of the front row safety belt 39±5 - -
Fixing bolt of the retracting device of the rear safety
39±5 - -
belt
Fixing bolt of rear safety belt up loop 39±5 - -
fixing bolt of rear middle seat and rear buckle 39±5 - -

CHANGAN-BENNI.MINI
501-08-3 Passenger’s Safety Belt System 501-08-3

Diagnose and Test

Safety Belt System

Operation Principle
Cautions: All safety belts comprise belt
winding devices, buckles, buckle ring supports of
the front safety belt (slide bar), child safety seats
and accessory components (if they are equipped),
which should be inspected after each collision. The
newly installed safety belts are required to be
inspected by the professional technician, to confirm
that the safety belts are flawless and can be
operated normally. Otherwise, it is possible that the
human damage is caused.
The front seat and the side seat of the rear row of
the vehicle model adopt the three-point diagonal line
surrounding safety belts. The middle seat of the rear
row adopts the two-point type safety belt.
The rear and right seat safety belt buckle are fixed on
the floor.

Emergency Locking Type Safety Belt

The safety belts of the two-sided seats of the rear
row have the emergency tightening function. Under the
normal state, the emergency tightener is in the loosened
state, thus the passenger can move freely. Once the
emergency situation occurs, through the emergency
tightener, the safety belts can be tightened, to avoid the
collision onwards of the passenger.

Inspection and Confirmation

1. The client’s problems are confirmed Through
operating the system.
2. Visually inspect the obvious mechanical and
electrical damage.

Visual Inspection Item Table

Mechanism
– The safety belt becomes loosened.
– Damage or wear of the safety belt.
– Retracting device of the safety belt and the
inserting tongue
The safety belt locking buckle

CHANGAN-BENNI• MINI
501-08-4 Passenger’s Safety Belt System 501-08-4

Disassembly and installation

Front Row Safety Belt (40 222 0)

Disassembly 4. disassemble up trim of column B

Notes: The fixing bolt of the anchoring
seat of the safety belt is provided with a paper
washer with the protective function. In the
disassembling and installation process, pay
attention to always remain the isolation sheet and
the paper washer on the anchoring seat.

Disassemble the bottom fixing bolts of safety

belt,

5．Disassemble safety belt guide bracket

disassemble the fixing bolt of guide bracket.

1．Disassemble the bottom trim of column B,

showing the belt and receivers.

6．Disassemble front safety belt receiver

Disassemble fixing bolt.

3．disassemble the safety belt up fixing bolt of

column B
1-1．Disassemble trim cover
1-2．Disassemble fixing bolts

CHANGAN-BENNI• MINI
501-08-5 Passenger’s Safety Belt System 501-08-5

Disassemble and Installation(continued)

7.disassemble the front line safety buckle of inside seat

disassemble the fixing bolt of safety belt buckle

Installation
The installation procedures are opposite to the disassembly procedures.

Rear Row Safety Belt (40 248 0)

Disassembly
1 Disassemble the bottom fixing bolt of safety
belt.

3．Disassemble the up trim panel of column C

2．Disassemble the safety belt’s fixing bolt of

column C
1．disassemble the trim cover
2．disassemble the fixing bolt

4．disassemble the rear side panel trim

CHANGAN-BENNI• MINI
501-08-6 Passenger’s Safety Belt System 501-08-6

Disassemble and Installation(continued)

2．Disassemble the fixing bolt

4．disassemble the receiver of safety belt 3．
Disassemble the fixing bolt and take off
receiver installation

The installation procedures is

opposite to the disassembly
procedures

rear safety belt of middle line(40 248 0)

Disassembly
1．Disassemble the rear seat pad
pull out the seat pad from the plastic buckle

CHANGAN-BENNI• MINI
501-09-1 Safety Handle And Inner Lining Of The Top Cover 501-09-1

Section 501-09 Safety Handle and Inner Lining of

the Top Cover
Applicable Vehicle Model : BENNI-MII

Contents page
Specifications

Instruction and Operation

Disassembly and Installation

Safety handle ..................................................................................................

Sun visor .........................................................................................................
Top lamp ......................................................................................................................
Inner lining of the top cover...............................................................................

CHANGAN-BENNI·MINI
501-09-2 Safety Handle And Inner Lining Of The Top Cover 501-09-2

Disassembly and installation

1. Disassemble the safety handle

disassemble the screws, and remove the three
safety handle.

3 Disassemble the top lamp

The front top lamp is clipped on the vehicle
body bracket through the screw. Take down the
lamp cover and disassemble the two screws,
then disassemble the top lamp

2. Disassemble the left and right sides sun

visors.
Open the sun visors, and disassemble
installation base seats. The sun visor is in three
screw connection. Disassemble the sun visors
finally with the left one identical to the right
one.

This is left side. the right side and

the left side are symmetry

CHANGAN-BENNI·MINI
501-09-3 Safety Handle And Inner Lining Of The Top Cover 501-09-3

4 Disassemble the inner lining of the top cover

Disassemble eight clips, that is, the inner lining of the top cover is disassembled.

Driver side

Looking up from the inside

Move direction

CHANGAN-BENNI·MINI
502-00-1 Vehicle body repair-Summarization 502-00-1

502-00 Chapter Vehicel body repair – Summarization

Vehicle model: CHANGAN.Benni MINI

MENU PAGE
Specification and Operation

Vehicle body repair............................................................................................................................ 502-00-2

Preface.............................................................................................................................................. 502-00-2
Introduction ....................................................................................................................................... 502-00-2
Integral frame construction ............................................................................................................... 502-00-2
Design of intergral frame construction .............................................................................................. 502-00-3
Safe passenger space ........................................................................................................................... 502-00-3
Deformation area .............................................................................................................................. 502-00-3
Alloy-steel.......................................................................................................................................... 502-00-4
Anti erosion proctection .................................................................................................................... 502-00-4
Accident repire and diagnosis........................................................................................................... 502-00-5
Repair plan........................................................................................................................................ 502-00-5
Preparation of spare parts ................................................................................................................ 502-00-9
Erecting ............................................................................................................................................. 502-00-9
Cut vehicle part ................................................................................................................................. 502-00-9
Finish repair ...................................................................................................................................... 502-00-10
Panel tapping .................................................................................................................................... 502-00-11
Heating panel .................................................................................................................................... 502-00-12
Repair panel by lead-material ........................................................................................................... 502-00-14
Welding ............................................................................................................................................. 502-00-15
Safety specification ........................................................................................................................... 502-00-16
Resistance welding ........................................................................................................................... 502-00-16
MIG/MAG joint................................................................................................................................... 502-00-16
Bronze welding.................................................................................................................................. 502-00-16
Jointing.............................................................................................................................................. 502-00-17
Remove and installation on wind shield screen................................................................................ 502-00-17
Special vehicle part repair................................................................................................................. 502-00-18
Safety protecion ................................................................................................................................ 502-00-19

CHANGAN·Benni MINI
502-00-2 Vehicle body repair-Summarization
Specification and Operation
DESCRIPTION AND OPERATION
Vehicle body repair
Preface
Vehicle body make a very important role in
modern time, body design and appearance
influence customer strongly, firmed vehicle body
is important for driver and passanger’s safety,
Benni MINI’s character is light frame, high
intensity of alloy-steel, high quality plastic and
precise joint.
In technology, the modern safety unit is
unquestionable, Benni MINI’s stable equiptment,
computer emluation test, impact test, material test
and experienced technician ensure high quality. In
service, product quality standard is very important,
it requires good equiptment, good environment,
high quality technician.
Modern manufacture technology and advanced
repair method is very important for high quality
vehicle body repair. Service manual and repair
technology guarantee repair quality.
Brief introduction
Vehicle research is getting to more complicated,
the service manual’s content is vary, in the future,
the most important repair method and technology
will be discribed in summary chapter, for example,
all repeated repair is included vehicle model
502-00-2
specification chapter. New vehicle special training
will provide information or special point.
Integral frame construction
In antomotive market, integral frame construction
is firmed.
The advantage as follow:
– Ensure maximum safety of driver and passenger
– Lighten weight
– Economic manufactuer techology.
Integral frame construction include door, engine
hood, bumper, etc. the advantage as follows:
– Firmed passenger space
– Rigid design of front of rear deformation
– Additional side firm
– High torque steelness
– High bending intensity
The specification of service procedure as follow:
– Only repair for single vehicle
– It’s prohitied to cut joint of door and window
when repairing.
– Ensure vehicle inner stress
– If possible, ensure vehicle integraty in service
CHANGAN·Benni MINI
502-00-3 Vehicle body repair-Summarization 502-00-3

Specification and Operation

Integral frame construction design

Design of integral frame constrcution – Dynamic absorb impact

To all vehicle design, the most important is safety – Protect passenger space
of driver and passenger. Vehicle body ‘s two – Following workshop service manual,
critical keys are: especially deformation chapter, ignore it will
– Safe passenger space lead to serious damage. For example,
transaxle joint area can not be cut or weld.
– Deformation area

Safe passenger space

– The design of safe passenger space as follow:
– Firmed pillar, door frame and door cnstruction.
– Integral side protection of vehicle door
– The design of open door successfully even
when the door is deformed.

Deformation area
– The safety passenger space is protected by
well-designed front and rear deformation are,
the purpose as follow:

CHANGAN·Benni MINI
502-00-4 Vehicle body repair-Summarization 502-00-4

Specification and Operation

Deformation are-Safety passenger space

No Part number Description

1 - Deformation area
2 - Safety passenger space

– Character of high intensity alloy-steel

High intensity alloy-steel
Summarization
High intensity alloy-steel is usually adopted on
joint panel, reinforced plate and pillar.
– High deforamtion revive ability
– More force when erecting
– All deformed parts need to use tool because of
it’s hard to revive.
– Because of high intensity, all tools will be
worn.
– Heating is forbidden when erecting, because
metal mechanical intensity will be reduced
when temperature reach to 400℃

CHANGAN·Benni MINI
 502-00-5 Vehicle body repair-Summarization 502-00-5

Specification and Operation

Low alloy-steel –
galvanization or
Steel category Performance zinc-nickle plate Galvanoplastics plate
Vehicle steel Good pl astic character, 110 110
plate use for low intensity area,
eg: door inner panel, wheel
hub
Quenching steel Good plastic character, 180. 220. 260. 300 180. 220. 260
good
Alloy-steel with Middle class instensity part, 220. 260. 300 220. 260. 300
phosphor eg: wheel hub
Alloy-steel High intensity steel for 260. 300. 340. 380. 420. 460 340. 380. 420
bearing part
homogeneous Middle class steel have 220. 260 260. 300. 340
steel good plastic, so have good
extension and deformation
character, eg: engine hood.
Form data reprent minimum extension limit N/mm 2

Anti-erosion protection

Damage
– When observe paint is abnormal, check
Accidental damage and diagnosis potential vehicle body damage or deformation,
it’s hard to observe by outside.
Summarization:
Reserved bend point
– Diagnose damage degree successfully can
help to suitable wervice plan. – When vehicle is evaluated, must check
reserved deform point is under initial impact. It
– Don’t alllowed to weld any extra reinforced is designed to can be curved.
plate.
– All vehicle body repair should be followed
Formed reserved deformation point of veicle
dervice manual specification.
panel
– Vehicle intensity and steelness should be
considered when vehicle body repairing,
–For example, deformation area absorb impact
energy, if repair non-specific or non-technical in
single area, it will threaten to basic vehicle
safety.

CHANGAN·Benni MINI
 502-00-6 Vehicle body repair-Summarization 502-00-6

Specification and Operation

Welding point
– Weld point is key point of vehicle body part, for
reason, we should check carefully any
damaged part, welding joint and vehicle part
when evaluation.

Influential welding point

Clearance

CHANGAN·Benni MINI
 502-00-7 Vehicle body repair-Summarization 502-00-7

Specification and Operation

– Clearance is a method of appearance

inspection, it means part dimension is wrong
when dimension vary or slide.
Vary clearance
Attention: Propeller shaft transfer vehicle power
If a vehicle is impacted, all parts and mechnism
should be inspected thoroughly, ensure apliance
is working normal or not.

Otherwise, we can judge damage degree by

impact direction and size, specific operation
need to abundant vehicle body knowledge.
– If impact is happened in left side of vehicle,
right side of vehicle will be influenced, usually,
side assy length will not be changed, we can
judge clearance or dimension bthrough check
door or side fender.
– When impact is serious, front of vehicle can
not absorb entier impact energy, then, it’s
trnasfered from girder to A-pillar, result in
deformation of roof and doorsill.
– Whatever, impact is transfered to entire
vehicle floor, so the passenger space is very
No Part number Description stable.
1 - Clearance is wide
2 - Clearane is narrow

Impact energy transfer from carling to A pillar

CHANGAN·Benni MINI
502-00-8 Vehicle body repair-Summarization 502-00-8

Specification and Operation

NO Part number Description

1 - Deformation area-upper girder
2 - Deformation area-roof
3 - Deformation area-doorsill

Vehicle body measurement

– Measurement items
- Measurement can measure vehicle
ouside. According to vehicle damage
degree, compare measurement and
diagonal measurement is done by
compasses, ruler or tapeline. No Part number Description
Attention: When measure dimension is 1 - bracket
changed, reference should be the same.
- All specification is shown in vehicle body 2 - measure rod
chapter. 3 - flexible measure rod
– Erecting tool measurement with measure sensor
- Erecting tool measurement need to 4 - measurement
measure vehicle floor precisely. There
are two kinds of measurement system:
- Mechanical measurement system Adjust clamp
- Optical measurement system
– Rapid and correct measure result can be
got by computer measurement system.
– Measurement of length, width and height
need to find three minimum measure
points
– In some condition, it means easy to reach
measure point, if all equiptment is alright,
all measurement system can be use to
measure vehicle bosy.

Vehicle body measurement equiptment

Repair plan
Preparation before starting repair
– Dose vehicle need erect tool, or if it can be
erected by other equiptment?
– Dose floor need to measure?
– Dosesaay need to disassemble like engine
or transaxle?
Attention: It’s better to repair parts than
replace parts, because it can keep vehicle
integrality

CHANGAN·Benni MINI
 502-00-9 Vehicle body repair-Summarization 502-00-9

Specification and Operation

– What parts need to be replaced? loading (in the pre-fold point, fold edges,
– What psrts need to be repaired? welding seams and other areas), use of
aluminum hammer beat the release of
stress.
Preparation of spare part – Special points:
Spare part preparation decides if it’s easy to - High intensity steel has a good ability of
repair, recommedatin as follow: keep defomation state.
- If necessary, open door or engine hood
– Achieve vehicle data, including vehicle
when erecting.
model, vehicle pointed code, inner code,
engine code, registration material. - It’s allowed heating when erecting.
– Confirm all metal parts need to be replaced. - Follow ‘equiptment/safety job protection’
chapter specification.
– Confirm all accessories parts which need to
replaced, like rivet, clamp.
– After receive all accessories, check it’s
Cut vehicle body part
correct and all ready.
According to parts joint/connection condition,
use different cut/release tools.

Attention: All other parts such as interior

Erect repair fittings, window glass, etc., must be anti-splash
Erecting is always needed after accident, protection.
equiptment as below: Attention: Confirm polish degree set is correct,
avoid to damage.
– Vertical tool
– Universal erecting and measure tool
– Weld tool system Weld point polish
To ensure professional repair and dimension
is correct after repaired, soe points must be
followed: Weld point polish

– Construction:
- Repair sequence depond on decided
repair plan.
- Clean accessory area
- Firm vehicle in relative system
- Brace and release vehicle stress
- Confirm measurement/assembly three
basic points in undamaged or distant
area.
- Check measure/install point dimension
– Erecting
Attention: Check clearance and dimension – Polish rod
when erecting. Attention: Wear PPE ro protect body from
- Impact in the opposite direction from the burning, hurt
body alignment. General assembly parts
with the body shell along with correction
(not pre-cut any parts). Complete the
corrective work required in several steps,
which can avoid over-sizing and the risk
of rupture of welded joints. Individual
correction process, when part by tensile

CHANGAN·Benni MINI
 502-00-10 Vehicle body repair-Summarization
Specification and Operation
- All joints grinding machine (diameter
greater than 8mm) inaccessible spot, you
should use polished rod polished. MIG
welding joints or welds are also
applicable.
Polish rod
– Split Cutting
Attention: Vehicle metal parts, wire harnesses,
hoses, etc., pre-demolition to avoid damage.
- Body saw is very appropriate universal
cutting tool.
- Short cut saw
- Body parts are usually separated by a
short cut saw. Even in a very limited
range, it is also very flexible.
Short cut saw
502-00-10
– Return Saw
- Return saw and short-cut saws are
available. Using these tools, can be
narrow and straight, accurate depth of
cut.
- Use of cooling oil, blade life can be
greatly extended. Iron produced by
sawing with a pumping method to be
removed from the cavity to prevent rust.
- If brazing parts need to cut the connection,
the use of uniform heating torch until the
solder melted copper, and then stripped
of the old parts.
Return saw
Repair finish
– Completely replacement
- Completely replace the old pieces of
totally damaged joints is the removal of its
original / connection, and then assemble
a new part.
– Combination replacement
- On many occasions because of
technical or economic reasons need
to be combined replacement. Reason
for this is based on two considerations,
first, the vehicle can maintain the
CHANGAN·Benni MINI
 502-00-11 Vehicle body repair-Summarization
Specification and Operation
original shell structure; second, to
maintain the lowest cost of repairs
- There are three different ways to
combination replacement.
– Weld slot joint
- New and old parts use continuous
MIG weld slot joint.
- Weld connections commonly used in
the combination of beams or columns to replace
or repair methods short of completely cut off.
Weld slot joint
– Connect fix plate
Attention: Although the butt joint is the
width of 12mm, but the new part of the edge
width is designed only 10mm. This naturally
calls for the old part of the fixed plate and
weld new parts set aside space between
the plates. Based on the reasons for
corrosion protection, installation of new
parts in the front, truncated butt plate fixed
to the 6mm.
- Fixed board is used for docking is still
connected to the car body repair old
parts. The old parts and new parts
connected by the intermittent weld.
Edge installation
502-00-11
– Metal liner
- Removed or new metal liner (about
30mm wide) connected to the seams
with a spot on the back.
Attention: Butt joint board or metal liner is
typically used for cutting longer truncated.
Attention: Location should be as close as
possible to sever cut replacement parts.
Only from the cut line of cut, see vehicle
specification sheet.
- Prohibited near the reinforcing plate
or intended cut crease line position
Attention: Before the arrival of the new
pieces do not began to remove the old
parts (repair parts may have a size
change).
Metal palte remove
No Part number Description
1 - Resistance spot
welding
2 - MIG welding
– For the residual parts / new parts.
- Leveling with a hammer and the horn
all the body parts and the adjacent
residue in the surface roughness
(make sure the new part shape and
the old parts match). Angle to the
CHANGAN·Benni MINI
 502-00-12 Vehicle body repair-Summarization
Specification and Operation
grinding wheel with solder or weld the
remaining
- With cutting the size of new parts
- Punching or drilling necessary to
prepare a fixed spot
Attention: Can not use torch to remove
paint residue (the heat will cause the metal
deformation)
- Double-sided polished bare metal
joints. Prohibit the use of angular
wheel (as they may weaken the
strength of the metal, damaged zinc
coating). Appropriate tools: rotary wire
brush, belt or plastic sand discs.
- In addition to copper welded, all welds
are available to deal with welding
primer.
- Stir well before using primer.
Attention: When using the spray treatment,
careful not to let part of aerosol pollution in
adjacent areas.
Attention: As supplementary information,
refer to the 501-25B "Body Repairs -
Corrosion Protection."
Match new spare part
– New parts dimension must be confirmed,
equiptment as below:
- Erect clamp
- Universal measure system
- Clamp system
- Ruler or tapeline
- Compasses
- Refer to vehicle specification chapter for
bone frame.
502-00-12
Attention: All subsidiary body parts
requires a precise straightness, with as with
as a whole must pay attention to, such as
bumpers, sealed, headlights, taillights and
lock after some parts. If you do not pay
attention cause leaks, wind noise and
follow-up work.
confirm the vehicle's shape change
Reliable new parts
Attention: If the correct alignment and fixed
welding operation, subsequent operations
can significantly reduce
According to the degree of accessibility,
safety method as below:
- Pincers (set)
- Screwdriver (set)
- Self screw
- Fix point welding
– Tool bar or screwdriver to use, the local
replacement parts can guarantee the
edge of the side contour line alignment,
then the method with a fixed spot to
ensure straight
Erect and fix point welding
No Part number Description
1 - Fix point welding
2 - Use of screwdriver
– Long welding seams usually fixed to
prevent the skin curled, fixed by welding
to complete the correct sequence is
important (see photo)
– Welding new parts according to the
maintenance manual instructions. Read
CHANGAN·Benni MINI
 502-00-13 Vehicle body repair-Summarization
Specification and Operation
and reference arc welding and brazing
repair.
Correct fix point weld sequence
Previous service/anti-erosion protection
– Those steps include:
- Polish weld slot, if necessary, fill cancave
by lead-material.
- All bare metal primer
- Seal weld slot
- Vehicel chassis protection。
- Paste the relevant part of the damping
coating。
- Cavity filled with foam
Attention: Refer to 502-00 / 501-25B /
501-25C / 501-25D / 501-25E chapter’Vehicle
bosy repair-antierosion protection’
- Fill cavity protection wax
502-00-13
Panel tapping
Vehicle body is made of many kinds of steel
material.
– Vehicle body is made of 0.7~2.5mm width
panel.
– Vehicel body panel compress steel
- Body skin is soft, easy to shape,
scalability particularly good, so easy
to crack.
– Low alloy-steel with high intensity
- Low alloy-steel with high intensity to
be much harder, for the manufacture
of molds or other uses, such as
B170P1 steel, it also has good
scalability.
Basic principle of panel tapping
– Replace or fully replace the combination
of body skin, you must carefully check
whether the injured skin correction
method can be used percussion.
– Skin repair damage skin percussion
method is the simplest and most
economical way.
Different skin percussion technology
example:
–Aluminum hammer and mallet
- Advantage：There is no risk of skin
over-extended.
- Can be applied to both sides of a small
pit close to the skin repair.
- The two kinds of percussion
instruments commonly used in the
final skin repair.
Using aluminum mallet hammer and
general quality of correction
– Flexible hammer
CHANGAN·Benni MINI
 502-00-14 Vehicle body repair-Summarization
Specification and Operation
- Only if the damage from the outer
surface of the skin close to correct
shape using elastic hammer. Elastic
concave suction cup and a hammer
on the exposed skin should be close
to the surface, adjusting the elastic
hammer of pits on the skin can be
eliminated.
Heating panel
– Due to mechanical strain, and some
body skin too often inevitable extension,
of any region over-stretch the material,
will cause localized instability leading to
different stresses. The instability of the
local heating techniques can be applied
to stability.
– – Leveling with fire and rasp
Attention: The principle is not suitable for
low-alloy steel with high intensity
Pinciple：Application of heat treatment of
material flattened skin contraction more
than the amount of material initially
extended.
Different heating technology
Attention: Using different materials, heat
treatment technology in accordance with an
extension rate.
– Leveling using a flame
502-00-14
- Flame extension for a wide range of
materials (welding torch size 0.5mm ~
1mm). Use soft torch.
- Short-term point of heated metal
surface and then immediately cooled
with a wet sponge.
- Requirement: The ability to secure the
use of welding torch and steel
annealing discoloration identification
knowledge.
- Advantage：Does not damage the
surface of the metal。
– Leveling using a flame, and
supplemented by a hammer and horn.
Attention: The effect of leveling with the
acceleration of heating and cooling rate
increased.
- If the material extension concentrated
in the heated aluminum hammer or
wooden hammer and carefully
re-treatment with better results.
- Requirement：feeling of recognition by
leveling the surface tension level of
knowledge of materials。
– Leveling the use of carbon electrodes
- If only from the side close to the skin
area, or only a slight deformation of
skin, then the best method is to use
the leveling carbon electrode
- Requirement：Bare metal surface
- Defect：Scarring and hardening the
surface
– Leveling using copper electrodes
- Small, and raised serious outward
processing copper electrode can be
used.
Attention: When used correctly, this
method can be used for all accessories are
still installed in the vehicle state (roof
accessories, cues, etc.).
CHANGAN·Benni MINI
502-00-15 Vehicle body repair-Summarization
Specification and Operation
- Small, gentle bump (only a small
extension): spiral inward protruding
handle, use an oxyacetylene torch
(nozzle size 1-2mm, reducing flame),
about 250°C.
- Heated from the edge of the area
accurately, quickly deal with the body
until the raised flat file. Filing cut
alternating heating and better.
502-00-15
Skin patch filled with lead materials
– Material filling method is to lead the
local joints smooth, or correct uneven
skin surface, the best small repair
methods.
– Advantage：
- In the bare metal surface has an
excellent adhesive.
- Very good shape characteristics.
- Repair performance.
- Permanent shape.
- Consistent with the expansion
characteristics of steel
Attention: tutania PB 25% / 75%，
method：Hammer lead filled material
removed before the completion of the
bubble.
Welding and brazing method
Safety specification
–
Attention: Refer to chapter of ‘equipetment
protection /safety production’
CHANGAN·Benni MINI
 502-00-16 Vehicle body repair-Summarization
Specification and Operation
For protecion of vehicle electronic part(ABS,
Airbag), don’t connect negative cable of
battery.
– Do not let the unit or wiring harness
electrical contact with ground or welding
electrodes.
– Remove battery when welding
– Installed near the oil tank or other
container, must be extremely careful,
because if the fuel filler or pipeline
welding work permit must be open, the
tank must be drained and removed.
– The absolute prohibition of welding,
brazing or brazing sealing air system,
the same, heating the air system is also
at risk.
– Welding of the ground directly to the
parts, verify that the ground was no
insulation between the electrodes and
welding objects.
– In order to prevent spatter and heat
radiation, near the auto parts and
vehicles must be isolated.
Resistance piont tapping
Ninety per cent of production is the
resistance spot welding. As a rule,
maintenance operations also use
resistance spot welding, spot welding
repair and production volume and diameter
must be the same. Unless special
circumstances, generally do not use other
welding methods.
Installation of equipment and
commissioning of welding parameters
– Equiptment:
- Instructions provided by equipment
manufacturers to install devices
- Select the correct electrode arm
length (as short as possible.)
- Accurately align the electrode arm
and electrode head.
- Electrode was to be convex (using
rasp coarse grinding, fine grinding
with sand and gravel).
– Vehicle body
502-00-16
- Ensure that the two joints between
parts are smooth.
- Metal bonding surfaces should be
kept clean (inside and outside).
– Attention to processes and technologies
- In the samples coated with a primer
on the test weld welding.
- If there are metal parts in between the
two electrode arm, then lose some
inductance and energy (to adjust the
current settings).
- Low alloy high strength steel to adjust
current.
- Repeated in the original spot weld will
lead to poor quality of welding.
- Maintain the electrode to a vertical
angle of contact welding surface.
- After completion of welding electrodes
to maintain the pressure a short time.
Attention: Spot welding electrodes 10 will
be cooled in water to ensure that the same
welding effect (no need to make the
electrode cold.)
- Pole shape is spherical joint, the best
quality. Periodically remove the electrode
contact surface.
Total thickness of 3mm or more in the use
of resistance spot welding
MINI cars for Benben all maintenance,
welding equipment must be suitable for
welding galvanized material, while for high
strength and high ductility of three or more
layers of materials, welding, welding is
required to achieve the total thickness of
5mm. If you can not satisfy this requirement,
for security reasons, you should use
electric arc welding. The electrical
characteristics of spot welding equipment
specifications (current, resistance and heat)
for different models have different valid
value. Therefore, manufacturers of welding
specifications to provide practical guidance
is very important.
CHANGAN·Benni MINI
 502-00-17 Vehicle body repair-Summarization 502-00-17

Specification and Operation

MIG / MAG welding - Fusion welding the skin from the

lower start welding, to ensure proper
Installation of equipment, adjust the
weld penetration.
welding parameters according to:
– Products of any MIG / MAG welding
must also be used in the maintenance Fuse welding
of MIG / MAG welding method, and
some welding required melting point
solder instead.
– If the approach difficult, or if not welding
welding thickness of 3mm or more of
skin, repair, replacement must be part
of the way into the fusion welding. At
this time, need to consider additional
anti-corrosion treatment.
– Only equipment installed correctly, the
correct adjustment Welded planning
parameters, welding repairs to
complete normally.
– Equiptment:
No Part number Description
- According to the manufacturer
instructions to install the equipment. 1 - Welding direction: from
- Hose must be removed the inside out spiral
- Tip can not have wear and tear. pattern welding.
- Gas nozzle can not have slag or 2 - Welding starting point:
residu。 the lower skin of the
- Note that the quality of the contact tip center hole.
and gas flow.
– Vehicel body:
- Confirm the integrity of joint surface Bronze welding
- Clean the surface of the metal so that – Don’t use other method to instead of bronze
the seam welding.
- Maintain the proper gap (fixed root). Attention: Remove all traces of slag to
– Technology / process considerations. prevent corrosion.
Attention: MIG welding, an increase in heat Brazing connection requires careful
damage to the primer and the zinc coating preparation. Tightly aligned, and the
than the resistance spot welding on large, bonding surface of a clean bonding
so in the future should pay more attention surface is very important.
to dealing with anti-corrosion protection.
Joint
Bonding structure of modern automobile
technology more widely, some body parts
more affected. Maintenance of all the
Attention: When it is determined not only adhesive joints must be re-processing.
the surface of the weld joints must – Application and safety guide
test welding
- In the bond or seal provided by the
manufacturer to comply with
- Received the negative parts (to operating instructions
ensure good contact.) Attention: Following manufacturer’s safety
guide.

CHANGAN·Benni MINI
 502-00-18 Vehicle body repair-Summarization
Specification and Operation
- Adhesives are chemical products, to
comply with specific safety rules。
– Adhesive joints
- Benben MINI models in the production of
the engine cover and door repair or
bonding methods are used.
- Pay more attention to sealing adhesive
(corrosion), while the adhesive
strength in the second.
注意: 遵守厂商的安全指导。
Outside the top of the stick joint
– Glass bonding
- Basically all models are directly
bonded to the windshield of the car
body on the windshield frame. In
addition, the side of the block and they
use a rear glass bonding methods.
- Glass bonding method is mainly
based on the strength of adhesive,
bonding the glass to give body to
provide additional torsional strength.
Glass adhesive bonding method
502-00-18
NO Part number Description
1 - Strips
2 - Windshield frame
3 - Viscose
4 - Windshield screen
Removal and installation of windshield
screen
Safety specification
– To prevent injuries, you must observe
the following safety requirements.
- Wear protective glove
- Wear protective glasses
Preparation
– Glue in the glass before cutting, loosen
and remove all get in the way cutting
attachment regions, such as: decorative
plates, decorative strips, and wire and
plug.
– Paint to cover all the neighboring
regions
– Remove all the glue, this will be easy to
cut glass.
– Remove the safety glass vertically.
Cut glass
– Accessible point of using the cutting
tools cut from adhesive layer.
– Carefully cut along the windscreen
frame, cutting through the adhesive
layer.
– Avoid contact with window frame and
body seams.
– Suction with suction cups were
removed from the windshield, and out of
the window frame.
Preparation of joint
– Folloe manufacturer specification.
– Remove the residual glue on the metal
framework of the layer, so that the
height of glue residue around 1mm, do
not touch and clean after the bonding
surface.
– Repair paint damage (the primer and
top coating).
–Necessary to re-apply adhesive.
Adhesive windshield
CHANGAN·Benni MINI
 502-00-19 Vehicle body repair-Summarization
Specification and Operation
– In the framework of the glass and glass
deposited on the smooth plastic
– The windshield into the frame (requires
two technicians.)
– Check clearance
Attention: The drying process, open the
door and door glass, do not move the
vehicle (hit the door may cause additional
stress caused by loose glass cross.)
Use adhesive tape to prevent falling or
sliding glass.
Completion of work
– Reconnect all the cables plug, check
the parts are working correctly.
– Assembly and check for proper
attachment, if it is safe
– Visually to ensure proper clearance and
joints.
– Thoroughly clean the windshield.
Special body repair parts
Variable parts
502-00-19
– Variable parts of the body shell from
ordinary cars are very different. These
differences not only in appearance, but
also in function. Because the stability of
certain parts of the special requirements,
which need to be reinforced in the
structure.
– A full body design is not possible
without Roof fence. Therefore be
through other means to strengthen its
stability, especially torsional stiffness
requirements. This needs to change the
existing structure of the body shell and
installing rebar to achieve.
Rocker ribs
Attention: If the body is not very serious
extent of the damage (no loss, and parts of
staggered phenomenon), when the
instrument is placed on the correction
should be given appropriate support, to
carry some weight.
During the body repair process should
note the following design parameters:
- Increase the threshold thickness of
the material car.
- Sizing process to change mode of
operation.
- Special parts of the installation
requires particularly high accuracy
(such as car roof railing installation
location)
– In the repair process and the end of the
fence should always pay attention to car
roof and around the site checks to
ensure good water resistance, wind
noise
CHANGAN·Benni MINI
 502-00-20 Vehicle body repair-Summarization
Specification and Operation
Off-road vehicle
–
Attention: If the body and chassis are
bolted together, in the sizing process, all
the connecting parts of the body and
chassis should be the extent of damage
inspection.
Attention: If the extent of damage to the
body and chassis are very serious, the
body must be separated from the chassis.
Part of separate form for each school
接部位都应进行损坏程度的检连接
Off-road vehicle chassis by a support
structure, which together with the body
through the bolt.
– 如果在修理过程中需要任何校形工作，则必
须使用专门的通用装配设备或校直夹具。
Safety and equiptment protection
– Observe the process of operation of
various safety measures and
regulations. All rules and regulations
related to health and safety should be
strictly followed.
Welding safe protection
– below safe protection must be followed to
avoid human damage.
- Safe mask(Face protection)
- Welding shield
- Safe glove
- Safe shoe
- Ventilation equiptment
– Welding work must be well-ventilated
place. And must be installed around the
fire extinguishers.
Ventilation equiptment
502-00-20
– Sealing material (sealing the bottom of
the body) can not use open flame
burning, as this will produce toxic gases.
Because of this, PVC materials are
burning will produce toxic gases
containing hydrochloric acid, so
grinding, welding or brazing equipment
must be used to produce the toxic
exhaust gases out.
– With the solubility of the material in the
operation, it is necessary to maintain
good ventilation, and require the use of
ventilation equipment.
– During cutting, grinding or metal sizing
operation, must wear hearing protection
ear plugs, because the noise generated
by these operations will reach or exceed
85 - 90 dB (A).
– Do not look directly with the naked eye a
variety of laser measurement systems,
such as laser systems for measuring
the floor.
– When the slope from the parking of
vehicles on the parts taken out, they
should pay attention to the vehicle
center of gravity changes. Placed on the
slope of vehicles should pay attention to
strengthening security protection to
prevent vehicle dumping measures.
– Shaped the course of the school should
pay attention to the safety chains and
chain cable set connections folder and
reliable.
Safe noose
CHANGAN·Benni MINI
502-01-1 Vehicle Body—Anti erosion protection 502-01-1

502-01 Chapter Vehicle Body – Anti erosion

protection
Vehicel model: CHANGAN·Benni MINI

MENU PAGE
Specification and Operation

Anti erosion protection ....................................................................................................................... 502-01-2

Summarization ................................................................................................................................... 502-01-2
Anti erosion prptection of new part .................................................................................................... 502-01-2
Welding Part....................................................................................................................................... 502-01-2
Part Update ........................................................................................................................................ 502-01-3

CHANGAN·Benni MINI
502-01-2 Vehicle Body—Anti erosion protection
Specification and Operation
Anti erosion protection
DESCRIPTION AND OPERATION
Summarization:
Anti erosion protection must be done when
repairing or after repaired. It can guarantee anti
erosion for a long time. (Refer to workshop
manual)。
Only special vehicle body and parts for Benni MINI
can be adopted in vehicle repair.
All Benni MINI parts have a protective coat.
Damp glue is the suitable and effective way for
impacting by sand, etc.
Attention: If possible, to avoid protective coat
is damaged by sand paper or other
mechanic method.
If vehciel body should be repaired, it must refer to
specifications and operations.
If minor crack in vehciel connection area, it must
be sure anti erosion protection have been done or
not. If necessary, anti erosion paint shoule be
painted in entire vehicle. To damaged vehicle
parts, it should be done after repaired.
After repair, please paint carefully in order to get
smoothful inner surface (twice paint, dey
intervane). If vehicle panel is damaged badly, it
means anti erosion material must be ruined, so it’s
necessary to deal with heat area again.
Pay attention to horizontal placement when anti
erosion protection.
Anti erosion protection measurement should be
done when vehicle part is repaired again.
Anti erosion protection of new parts
All new parts must be check if cratch, impact when
transportation, according to part damage degree,
operation as follows:
502-01-2
1. New parts without damage
• Don’t polish electrophoresis coat
• Cleaning totally by silica cleaner
2. New parts with little damage
• Smooth scratch
• Smooth outer surface slightly
• Cleaning totally by silica cleaner
• Anti erosion protection in bare area.
3. Damaged part
• Polish abre area and smooth it.
• fill polyester dust in bare metal
• Fillment
• Polish entire part slightly
• Cleaning totally by silica cleaner
• Anti erosion protection in bare area.
According vehicle model, engine hood, door, rear
mudguard and boot must be sealed tightly.
Repaired paint must be operated by anti erosion
protection.
Welding Part
Use rotary steel wire to clean welding area, pay
attention don’t damage zincifiation coat.
Attention: Making anti erosion protection as more
as possible.
Attention: Welding paint must be mixed
thoroughly before using it.
Cleaning repaired area thoroughly.
Attention: Welding operation must be done after
weld paint is dry.
CHANGAN·Benni MINI
502-01-3 Vehicle Body—Anti erosion protection
Specification and Operation
Use welding
Clean steel chip after welding, pay attention to not
damage material intensity.
All weld slot cancave filled by lead-material.
If necessary, weld T-type in suitable place in order
to fasten trim. Vehicle should be totally cleaned
dust and steel chip because of danger of erosion.
Clean and fill inner area
Seal all welding area and connector.
Attention: It must be dried when chassis
protection.
The initial anti-noise damp coat ust be dealed with
again.
Chamber protection of door after local repair
502-01-3
Use chamber protection in all repaired parts after
painting.
Part update
When local repair si the same with ‘weld part’
chapter’s description, as following:
The main difference between local repair and
entire repair is connection.
When vehicle part is cut totally, clean inner
paint and zincification coat, especially hard to
reachable area.
Bare metal in inner area is very important to
welding quality. Zincification coat and paint in
welding area is easy to burn.
Zinc and paint will be burned if zincification
coat and paint coat is mot cleaned.
Method
– The paint coat near weld slot 30mm must be
cleaned by rotary steel wire.
– No matter new parts or old parts, it should be
done.
– According to different vehicle parts,
zincification coat near weld slot 10mm must be
cleaned.
Attention: We can use blade or steel brush
instead of rotary steel wire.
CHANGAN·Benni MINI
502-01-4 Vehicle Body—Anti erosion protection 502-01-4

Specification and Operation

ITEM Part name Description Fill wax in chamber wich hard to reach, drill a hole
in suitable are, then clean it, epecially steel chip,
1 - Weld slot or is can be rusty, finally, use plug or sealant block
2 - Injector it.

3 - Distant location
4 - Inject gun

Fillment anti erosion protection method classify:

Reachable inner Unreachable inner
Anti erosion protection method Outer surface surface surface
Paint X X
Chamber protection X

Replacement anti erosion protection method classify:

Erosion method (Reachable area ） weld All polished Reachable Unreachable
slot edge before welding bare area weld slot edge weld slot
area edge area
Paint slot paint X
Paint X X
Flange protection X
Chanber protection X

CHANGAN·Benni MINI
502-02-1 Body Repair – Plastic parts repair 502-02-1

502-02Chapter Vehicle body – Plastic parts repair

Vehiucle model：CHANGAN• Benni MINI

MENU PAGE
Specification and Operation

Plastic parts repair ......................................................................................................................... 502-02-2

Summarization.................................................................................................................................... 502-02-2
Plastic parts confirmation ............................................................................................................ 502-02-2
Heat plastic parts emendation....................................................................................................... 502-02-3
Plastic weldinging........................................................................................................................... 502-02-3
Plastic parts waving welding......................................................................................................... 502-02-6
Plastic felt...................................................................................................................................... 502-02-7
Safety specification ....................................................................................................................... 502-02-9

CHANGAN·Benni MINI
502-02-2 Body Repair – Plastic parts repair 502-02-2

Specificatin and Operation

DESCRIPTION AND OPERATION

Plastic parts repair

Summarization – Thermoplastic
Different plastic parts adopt different repair – Hard plastic
method because of different material.
– Heat plastic emendaton Thermoplastic
– Plastic welding technology (PC, – Thermoplastic becomes to flexible from solid
PP/EPDM,etc) state then become to thermo state.
– Plastic welding technology (All plastic parts) – Thermoplastic become solid state when
– Plastic cpmpress technology (Steel glass colding.
parts)
It’s very important to undeestand plastic parts Hard plastic
material when repairing. Plastic parts can be
– Hard plastic is harden and fragile than
classified to two types:
thermoplastic
- State hard to change when heating.
- Hard plastic will be damaged when
temperature excess limit.
- Hard to recover when colding.

Abbreviation Full name

ABS Acrolein/butadiene/styrene
PA polyurethane
PC polysaccharide
PP polypropylene
PP/EPDM polypropylen/ ethene /polyrubber
PUR polyurethane

Plastic Parts Confirmation

Unmarked palstic can be identified by two ways:
– Visual Inspection
– Mechanical Inspection
Plastic welding technology divides to plastic
model, in order to use different welding wedge.
Visual Inspection
Visual inspection is usually to identify the
polyurethane and steel glass material,
thermoplastic usually covers paint and hard to
identify:
– Polyurethane： Bubble or hole will be existed if
it’s broken or damaged.
– Steel glass：Possible to see glass fiber.
Mechanical Inspection
– Hardness：The sound is more crisp means
more hardness when hiting.
– Flexibility：The sound is more means more
flexibility when hiting.
Attention: Mechanical inspection can confirm
plastic types, but cannot identify specific
types.
Plastic bumper can be repaired easily according
to statistics

CHANGAN·Benni MINI
502-02-3 Body Repair – Plastic parts repair 502-02-3

Specification and Operation

Attention: If foam polyurethane seals to bumper, - Heat air gun (appro. 1500 W)
please don’t clean it when repairing. If badly - Welding injector
damaged, replacemnt should be use to instead of
- Defferent welding rod
repair.
- Horizontal cut machine（ Ø 5.5 mm）。
Bumper is made of thermo material, it can be
- Blade (Heart-shape)。
repaired follows:
– Thermo emendation
Plastic welding torch
– Seal
– Welding

Thermoplastic parts emendation

Bumper always deform in flexible area, like bend,
sunken, etc. Mostly deformation can be recovered
automatically, flexible area can be recovered by
heat air gun.

Slight flexible deformation

Attention: According to deifferent plastic material

to use heat method or not. It’s forbidden to heat
other area except flexible area. Plastic
deformation cannot be reversable. No flame. ITEM Part name Description
Slight cancave or lence can be recovered by 1 - Plastic welding torch
by heat to 200°C by heat air gun.
– Otherwise, wooden hammer or plastic wedge 2 - Quick weld injector
can be assistanted to emendation. 3 - Cuniform injector
4 - Incise machine
Crack extend and distort
Joint method is better than thermoplastic
Preparetion work (Crack)
amendation method if crack or distortion happend.
Cut crack into V-type to prepare welding.
– Cut damaged or ditorted area to avoid material
strentch.
– Heating distorted are to 200°C equable then V-modle weld slot
recover it by wooden hammer.

Plastic welding
Attention: Don’t weld in foam material.
Plastic joint method is the best way to recover
plastic bumper crack, for inner side of damaged
area is not suitable for joint method.

Required tool and material

– Besides normal tools, this tool need to be used
in plastic welding as below:

CHANGAN·Benni MINI
502-02-4 Body Repair – Plastic parts repair 502-02-4

Specification and Operation

ITEM Part name Description Finally，drilling in th end of crack.

1 - Repairing part
Preparation of heat air gun and welding rod
2 - Welding part
Connect heat air gun to plastic welding gun
Cut V-type welding slot:
– Set weld temperature according
– Cut welding slot by blade specification(200°C -700°C)。
– Welding slot open angle is 60° - 70°.
Welding temperature
Attention: Drilling 3mm hole in end of crack to Welding temperature decide by two factors:
avoid crack extension. Smooth it if welding area is
uneven. – Plastic material
– Wedge thickness

Recommended welding temperature of usual material and thckness of usual welding rod(5.7 mm
x 3.7 mm)
Recommend welding temp
Thermoplastic （°C） Plastic welding torch control unit
Cuniform Injector 5.7mmquick welding injector
ABS 350 4,5 5,3
PP 300 3,8 4,5
PP/EPDM 300 3,8 4,5
– Only use PP welding and PBT/PC plastic ITEM Part name Description
– Steel glass fiber plastic is not allowed to weld. 4 - Air flow switch
– This temp is air temp in plastic welding gun,
much higher than plastic part temp.
Rear of palstic welding torch – Set temp according to supplier specification
– Preheat welding machine in 3-4 minutes,
– Cut welding rod front to slope, fillment start to
beginning of crack.

Welding
Pastic welding condition as follows:
– Correct temperature set
– Stable welding speed
– Stable operation pressure

ITEM Part name Description

1 - Inlet
2 - Temperature control unit
3 - Rock arm switch

CHANGAN·Benni MINI
502-02-5 Body Repair – Plastic parts repair 502-02-5

Specification and Operation

Put pressure on welding rod when welding.

Speed welding injector location ITEM Part name Description
1 - Weld slot heave
2 - Weld slot height
3 - Welding crack boot

Welding default

Deformation:
– Repaired part is too heat
– Material strentch when welding
– Plastic material is too lean

Quick welding injector should move parallelly with
area surface.
Location of plastic welding torch
Poor connection of welding
– Weld temperature is too low
– Weld temperature is too quick
– Welding different material together.
Welding plastic material is too low
– Welding slot is too wide
– Welding temperature is too high
塑料件摆动焊接难接近区域的损伤进行修理。

Welding again
– When cooling, heave part can be polished
bysand wheel machine, sand paper type: P80
tough sand paper.
– Polishing surface by sand wheel machine,
sand paper type: P120-P220 sand paper.
– Keep welding rod and crack verticl when
– Clean repaired surface by plastic brush.
moving plastic welding gun.
– Painting palstic paint on repaired surface.
– Welding operation can be started when
welding rod is in plastic state.
Plastic part waving weld
Welding joint end
Waving weld in order to repaired area which hard
to reach.

Attention: 如焊接时沿焊缝边缘只形成了很小的或
平滑的

CHANGAN·Benni MINI
502-02-6 Body Repair – Plastic parts repair 502-02-6

Specification and Operation

– Welding rod can be moved freely when waving

weld.
– Welding preparation as previous.

Welding
– Plastic weld gun eqiupt srentch injector.
– Through injector moving forward and back,
become welding rod and crack to plastic state.
– Pressing plstic state welding rod into slot,

Waving weld

ITEM Part name Descripton

1 - Welding rod
2 - Plastic weld gun
3 - Welding slot
4 - Welding direction

Pay attention as follows:

– Heating welding rod and slot equally.
– Stable welding speed
– Vetical location of welding rod
Other repair spet of welding—Introduce it in next
chapter.

CHANGAN·Benni MINI
502-02-7 Body Repair – Plastic parts repair 502-02-7

Specification and Operation

Plastic jointing ITEM Part name Description

2 - Sand wheel machine
Summarization
3 - Plastic plug
Comparing to welding technology, the advantage
of jointing technology as below: 4 - Blade
– In thermoplastic material parts, all sub-steel 5 - Paint blade
assistant parts, like bumper, front trim can be 6 - Pincers
repaired without identity.
– Polyurethane sealant must be adopted when
repair all thermoplastic parts. Preparation of repair parts
– We can reinforce welding crack and slot to Before repair, use high pressure cleaner to clean
ensure initial strentch. two sides of plastic parts then dry it.
– Use plastic clenaner to clean repair surface.
All required tools and equipments
Equiptment and tool in paint workshop can joint Polish scratch
thermoplastic part. Angular sand wheel machine
can repair scratch and crack. Track and wheel
machine can polish. Infrared heat machine can
clean parts quickly.
Plastic repair parts
– Plastic cleaner
– Plastic paint
– Joint repair parts
- Three container
- Three emulsion tube
– Metal reinforcement bandage
– Reinforced glass fiber

Tools and assistant equiptrment

ITEM Part name Description
1 - Prepare scratch area
2 - Prepare crack area
– Use sand wheel machine and P80-P120 sand
paper to smooth scratch.
– Smoothing by sand wheel machine and P120
sand paper

Attention: Wear protective glove

ITEM Part name Description

1 - Angular sand wheel
machine with speed control

CHANGAN·Benni MINI
502-02-8 Body Repair – Plastic parts repair
Specification and Operation
Cleaning repair surface by plastic cleaner or
paper.
– Painting repair surface equally.
Repair part preparation(Crack)
– Polish front crack by angular sand wheel
machine or belt sand wheel machine. Polished
surface width is 40-60mm
– Polishing track sand wheel machine again,
sand paper type: P120
– Drilling hole in end of crack to avoid strentch
– Drill crack
– Cleaning repair part by plastic cleaner and
paper.
– Painting plastic paint in repair part.
Joint preparation
– Using hand paint gun paint plastic part of
sealant after clean it.
– Insert resin and hardener from container into
emulsion tube by inject gun
Scratch joint
Even slight crack need to be repaired. Paint
enough on repairing surface to prevent crack
getting to badly
– Fill crack by sealant after cleaning and
painting.
– Merging end of emulsion tube into sealant
prevent air.
– Smoothing sealant by feeler ruler.
– Dry it by infreared heater or drier.
Joint and repaire crack
When large area crack happened, reinforce
reapiring part. Prepar reinforced material should
be attached back of parts.
502-02-8
– Cover front crack by PE slice or bandage.
– Fill crack by plastic sealant.
– Fill reinforced fiber with sealant together.ly
– Reinforce end of carck by steel bandage
– Dry it by infrared heater or drier.
– PE slice prevent sealant is splashing from
crack.
– Remove PE slice when sealant is dry.
– Put sealant in front of repairing part.
– Dry it by infrared heater or drier.
– Cooling sealant to normal temperature to
avoid sand paper is too hot.
Polish
Attention: Use dust cleaner and wear dust
mask when polishing.
Polishing heave part of sealant by track sand
wheel machine, sand paper type: P120-P220.
– Repair heave or bend area by hand.
– Scratch paint surface by liner pad
– Clean plastic part by using plastic cleaner or
paper.
Attention: Dry plastic paint thoroughly (Rough
surface)
Paint plastic paint in repairing surface.
Using of fill material
We suggest mix 2K material (MS, HS) to avoid
crack and unsmooth surface.
– When dried. Cold 2K material to normal
temperature, then polish it by track sand wheel
machine and sand paper.
– Repair heave or bend surface again by sand
paper.
– Check smoothness, polish it if it’s uneven.
– Painting according to supplier suggestion.
CHANGAN·Benni MINI
502-02-9 Body Repair – Plastic parts repair 502-02-9

Specification and Operation

Safety specification
– Polyester resin, sealant, solvent and thinner
belong to flammable product, flame mubt be
forbidden.
– Polishment and cut should be operated in area
which equipt cleaner.
– Clean system tools must be operated without
this area.
– Protective equiptment, such as glove,
eye-proof glass, apron and mask is very
important.
Refer to 502-00, 502-01 and 502-02 chapter for
more inforamtion. Following secification when
using polyester resin, sealant, solvent and thinner.

CHANGAN·Benni MINI
502-03-1 Body Repair—Concave repair without painting 502-03-1

502-03Chapter Body Repair - Concave repair without

painting
Vehicle midel: CHANGAN·Benni MINI

MENU PAGE
Specification and Operation

Concave repair without painting......................................................................................................... 502-03-2

Summarization.................................................................................................................................... 502-03-2
Economical condsideration .............................................................................................................. 502-03-2
Damage degree.................................................................................................................................... 502-03-2
Repair preparation........................................................................................................................... 502-03-3
Repair method.................................................................................................................................... 502-03-3
Service tool/help ............................................................................................................................... 502-03-3
Service procedure ............................................................................................................................... 502-03-3
Unstale pressure area ..................................................................................................................... 502-03-4
Stable pressure area .......................................................................................................................... 502-03-4
Independent vehhicle body ................................................................................................................ 502-03-5
Anti-erosion protect ....................................................................................................................... 502-03-6
Quality control.................................................................................................................................... 502-03-6

CHANGAN·Benni MINI
502-03-2 Body Repair—Cancave repair without painting 502-03-2

Specification and Operation

DESCRIPTION AND OPERATION

Cancave repair without painting

Summarization - Cancave’s depth and area

Small cancave can be repaired without damage - Suitabe repair method
paint, Cancave can be repaired by special tools if - Tough repair area
malfunction is diagnosed, correct method is - Suitable material
adopted and technician experiences about how to - Cancave number of vehicle panel
use special tool and material knowledge.
- Does paint damaged
– This method can only adopt cancave which
locate sides of vehicle. It’s also suitable for
margin area, hard wrinkle area. Damage degree
– This method can only adopt cancave which This method is adopted for cancave which
have little diameter. It is suitable for damage diameter is 50mm.
caused by hail, parking or transportation.

Ecomonical consideration
– Is it ecomonical to repair cancave withou
painting deponds on:

Value ecomonical deponds ondamage degree

CHANGAN·Benni MINI
502-03-3 Body Repair—Cancave repair without painting 502-03-3

Specification and Operation

ITEM Part name Depscription

1 - Cancave center
2 - Cancave edge

Repair preparation
Cancave material cannot exceed formation limit

Repair method
– Dagnose damaged area
– Remark cancave
– Prepare repair method ITEM Part name Description
– Place adjustable illumination lamp 1 - Cancave without pressure
– Repair cancave
2 - Cancave with pressure
– Anti-erosion protection
5. location of pressure tool
– Carry on quality control
• Top point of pressire tool is placed on the
edge of cancave.
Repair tool/Help • Pressing cancave and moving forward and
back by top of pressure tool
– Special tools for repair cancave
6. Working principle of pressure adjustment
– Adjustable illumination lamp • Suquence operation follows half circle
• Repair follows half circle
Repair procedure • Unrepaired area can resolve automatically
by pressure aroud it.
1. Confirm repair method
2. Remark cancave
Attention: Remarked repair area is easy to
identity

3. Prepare repair area

• It need not open a hole if repair area can be
reached directly.
• Clean damaged area, Check carefully is
important to repair sucessfully.
• It need to polish if the repaire area is tough.
4. Place adjustable illumination lamp
• Illumnation lamp should be adjusted until
the cancave is seen clearly.
•

Light reflection when pressing

ITEM Part name Description
1 - Pressure sequence
2 - Starting place

CHANGAN·Benni MINI
502-03-4 Body Repair—Cancave repair without painting 502-03-4

Specification and Operation

Attention: It’s not allowed to repair cancave begin ITEM Part name Description
center, because edge will be heaved and it need
to more time to smooth it. 1 - Repair way
2 - Pressure tool
Edge heave point

Stable pressure area

Attention: If working area near renforced plate,

small pressure is needed.
Material flexibilityof inner leaner is small, so
small pressure is enough.
– Pay attention to more pressure if contact area
between tool and part is small.
– Visual inspection：
- The only way to solve all the uneven area is
adjust illumination lamp to check all area.

ITEM Part name Description Press cancave near reinfored plate

1 - Egde heave point
2 - Pressure tool
– Exception:
- Slight material formation is starting in center.
- Press cancave, then heave are will be seen,
because canvace material is prolonged.
- Use plastic tool to smooth slight heave area.

Unstable pressure area

If we deal with large area, poor steelness vehicle
body, pressure tool need to be use frequently and
repair time need bt be prolonged. ITEM Part name Description
1 - Roof
Big cancave
2 - Pressue tool
3 - Sealant
4 - Roof bracement

CHANGAN·Benni MINI
502-03-5 Body Repair—Cancave repair without painting 502-03-5

Specification and Operation

Indepengdent vehciel body ITEM Part name Description

1 - Contact point
Roof area
2 - Motion direction

S-type hook to brace pressure tool

Door area
– Cancave can be repaired without remove trim
– We need to put protection set to avoid any
damage of door and vindow.
– Ensure plastic wedge inserted

Equipment

ITEM Part name Description

1 - Brace by S-type hook
2 - Pressure tool
– S-type hook must be used to reinforce
intensity of roof.
– Loose it according to number and location of
cancave
– Cancave can be reach repair through remoce
parts.
– Before working, check part reachability if
cancave near smooth roof.
– Use special tool to repair area near inner
brace.

Special lever near brace repair cancave

ITEM Part name Description

1 - Protection
2 - Plastic wedge

CHANGAN·Benni MINI
502-03-6 Body Repair—Cancave repair without painting 502-03-6

Specification and Operation

– It need rotary pressure tool instead of any

other brace in this operation situation.

Smooth cancave by window slot

Protection
– Use lever to move hood to located place and
fasten it by bandage.
– In brace area, sealent need to be opend by
steel shave in order to neat cancave.

Anti-erosion protection
– All repaired area which can be reached must
be painted.
- Clean inner area
- Painting work on inner area.
- It’s not allowed to use protective wax in near
area

Quality control
– Items should be followed in order to meets
quality requirement
- Inspect uneven area visually in different
degree.
- Painting repaired area and polishment if
necessary.
- Inspect if accessory or inner trim is fastened
firmly or damaged.

CHANGAN·Benni MINI
502-04-1 Body repair—Noise, Vibration and Harnessment 502-04-1

502-04 Chapter
Body repair－Noise, Vibration and harnessment
Vehicle model: CHANGAN• Benni MINI

MENU PAGE
Specification and Operation

Noise, Vibreation and harnessment ....................................................................................... 502-04-2

Introduction ......................................................................................................................... 502-04-2
NVH definiton in auto engineering ....................................................................................... 502-04-2
Noise type in auto engineering ............................................................................................ 502-04-2
Sound transmission by air .................................................................................................... 502-04-2
Sound transmission by object ............................................................................................... 502-04-2
Sound transmission by air and object................................................................................... 502-04-3
Vibration technology ............................................................................................................ 502-04-3
Noise and vibration in vehicle ............................................................................................ 502-04-6
Noise and vibration in Air inlet system and Exhaust system .............................................. 502-04-7
Vehicle body ......................................................................................................................... 502-04-9

CHANGAN• Benni MINI

502-04-2 Body repair—Noise, Vibration and Harnessment 502-04-2

Specification and Operation

DESCRIPTION AND OPERATION

Noise, Vibration and Harnessment

Introduction - low noise

This chapter gets entire description on how noise - middle noise
and vibration happened and eliminated in - high noise
vehice.

NVH definition in auto engineering Different intense noise happened in vehicle

parts:
N = Noise - sound can be heard
– low noise is mostly happened by engine
V = Vibration – vibration can be feeled
– low noise is possible happened by tough road
H = Harnessment – sound and vibration can be – High noise is usually happened by air flow and
heard and feeled. accessery
– Noise is happened by loosing parts which is
absorber, chassis etc when vehicle is
Noise type in auto engineering
running on tough road.
– Noise is classfied in auto engineering by
sound intensity
Sound transmission by object

Sound transmission by air

– Sound wave transmitted by compress air.

ITEM Part Description
name
1 - Sound resource Sound transmission by object
2 - Sound wave Sound transmitted by luquid and solid
3 - Wave intensity Sound transission speed depends on medium
meterial. Sound is transmitted 5 times faster in
liquid or solid medium than in air.

CHANGAN• Benni MINI

502-04-3 Body repair—Noise, Vibration and Harnessment 502-04-3

Specifications and Operation

Sound transmission by air and object Attention: Nosie transmission by air and
object is mainly issue in vehicle
engineering.

Sound transmission in vehicle

ITEM Part name Description

1 - Noise transmission by air
2 - Noise transmission in vehicle
– Example
- Noise from engine
- Noise through air directly
- Noise transmitted form engien to vehicle
body by vibration.

Vibration technology
– Human beings can not hear the sound lower
than 20 Hz or higher than 20 kHz vibrated
noise.
– Engine is installed flexibly, it can vibrate when
vehicle is running on tough road.
– Noise will be transmitted from engine to
vehicle body when flexible installation is failed.
– principles are suitabe as follow:

CHANGAN• Benni MINI

502-04-4 Body repair—Noise, Vibration and Harnessment 502-04-4

Specification and Operation

- Auto technology not only research low

vibration cannot be heard, but also high
vibration can be heard.
- low vibration can be visible.
- High vibratin can be visible and perceive.

Resonance
– Each object have it’s certain frequency.
– Resonance will be happened when object
vibrates in it’s certain frequency.
– Engine will be unstable when it vibrates in it’s
certain frequency.

Damp
– Object vibration will be reduced if connect it
with spring.
– Vehicle absorber is made on this principle.
– Damp affects resonance of system and object.
– Absorber function is reduce vibration.
– Vehicle absorber is a kind of damper which
can reduce vehicle vibration.

Harnessment

ITEM Part name Description

1 - Vibration without damp
2 - Vibraton with damp

Sound insulation
In vibration technology
– Example
- Engine installed by flexbile suspension
- In auto engineering, rubber can reduce
vibration of systems and objects, it’s function
like sring.

CHANGAN• Benni MINI

502-04-5 Body repair—Noise, Vibration and Harnessment 502-04-5

Specification and Operation

Install directional rubber to gets best sound insulation effective

Absorb
ITEM Part name Description
– Sound will be reflected by solid surface
1 - Engine
– Sound will be absorbed by soft surface
2 - Engien installation

ITEM Part name Description

1 - Reflect wave – Example：

2 - Absorb wave

CHANGAN• Benni MINI

502-04-6 Body repair—Noise, Vibration and Harnessment 502-04-6

Specification and Operation

- All insulation parts like trimpanel, carpet, roof, Noise and vibration in vehicle
lugguge rack, is insulated from vehicle body.
Passenger in different vehicle position feels
- It reflects sound wave and reduce hall effectice. different noise intensity.

Vehicle sound and noise

ITEM Part name Description

1 - Driver on trough
2 - Passenger on wave crest

Noise and vibration on Air inlet system and

Exhuast system

Air inlet system is aie and solid noise

resource.

Exhuast system is aie and solid noise

resource.

CHANGAN• Benni MINI

502-04-7 Body repair—Noise, Vibration and Harnessment 502-04-7

Specifications and Operation

Sound transmission way：

- Noise transmission way from Air inlet
system and exhaust system.
- Solid noise is main resource in inlet and
exhaust system besides air noise. Insulation
should be installed firmly in order to reduce
noise in maximum.
- Exhaust system is a typical vibration parts, it
requires good insulation when installation.
Air inlet system
Air inlet system
– Air inlet system’s length and volume is and
connot changed. Be careful about connection.
– When air inlet system is forcely compressed,
it’s easy vibrated.
– Temperature effective.
– To avoid vibration from air inlet system to
vehicle body, pay attention to as follows:
- Entire air inlet system is installed in rubber
and insulate from vehicle body.
- Inlet pipe cannot contact with vehicle body
directly.
- Contact place should cover foam.
- Exhaust system

ITEM Part name Description

1 - Inlet manifold
2 - Connecting pipe
3 - Rubber
4 - Air cleaner
5 - Renonance box

CHANGAN• Benni MINI

502-04-8 Body repair—Noise, Vibration and Harnessment 502-04-8

Specification and Operation

Exhaust system construction

ITEM Part name Description

1 - Exhaust pipe
2 -
3 - Front muffler
4 - Rear muffler
– Exhaust system is installed tightly.

Attention: Rubber cushion of exhaust system can

transmit vibration also. So it’s very necessary to
keep free emptiness when installation.
Rubber cannot be too tightly.
– Exhaust manifold should connect with engine
directly.
– simple question test：

CHANGAN• Benni MINI

502-04-9 Body repair—Noise, Vibration and Harnessment 502-04-9

Specifications and Operation

- remove all uspension gaskets of exhaust - All the ways to the engine carbin
system. - sealant of door and widow
- Suspending suspension system by rope. - heater and vetilation
- check noise in carbin by take a drive test.
- If noise has gone, it means noise is from – The connection area between fender and
exhaust gasket. vehicle body mainly make noise, the method
- installing gasket one by oen to check the as follow:
noise. - Installing on A pillar to get good effective.
- We can find out the gasket which make Attention: Use foam and rubber is a good
noise method for sound insulation. We should
check relative foam if noise come from wind,
tyre, engine or road.
Vehicle body - filling foam in effected area.
- filling foam in relative hole.
Function
– The requirement of vehicle is diverse,
especially running vehicle, mostly parts which
make noise is engine and gasket, but vehicle
body is main part of NVH.
– The described parts mean which make noise.
Vehicle body includes all the relative parts.
– Vehicle body includes air noise and solid
noise.
– Vehicle should absorb all the parts vibration
and don’t transmit noise to carbin as can as
possible.
– The main part of NVH in vehicle body is steel
roof, fender and floor. Because of construction,
noise will be amplifed when transmit to this
places.

High requriement for vehciel body

– Excellent fall or impact performance
– Spacious interior
– Anti-erosion
– Light weight
– Good aerodynamics
Because all requirements cannot be satisfied at
the same time, a compromise method should be
adopted. For example, the vehicle body should
be tough and flexible to meets NVH
requirements.
Example:
– Ensure the cehicel body’s water tightness
butcannot sure requirement of noise and
vibration. This factor should be considered:
- Installing door window correctly.
- Installing sealant corectly.
– Other attentions

CHANGAN• Benni MINI