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

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
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
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
　 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
Applicable : step four
1 Controller plug A B
2 Repair line
3 body bottom panel
Plug B Plug A
BENNI·MINI
204-01-12
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

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
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

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
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
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
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
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

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

there is no speed signal input for 5 seconds continuously after found the engine speed reduce
beyond the standard
BENNI·MINI
204-01-18
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
connection and line replace a better odometer

are normal replace a and check again
new speed meter and
check again
Applicable : step four
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

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
Applicable: step two

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

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
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

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.

Replace a new EPS controller ,check again.

Replace a new EPS controller , check again.
BENNI·MINI
204-01-23
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
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
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
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
U-shine
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 -
U-shine
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:
U-shine
Diagnosis and Test

DIAGNOSIS AND TESTING
Steering Mechanism
See Section 204-00 for relevant information.
U-shine
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.
U-shine
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.
U-shine
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
Steering Column ................................................................................................................................... 204-03-3
Steering Column ….
204-03-4
CHANA.BENNI -MINI
SPECIFICATION
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
Description and Operation
Up steering shaft
Connection joint
Down steering shaft
CHANA.BENNI -MINI
Description and Operation
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
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
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
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
Disassembly and installation
Gear-Shifting Mechanism (16 534 0)
CHANA.BENNI-MINI
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
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
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
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
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
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
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
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
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.
Chana·Benni MINI
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.
Chana·Benni MINI
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
Chana·Benni MINI
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.
Chana·Benni MINI
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.
Chana·Benni MINI
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.
Chana·Benni MINI
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.
Chana·Benni MINI
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.
Chana·Benni MINI
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
Chana·Benni MINI
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
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.
Chana·Benni MINI
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
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.
Chana·Benni MINI
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
Cylinder gasket installation
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
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
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
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
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
Chana·Benni MINI
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

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.
Chana·Benni MINI
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
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.
Assembly
Warning： The assembly is contrary to the disassembly.
In order to avoid scald, do not do the Notice：
maintenance when the exhaust manifold is ⑴.The part fabrication of some parts should be
hot. It only can be done when the system done first, such as the eshaust manifold
is cool. 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
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
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
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
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
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
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
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
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
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
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
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
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
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
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.
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.
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.）
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
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.
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 ● Before any part of the cooling system is disassembled,
1) Empty the cooling system. check and ensure that the coolant has been cooled.
2) In order to disassemble the cooling water pipe ● Ensure that the cathode wire is disconnected from the
or hose, the pipe clip bolts of each water pipe or battery terminal before any part of the engine is
hose shall be loosened, and the hose shall be disassembled.
drawn out.
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
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
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.
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.
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
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
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
1.6 Parts list
Parts of transmission box and housing
Changan·Benni MINI
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
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
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
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
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
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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
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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
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
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
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
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
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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
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
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
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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
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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
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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
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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
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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.
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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
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Attention: First install the interlocking pin, and then install the interlocking plate
Install the bolts
3.3.16 Install the left case cover
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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
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
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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.
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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
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
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.
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
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
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
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.
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Failure Phenomenon Table
Failure Description Possibe Causes Maintenance Action

• Clutch skidding. • 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.
disc is excessively hardened or has
oil stains.
• The flywheel
• The clutch has the noise of click or • The engine bracket • Turn to the fixed point inspection
shakes. • The surface of the clutch friction B
disc has oil stains
• The clutch platen
disc
• The flywheel
• The clutch is procrastinated. • Air is in the hydraulic system. • Turn to the fixed point inspection
• The free travel of the clutch pedal. C
• The clutch friction disc
• The spline of the clutch friction disc
disc has oil stains.
• The clutch pedal is pulsed. •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 clutch is shaking. • 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 gearshift is difficult. • The free travel of the clutch pedal • Turn to the fixed point inspection
• The manual transaxle has failure. F
• The noise is over high. • 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
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
B1: Inspection of the Noise of Click or the Shaking of the Clutch
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

　 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

C1: Inspection of the Free Travel of the Clutch
Pedal
Changan·Benni MINI
302-00-9 Clutch–General Description
302-00- 9

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
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

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
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
Fixed Point Inspection F: Difficult Gear Shifting

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

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
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
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

Adjust the free travel to 10-15
Clutch Skidding ．The free travel of the clutch pedal is improper.
mm.
．The friction disc assembly is abraded or has oil Replace the friction disc
stains. assembly.
．The clutch platen assembly or the flywheel Replace the clutch platen
surface is deformed. assembly of the flywheel.
．The diaphragm spring is deformed. Replace the clutch cover.
．The dragline of the clutch is corroded. Replace.
Difficult Clutch
The travel is adjusted to 10-15
Release ．The free travel of the clutch pedal is improper.
mm.
． The diaphragm spring is deformed or the
Replace the clutch plate.
spring part is abraded.
The input axle spline has pitting. Lubricate.
The input axle spline of the transmission gear is
Replace the input axle.
damaged or abraded.
The swinging of the clutch plate is serious. Replace the input axle.
The clutch plate is damaged or has oil stains. Replace the input axle.
Clutch
Vibration
．The clutch plate is brightened. Repair or replace the input axle.
The clutch plate has oil stains. Replace the clutch plate.
．The release bearing can not smoothly slide on Lubricate or replace the guard
the bearing protective ring of the input axle ring of the input axle bearing.
．The clutch plate swings or has bad contact. Replace the clutch.
． The torsion spring in the clutch plate is
Replace the clutch plate.
deformed.
．The rivets of the clutch cover are loosened. Replace the clutch cover.
．The platen or the flywheel surface is deformed. Replace the clutch plate or the
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
302-03-3 Starter motor 302-03-3
·Burnt commutator
·Layer short-circuit of armature

·Crankshaft rotation obstructed
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
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
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
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
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
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.
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 Possible Causes Elimination Methods
The charging indicating lamp z The safety fuse is broken Check the safety fuse
is off when the ignition switch z The lamp bulb is burnt Replace the indicating lamp.
is switched on and the engine z The binding post is Tighten the loose connection.
is stopped to run. loosened and dropped. Replace the integrated circuit
z The integrated circuit regulator.
regulator is failed. Maintain or replace
z The electrical brush and
the sliding ring are not
well connected.
The charging indicating lamp z The transmission belt gets Adjust or replace the
is not turned off when the loose or is abraded transmission belt.
engine runs (the accumulator z The integrated circuit Check the charging system.
requires frequent charging) regulator or the generator Repair the circuit.
is out of condition.
z The circuit is failed.
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.

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 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 302-03-10

The belt pulley skids Adjust the belt tension.
The charging The rotating speed of the generator is Make the rotating speed of the
indicating lamp can too low. generator larger than 1250 r/min
not be turned off The external conducting wire of the Reconnect the wire.
generator is not well contacted.
The vehicle body wiring hardness is Eliminate the fault.
broken and short-circuited.
The accumulator is failed, and the inner The accumulator is changed
resistance is over large.
The charging The voltage regulator is damaged Replace the voltage regulator.
indicating lamp can The rectifier diode is failed. Replace the rectifier.
not be turned off The magnet exciting coil is Replace the rotor.
disconnected or short-circuited.
The electrical brush is completely or Replace the electrical brush.
over abraded.
The screw gets loose. Fasten the screw.
The noise gets There is foreign matter in the generator. Remove the foreign matter.
louder The bearing is damaged. Replace the bearing.
Generator Output Characteristic Curve
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
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
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
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
Specifications
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

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
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
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
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
accident.
1. The installation process is opposite to the
disassembly process.
CHANA.BENNI-MINI
Fuel Pump Module
Disassembly 4. Remove and discard the O-shaped sealing ring.
Warnings: The procedures comprise the fuel

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
accident.
3. Remove the fuel pump module.
CHANA.BENNI-MINI
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
CHANA.BENNI-MINI
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.
Notes: Pay attention to the arrow of the fuel

flowing direction.
5. Remove the bolts of the fixing clips of the fuel
filter.
CHANA.BENNI-MINI
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
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.
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
Installation
accident.
CHANA.BENNI-MINI
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.
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

Applicable Vehicle Model: U-Shine

Electric Vehicle Window Switch
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
U-Shine

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
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
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

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
…………………………………………………………………………………………………… 403-02-3
Circuit Schematic Diagram
…………………………………………………………………………………………………… 403-02-3
Pin Definition 、Gear Position Table of Emergency Alarming Switch
…………………………………………………………………………………………………… 403-02-3
…………………………………………………………………………………………………… 403-02-4
U-Shine
403-02-2 403-02-2
Emergency alarming switch
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
Emergency Alarming Switch
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
Gear Position Table of Emergency Alarming Switch
Pin Definition

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

Contents
Instruction and Operation Pages
Front Fog Lamp Switch…………………………………………………………………………………… 403-02-2
Rear vision mirror switch PIN DEFINITION
Front Fog Lamp Switch………………………………………………………………………………… 403-02-4
Front Fog Lamp Switch……………………………………………………………………………… 403-02-5
U-Shine
403-02-2 403-02-2
Front Fog Lamp Switch
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

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
Gear Position Table of Rear Fog Lamp Switch
Pin definition

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

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
Benni MINI
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
Benni MINI
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
Benni MINI
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
Benni MINI
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
Benni MINI
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)
Benni MINI
Principles of the front lamps (Schematic Diagram V)
Benni MINI
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．
Benni MINI
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
Benni MINI
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.
Benni MINI
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
Benni MINI
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
Benni MINI

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

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

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204-01-7 Electric Power Assistant Steering Column

Controller instruction and inspection