Professional Documents
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Content
320
Welcome to use LF320. To assist you for better use and maintenance of LF320, do please read this manual carefully.
Major technical specifications and vehicle identification of LF320 2
LF320 applies electronic fuel injection engine with complicated circuit structure of the entire vehicle. Please do not add or Chapter 1 Operation of instrument and controller 7
install electrical equipment that is not recommended by the original factory yourself. Otherwise, the fault generated will not 1-1 Appearance of instrument panel and controller 8
be covered by the warranty of the Company.
1-2 Key and door 12
In this manual, for places with note of “safety warning” or “vehicle damage”, operation shall be carried out following the 1-3 Seat, seat belt and rearview mirror 22
notice content carefully to avoid personal injury or vehicle damage. 1-4 Illumination, wiper and defroster 46
1-5 Instrument and maintenance indicator lamp 52
The note expression as follows: Safety mark
1-6 Ignition switch, manual transmission and parking brake 61
1-7 Audio system 64
Notice 1-8 Air conditioning system 69
Items must be followed for inspection convenience 1-9 Other equipments 75
Chapter 2 Drive guide for LF320 78
Chapter 3 Starting and driving 87
Warning
Chapter 4 Urgent trouble treatment 93
Avoid items endangering The safety mark in above picture means “can not
vehicle or personal safety do this” or “can not make this happen” Chapter 5 Anti-corrosive and vehicle exterior maintenance 106
Chapter 6 Maintenance instruction 112
The pictures in this manual are all illustrations, only for reference. For this manual is the general description of this vehicle Chapter 7 Self-maintenance 115
model which covers various schemes of the model, part of the description features might not be applicable for your specific 7-1 Engine Compartment appearonce 116
vehicle. For vehicle purchase, please consult the real product. 7-2 Engine and chassis 120
Lifan Indusry(Group) IMP.& EXP. CO.,LTD maintains the modification right of the technical features and content of this
manual without any restriction and giving prior notice. 7-3 Electrical Components 127
Thanks for choosing LF320. Any precious idea and suggestion are welcomed Chapter 8 Maintenance Specification 131
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Owner’s Manual LIFAN
320 Owner’s Manual LIFAN
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Major technical specifications and vehicle identification of Lf320 Major technical specifications
Height mm 1430
Front mm 1385
Track
Rear mm 1365
Approach angle ° 20
Departure angle ° 23
Seats 5
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Owner’s Manual LIFAN
320 Owner’s Manual LIFAN
Displacement ml 1342
Maximum power kW 65
Emission
Euro Ⅲ Euro Ⅲ Euro Ⅳ
standard
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Indicator and warning sign
Owner’s Manual LIFAN
320 Owner’s Manual LIFAN
Section 1-1
320
1 Operation of instrument and controller
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1.Power steering fluid warning sign Tire pressure sign, locating in the middle of Fuel sign, locating in the inner side of the
2.washer fluidWindshiled washer fluid warning the two hinges of left front door. fuel tank cap.
sign
3. Oil filling and coolant warning sign
4. A/C refrigerant warning sign
5. Engine coolant warning sign
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Owner’s Manual LIFAN
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10 4 9 8 7 6 5
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Owner’s Manual LIFAN
svs
1.Speedometer 2. Tachometer 3. Fuel gauge 4. Odometer 5. Clock display ABC indicator svs Engine electronic injection system fault indicator
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Owner’s Manual LIFAN
Section 1-2
320 Key
Owner’s Manual LIFAN
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Owner’s Manual LIFAN
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Power window (optional)
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Trunk lid Engine hood
Use of switch on driver’s door Note
Door window lock switch
Automatic: press for less than 300ms to enter ● Button pressing duration of less than
automatic descending operation, glass window 300ms: if the window controlled by the
stops automatically after reaching the due button is in lifting operation, the window
place. lifting operation will be stopped;
otherwise automatic work condition will
Manual: press for 300ms or more to enter be applied.
manual ascending or descending operation, ● Button pressing duration of 300ms or
press the button and hold it to operate, leave the more: if the window is in operation with the
button to stop operation. lifting direction different with the operation
direction controlled by the button, the
Time delay: window regulator system can work original operation will be stopped, then
manual lifting work condition will be Passenger’s window operation
Door window locking switch in 60s after turning off the ignition switch; if To open the trunk lid, pull up the trunk lid Open engine hood:
Switch on each door can operate the relevant press the remote controller lock switch within applied; for same direction, manual lifting open handle at the driver’s seat.
work condition will be applied directly. Any switch on passenger’s door or switch on
window the 60s, vehicle enters anti-theft condition, in 1. Pull up the open handle of engine hood,
driver’s door can control passenger’s window.
which condition window regulator system is To close the trunk lid, pull down and press the the engine hood will jump upwards slightly
Ignition key must be put at position “II”. prohibited from working. trunk lid. After closing it, try to pull it up to check
Open: press the switch.
whether it is closed tightly. Warning
Close: pull up the switch.
Operation of driver’s window Remote control: if press the remote controller
If the window lock switch of driver’s door side Warning Before driving, please confirm engine
lock switch and holding on, four glass windows
is pressed, operation of passenger’s side hood is closed and locked tightly.
Open: press the switch. will ascend to top, the frame riser stops when the Trunk lid must keep close in driving. Then
window is invalid. Otherwise, in driving, the possible sudden
Close: pull up the switch. switch is released or glass touches the top. luggage throwing out can be prevented, open of engine hood can cause accidents.
exhaust gas can be kept out of the vehicle.
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Owner’s Manual LIFAN
320 Fuel tank cover
Owner’s Manual LIFAN
320
Warning
After putting engine hood brace rod into
the hole, please confirm the brace rod is
supporting the engine hood firmly to avoid
head or body injury caused by engine
hood falling.
Note
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Owner’s Manual LIFAN
Section 1-3
320 Seat
Owner’s Manual LIFAN
Front seat
320
—Precautions for front seat Driver’s seat
Operation of instrument and controller In driving, passenger of the vehicle shall Warning
adjust the seat back to a comfortable position drivers’ seats, when they completely lean
and use seat belt correctly. SRS front seat air bag will be extended with forward, the distance of 250mm can be
Seat, seat belt and rearview mirror great power. Especially, severe injury and achieved by merely leaning the seat back
Warning death of front passenger can be caused by backward slightly. If it is difficult to see the
Seat… … … … … … … … … … … … … … … … … … … … … … … … … … … …23 road after leaning the back pad backward,
over short distance between front seat
Front seat… … … … … … … … … … … … … … … … … … … … … … … … …23 ● Do not drive before passengers use solid nonskid cushion to lift or apply
passenger and the air bag.
s i t t i n g c o r r e c t l y. P r o h i b i t a n y elevated seat if it is available by the vehicle.
Rear seat… … … … … … … … … … … … … … … … … … … … … … … … …25 passenger from sitting on folded seat
For the 50-75mm of initial charging is the
dangerous area of driver air bag, 250mm off
Headrest… … … … … … … … … … … … … … … … … … … … … … … … … …26 back or in luggage or on goods. For
from the driver air bag can guarantee a clear Shall adjust the seat following the above
emergency brake or collision,
Seat belt… … … … … … … … … … … … … … … … … … … … … … … … … …26 incorrect seated position or seat belt
safety range. The distance is the measured recommended measures. Besides control
distance from the center of steering wheel on the pedal and steering wheel, and
Air bag (SRS)… … … … … … … … … … … … … … … … … … … … … … … …31 application can cause severe personal
to breast bone. If the distance of current observation on instrument panel must be
Electric exterior rearview mirror… … … … … … … … … … … … … … … …44 injury.
seat is less than 250mm, seat position can maintained.
Interior rearview mirror… … … … … … … … … … … … … … … … … … … …45 ●In driving, any passenger is not allowed to be adjusted by the following measures:
stand up or move between seats. Otherwise, ● Remove seat backwards as much as
Vanity mirror… … … … … … … … … … … … … … … … … … … … … … … …45
severe injury can be caused on emergent possible and keep comfortable stepping on
accidents like emergency brake or collision. the pedal at the same time.
● Lean the seat back backward slightly.
Although vehicle design varies, for many
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Front passenger seat
Owner’s Manual LIFAN
Rear seat
320
Warning Warning Front seat adjustment 1. Seat position regulator handle Warning
Hold the middle of handle and pull
SRS front seat air bag will be extended ● Do not adjust seat when vehicle is still upward. Then make use of slight body When recover rear seat back to vertical
with great power. Especially, severe injury moving, which could cause accident move pressure to slide the seat to the needed position, to prevent personal injury in
and death of front passenger can be and make driver lose control of the vehicle. position; release the handle. accident or emergency brake, the
caused by over short distance between following protective measures must be
front seat passenger and the air bag. ● Attention shall be paid to ensure no 2. Seat back angle regulator handle followed:
Front passenger seat shall be removed by collision between seat and passenger or seat Lean forward, and pull the handle upward;
adjusting seat back; the longer distance and luggage. then lean backward to the needed angle; ●Push and pull the upper part of rear seat
release the handle.
between the seat and the air bag the back forward and backward to confirm the
better. ●After seat adjustment, loose the rod, try to rear seat back is locked tightly. Otherwise
slide the seat forward and backward to check the normal operation of seat belt will be
whether the seat is locked in due position. Pulling the buttons on the top of rear seat influenced.
back upward can unlock the seat back
●Do not put things under seat. Otherwise, and then it can be folded downwards. ● Confirm the ribbon of seat belt is not twisty
seat locking structure can be influenced or or jammed in the rear seat back. Put it in the
seat position regulator handle can be pushed right position for use preparation.
upwards accidentally which can cause
sudden seat move and make driver lose
control of the vehicle.
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Headrest
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Seat belt
For security and comfort, headrest must —Precautions for seat belt Warning
be adjusted before driving touch the safety part of shoulder. On front liquid or abrasive for cleaning, which are also
LIFAN reminds you that driver and
In driving, all passengers of the collision accident, the over lean of seat can not allowed to contact with seat belt directly.
Higher: pull headrest upward. passengers on the vehicle shall buckle seat
vehicle must sit on the seat with seat increase the danger of personal injury or death. Otherwise, seat belt can be greatly damaged.
Lower: press lock release button, press belts at any time to reduce injury or severe
headrest. belt correctly applied. Otherwise,
injury possibility in accidents.
severe body injury or death can be ●Note: do not damage belt or hardware of
The closer to the head position, the better
The seat belts of the vehicle are designed to fit caused much easier in emergency seat belt. Do not make them seized or
protective effect will the headrest have.
Therefore, it is not necessary to use cushion on adults, and a child can sit on a rear seat with brake or collision accident. jammed in the seat or door.
the seat back. protection of the seat belt. According to accident
statistics, a child sitting in rear seat with proper Use seat belt following instructions below: ● Check seat belt system regularly. Check
protection are much safer than whom sitting in for the existence of parts with incision,
Front front seat. ●In the same period, a seat belt can only be abrasion or loose. Do not disassemble or
Warning
applied by one person alone. It is not modify the system.
If a child has to sit in the front seat, seat belt
●Adjust, make the central part of headrest allowed to use one seat belt by 2 or more
must be applied correctly. For improper
close to the upper side of ears. people jointly, even for children. ● For severe collision accident, seat belt
application of seat belt in accident, the rapid
devices (including bolts) must be replaced.
● After adjustment, confirm it is locked extension of air bag can cause severe injury or
on the position. ●Avoid over lean of seat back. When driver and The entire device must be replaced even
death to the child.
front passenger sitting straight against the seat, though the damage is not obvious.
●Do not drive without headrest. No matter in front seat or rear seat, do not allow child to seat belt can provide maximum protection for
stand up or kneel on the seat. For emergency brake or front or rear collision accident. If lean on the ●Keep seat belt clean and dry. For cleaning
collision, the unprotected child can suffer severe injury or seat, seat belt part of waist can slide to breech necessity, apply neutral soap water or mild
even death. Besides, do not put child on your leg which and press pressure on abdomen, or neck will warm water. Do not use bleaching agent, fuel
Rear can not provide sufficient protection to the child.
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320
—Buckle front and outside seat belts Content
For emergency brake or collision, retractor Warning Adjust position of waist and shoulder seat
will lock seat belt. It will also lock up for too belt parts
rapid forward lean. Seat belt can stretch out ● After putting in the belt head, please
Tighten loose part
for slow and stable move for free action. confirm the belt and lock catch are
Keep waist seat belt buckle at breech position as
locked firmly and seat belt ribbon is not
much as possible — do not keep it at waist part.
For failed seat belt pulling from the retractor, twisty. Too high
Then pull the shoulder part upward by the bar plate,
seat belt can be pulled out from the retractor adjust seat belt to a proper position.
smoothly by pulling it tightly first and then ● Do not put things like coin and clip into the
releasing it. lock catch to prevent blockage on the correct
buckle of belt head and lock catch. Keep it at breech position as well as you can
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Owner’s Manual LIFAN
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—Buckle rear middle seat belt tightly Air bag (SRS)
Warning — SRS for Driver and Front Passenger
Pull out
● For safety, please carefully read the
● After putting in belt head, please following information before use.
confirm that belt head and lock catch Information for use of SRS and air bag:
are locked firmly and seat belt is not ● Carefully read the Information Manual and
twisty. check your vehicle for the installation of air
Too high bags (driver side air bag and passenger side
●Do not put things like coin and clip into Adjust to suitable air bag).
the lock catch to prevent blockage on the position
● The front passenger SRS includes 2 air
correct buckle of belt head and lock catch.
Keep it at breech position as well as you can bags:
● For abnormal seat belt function, ●Driver side air bag
Pull out i n f o r m L I FA N s e r v i c e s t a t i o n Too high ●Passenger side air bag
Keep it at breech position as well as you can Adjust to suitable position
immediately. Before seat belt repair, do
not use the seat, for its failed protection
Sitting on rear seat, to tighten seat belt to passenger can cause personal injury. Retract the overlong seat belt ribbon, adjust the For seat belt release, press the open button The driver side air bag is installed at the
center of the steering wheel. The passenger
buckle, put belt head into lock catch. seat belt position. on lock catch.
side air bag is installed in the dash board
After putting belt head into the lock catch, you For seat belt ribbon retraction, pull the Warning under the cover marked with SRS/AIR BAG
can hear a clatter. unfixed end of the seat belt. above the glove box. While deploying at a
For collision or other accidents, waist high speed, the impact force of the air bag is
Please keep the waist seat belt at the breech seat belt at high position and loose seat very strong. The air bag can not well protect
For improper ribbon length of seat belt, make
position as much as possible — can not lock belt can cause severe injury for slide of the driver and the front passenger individually
belt head and seat belt at right angle, then pull
at the waist position; then adjust seat belt to waist seat belt. Keep waist seat belt at unless working together with the knee
the belt head to adjust ribbon length.
suitable position. breech position as much as possible. protection board within the dash board as
well as the seat belt.
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●The main parts of the system include: ● Lower risk of personal injury in such Caution Caution Caution
●Steering wheel assembly accident as rollover or crash on the rear
● Steering wheel side air bag module without the deployment of air bag Seat belt must be used.Safety belt must The children should not be seated in Rearward-facing children restraint
component/passenger side air bag module ● Lower risk of personal injury in the frontal be used. the front, or serious personal injury will system: extremely dangerous!
component crash without the deployment of air bag occur.
●Passenger side module cover ●Lower risk of being thrown out ●The electronic air bag system is only a part
● Lower risk of lower body and leg injury in of the front passenger restraint system, which It is very dangerous to seat a child of 12 years Do not adopt the rearward-facing children
Spiral cable an accident can not provide protection individually unless old or below in the front, since the child may restraint system for the front passenger seat.
● Air bag module electronic control unit ● Restraint of driver for better control on working together with the seat seat belt. be seriously injured and even die under the Hit by the deployment of the air bag, the
(ECU) vehicle deployment of the air bag. If possible, please children restraint system will be moved
●Air bag harness ● The electronic air bag will not be deployed seat the child of 12 years old or below in the backward and seriously injure the children
● Rear cover plate of steering wheel, ECU Important safety tips in such accidents as crash on the rear, rear and adopt the special restraint system and even make them die. Never use the
bracket, connection screw, and other rollover, or the frontal crash without sufficient for children with suitable size. rearward-facing children restraint system for
accessories. force and so the upper body and lower body the front passenger seat with an air bag.
of the driver and passenger in the vehicle are Caution
● The air bag SRS is a supplementary only protected by the seat belt at this
restraint protection system designed for the moment. The air bag system will only be In front of the air bag: it is extremely
driver and front passenger under a particular deployed under a huge impact force and you dangerous to put your hand or foot too
situation. Without the seat belt, the air bag will be better protected only if you are in a close to the air bag.
will fail to give enough protection in an correct sitting posture.
accident. Therefore, the seat belt is also very
important for the safety of passengers.
Restraint of passenger body, keeping the
passenger away from the inflating air bag
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While deploying at a very fast speed, the To protect the passengers in the vehicle, the Adjustment of vehicle suspension will component by the harness (the dismantling of incorrect deployment of the system. After the action of the system, the deployment
impact force of the front air bag is extremely electronic air bag system will be deployed in cause potential risk. If the vehicle height some interfaces requires special skills). In of the gas generator will generate a lot of heat
strong. If too close, serious personal injury a flash. Accordingly, the air bag system or suspension changed, the vehicle will addition, the gas generator in the system All the components of the air bag system are energy, so the components touching it will
may occur. Driver’s hand should always hold needs to be deployed by a huge opening fail to check the crash correctly and then includes some chemicals and the deployment exclusive for your vehicle model, thus they become hot and the hot air bag gas generator
on the rim of the steering wheel. The legs of force. The driver and passenger should sit as cause incorrect actuation of the air bag. of the generator is realized through the can not be moved and installed on other is dangerous. At the moment of the air bag
the front passenger should rest on the floor. backward as possible in a comfortable The accidental deployment of air bag may electrical signal; therefore, only the vehicle models. The installation of such deployment, the steering wheel and dash
Keep the front passenger seat as backward posture, leaving a space in front for the result in serious personal injury. personnel having received the training course components on other vehicle models may board will be very hot, so you may be burnt.
as possible and adjust the seat back for a deployment of the air bag. Do not put the of electronic air bag system can move some lead to injuries caused by the system After the deployment of the air bag, do not
normal sitting. Always wear your seat belt. child or any other thing between the front Do not place any sign or label on the component of the system appropriately inefficiency. touch the components within the air bag
passenger and the air bag. While deployed, steering wheel or on the front air bag, during the repairing, otherwise the non- deployment area. Maybe chemicals remained
Caution the air bag will greatly hit the driver or front which may influence the deployment of the professionals’ unnecessary maintenance and are contained as well. Therefore, after the
passenger if too close to the air bag or even air bag or even injure the passengers in movement may cause the unnecessary fault action of the system, please try to avoid
Do not put a child or any other thing injure the children more seriously if sit the vehicle while flying to the passengers of the system and even after-effect on the
Caution touching these places and wash the naked
between the front passenger and the air between the front passenger and the air bag. during the deployment of the air bag. future work. After the action of the system, avoid skin with the neutral soap.
bag. touching the middle of the air bag
Caution Do not try to maintain or remove any part Any component design in the system cannot bracket or the inside of the air bag.
of the electronic air bag system by be modified without the permission of the
Installation of front and rear devices yourself (only operated by the qualified qualified professionals, because the position
(e.g. front bumper): snowplow or technician). of any component and the linkage between
winch will cause potential risk, which components in the system are designed
may actuate the air bag collision professionally, and any modification may
sensor system. As a result, the air bag The sensor of air bag system is installed on cause the inefficiency of some components or
may be accidentally deployed, or fail to the chassis of the vehicle. Due to its even the whole system during the collision of
be deployed in an accident. performances, it is connected to every the vehicle, or even cause injuries due to the
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Air bag indicator in the instrument Notes for air bag deployment
cluster This air bag system is designed not to be The speed of the air bag inflation and the gas dashes out from the center of the is not deprived of driving functions, the air bag system properly. If you do not install a
maintained. The air bag indicator in the dash deflation of the electronic air bag system is steering wheel and upper right of the dash driver can go on driving. The driver ’s air new air bag system (if the harness is not
board indicates the working condition of the so fast that you cannot know how the action board, the nylon material of the air bag may bag can be inserted into the protective cap damaged, keep the harness), you may
air bag system. That the warning lamp happens. The air bag is designed to deflate cause the bruise and/or erubescence of the at the center of the steering wheel for increase the injury risk during the next
illuminates or flashes for 6 to 8 seconds and quickly after the inflation to (A) absorb the driver and the front passenger. Such bruises driving convenience. The front passenger ’s collision.
then goes out means the normal condition of impulsive force of passengers’ head going are similar to that by ropes or carpets or air bag can be inserted into the cap at
this air bag system. ahead and (B) ensure passengers’ eyeshot floors, which are not caused by chemicals, upper right of the dash board. However, if
and guarantee the driver ’s driving so the symptoms will never last for a long the collision happens again, your safety
Please go to Lifan service station for capability after the collision. Do not touch time. If the blister appears on the skin, cannot be guaranteed.
maintenance if the following conditions the components in the system after the please go to hospital.
appear when starting up the vehicle: deployment to avoid burning. The Once the electronic air bag system acts, it
passengers will find the special gas and During the air bag deployment, all the cannot be used, so for your safety, the vehicle
● The warning lamp does not illuminate or smoke on their seats. That is normal and propellants will be used up, but some may should be maintained with the normal ways
flash for 6 to 8 seconds; the gas thus generated is harmless. These be left inside the air bag or at the edge of and the electronic air bag system as a whole
● The warning lamp always illuminates or particles will result in the irritant effect on the bag. Do not touch such exposed should be dismantled (if possible, keep the
flashes in driving. the skin, eyes, noses or throats. Please chemicals and do not cut the air bag having harness) and a brand new system should be
wash the skin or eyes with cold water and acted, but replace it with a new complete installed. Abnormal maintenance and no
turn to fresh air. If the effect cannot be one, which should be carried out by the m a i n t e n a n c e o f t h e v e h i c l e ’s b r o k e n
relieved, please go to hospital. If the qualified professionals dealing with air bag components will cause bad effect on the
particles drop on clothes, please clean the system technology. Wash your hands and whole air bag system. After the action of the
clothes according to the washing face with the neutral soap after the air bag air bag, please drive your car to Lifan service
indication. action. station and make the technicians change a
new electronic air bag system for you. The
At the moment of air bag deployment, when After the air bag deployment, if the vehicle technician will dispose and withdraw the used
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Maintenance and service of air Air bag activation/deactivation
bag system Working principle of air bag Front air bag activation
Frequent maintenance is unnecessary if Caution The front air bag will expand for the following
there is no failure of air bag system (Self- collisions exceeding moderate degree:
checking will function when starting the Savagely driving on rough road on
system each time). The design can ensure purpose or cleaning up accumulated The front of the vehicle bumps against the
normal operation for 10 years from the day of snow with the vehicle with electronic hard wall at a speed over 22km\h (14mph).
installation. 10 years later, the professional air bag system may result in incorrect
technician of air bag system will renew it with deployment or malfunction of the
a new system. system.
Please send your vehicle to Lifan service The air bag system is exclusive for your
station in the following conditions: vehicle model, so any change of the original
● Air bag system indicator is continuously spare parts may result in adverse effect to
blinking. the air bag system.
●Air bag system indicator is always on.
When the air bag collision sensor detects a The vehicle bumps against curbstone, Hard landing or vehicle falling.
●Air bag system indicator can not illuminate
signal of collision exceeding medium power in pavement steps or hard objects.
when the ignition switch is on.
●Air bag is expanding. front or at side, it will send a current to the gas
generator.
When the air bag is full of gas, it will deflate
gas quickly.
The air bag can only be used for once. After
that, it doesn’t work and must be replaced. Front collision in an angle within 30.
Only the technician having received
professional training can renew the air bag
system.
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The vehicle bumps against cement The vehicle bumps against the lower The vehicle bumps against the wall at The rear is bumped by another
pillar, tree or other long thin objects. part of the truck. its side part. vehicle.
The vehicle drives into a big hole or bumps Limit of front air bag activation The rear is bumped against by another The vehicle bumps against the wall at its side Front air bag deactivation The deployment of the front air bag may not
against the far side of the hole. vehicle or the vehicle bumps against the part, thus the resistance from the collision is The air bag will not deploy in the following occur when the vehicle turns over on one
lower part of the truck, but such collision is not strong enough to activate the air bag. cases. side.
Depending on the impact strength, the front
not strong enough to activate the air bag.
air bag may not expand in the following
The rear is bumped by another vehicle.
conditions:
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Owner’s Manual LIFAN
320 Owner’s Manual LIFAN
320
Maintenance
Regular maintenance is unnecessary for the Caution Dismantling of inside components:
The side is bumped by another vehicle.
air bag system, but please send your vehicle
to Lifan service station in case of the following Private maintenance of air bag safety Remove spare parts in the air bag and
conditions: system: components in the sensor. Front seat, front
● The air bag system indicator is dash board, components, steering wheel,
continuously blinking. It’s very dangerous to privately maintain or spare parts on the front and rear window
●The air bag system indicator is always on. modify the system. The occasional operation posts and the roof edge are very dangerous,
● The air bag system indicator can not or thorough damage of the air bag system because they contain the main parts of the air
illuminate when turning on the ignition
may cause much severe damage. Never bag. The occasional start-up of air bag may
switch.
●Air bag is expanding. m o d i f y t h e s y s t e m p r i v a t e l y. A s k t h e cause a series of adverse effects. Please ask
The air bag brake system indicator will technician having received professional the technician having received professional
illuminate in case of the following training to repair it. training for advice before moving these parts.
conditions:
●Children restrain system is not available Damaged air bag sensor: Handling of air bag:
The deployment of the front air bag may not occur when the side is bumped by another Real time monitoring on the front seat.
vehicle. ● There is a passenger or things on the It’s very dangerous to drive the vehicle with a It’s very dangerous to handle the air bag
The following components of the air bag front seat. damaged air bag sensor. The sensor can be inappropriately and if there is an active air
system are monitored by the diagnostic Children restrain system designed for air
damaged by minor collision that even can not bag in the vehicle. Please obey all the safety
bag brake system is installed on the front
system: activate the air bag. If collision persists, the measures so as to avoid any injury. Please
seat, but the air bag brake indicator can
not illuminate. air bag won’t expand for the damaged sensor. ask the technician having received
After the collision, please ask the technician professional training for how to handle the air
having received professional training to bag safely or scrap the useless vehicle with
check the air bag system. an air bag.
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Owner’s Manual LIFAN
320 Owner’s Manual LIFAN
320
Other matters Electric exterior rearview mirror (optional) Electric exterior rearview mirror switch Interior rearview mirror
● If you want to transfer or demolish your Note Warning
vehicle, read the manual carefully and inform the
● Do not operate the switches or scrape Do not adjust the rearview mirror when
new owner or demolishing unit that your vehicle 1 the surface of rearview mirror if the mirror driving. Otherwise, this action may cause
has been equipped with air bag system, and
suggest them to read this manual carefully. is frosted. Adjust it after the deicing with driver to steer the vehicle by mistake, thus
L . R spray deicer or other methods. accident happens.
●Avoid contacting the air bag module assembly 1 2
directly (otherwise you may suffer scald or Vanity mirror
toxicosis) after the air bag system played its role. Warning
Adjust the interior rearview mirror to a proper
Removal work for air bag should be done by 2 ● Do not touch the rearview mirror when position so that you can see the rear part of
LIFAN service station. Once the air bag system vehicle in the mirror.
moving,avoiding injuries and rearview mirror
plays its role, replace a new one at once.
fault. Adjust the interior rearview mirror as per the
●Do not drive the vehicle when the rearview direction 2 shown in the figure above to
●Air bag system plays its role in case of a front Adjust the electric exterior rearview mirror 1.Selection switch, used to select the exterior
mirror is folding backward. Unfold and weaken the light from the Headlamp of
collision to certain extent. No problem may exist to the position that you can see the side of rearview mirror which needs adjusting. Press
correctly adjust the rearview mirror at driver vehicles behind it and prevent against dazzle
vehicle in the rearview mirror.
in the system itself even though it is not switch to “L” (left) or “R" (right). when driving at night.
and passenger side.
triggered. Damage of vehicle or abnormal repair
Warning Joystick at Position 1 in daytime: Rearview
can affect normal operation of air bag system. 2. Control switch is used to adjust exterior rearview
mirror boasts a good definition at this position.
Do not adjust the rearview mirror when driving. mirror. Press the switch as per the direction
required. Joystick at Position 2 at night: Bear in mind Fold down the sunshade and open the cover
This action may cause driver to steer the
that to decrease glare,the definition of rearview when using the mirror.
vehicle by mistake, thus accident happens.
mirror will be reduced.
The mirror can be adjusted when the key is at
“I” or “II”.
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Section 1-4
Owner’s Manual LIFAN
320 Owner’s Manual LIFAN
320
Headlamp and turn signal lamp Turn signal lamp
Operation of instrument and controller
3 1
2
2
Illumination, wiper and defroster 1 2
Headlamp and turn signal lamp…………………………………………………47 OFF
Warning light………………………………………………………………………48 OF F
2 OF F
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Section 1-5
Owner’s Manual LIFAN
320 Owner’s Manual LIFAN
320
Fuel gauge Tachometer Milometer and trip odometer
Operation of instrument and controller
Fuel gauge………………………………………………………………………53
Tachometer…………………………………………………………………… 53
Milometer and trip odometer…………………………………………………53
Dashboard lamp luminance adjustment…………………………………… 54 svs
The gauge indicates the fuel volume in the Tachometer shows the rotation speed of engine
fuel tank when the ignition switch is at with 1/1000 of “ rpm” (round per minute). Its
“ON”. function is to select the right shift time to prevent
the engine from lugging down and overrunning.
Close to fill up --- pointer near “2/2”
3
Close to use up --- pointer near “0” The engine will be abraded excessively and waste
the fuel if driving the vehicle when the engine
overruns. 1
Caution to fill fuel-the yellow fuel warning lamp
illuminates. The cursor of fuel gauge will sway Note 2
when braking, accelerating or turning a corner,
which is caused by the sloshing fuel in the tank. Do not let the cursor turn into the red zone,
which may cause a serious damage to engine.
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Owner’s Manual LIFAN
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320
Dashboard lamp luminance adjustment Warning indicator
The display shows the following information.
If the indicator illuminates Please do as per the sign instruction
1. Clock shows the 24-hour time.
Check whether the brake fluid is insufficient; if it is sufficient, please
2. Odometer (ODO) displays the total traveled mileage (a)
stop at once and contact the with LIFAN service station.
L . R
and short-distance mileage of the vehicle.
3. Buttons for setting set the return-to-zero for the clock (b) Fasten seat belt.
and the trip odometer as well as the switch of the
odometer display.
(c) Stop and check.
When switching odometer display, press this button so
that the odometer display will be switched between the
Move this button to adjust the illuminance of (d) Stop and check.
total mileage and the short-distance mileage.
the dashboard lamp.
When adjusting the clock, switch the odometer display to
(e) Vehicle brought to the LIFAN service station for check and repair.
the total mileage display, press the button till the clock
twinkling and press the button to adjust the time.
Vehicle brought to the LIFAN service station for check and repair. If the warning
(f) lamp also illuminates, stop the car immediately and contact the LIFAN service
If you want to adjust the TRIP to zero, press the button till
station.
the instrument is set to zero after the display shows the
reading of TRIP.
(g) Close all doors.
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Owner’s Manual LIFAN
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320
( a ) Brake fluid low level indicator Warning (b) Seat belt indicator
If the indicator illuminates Please do as per the sign instruction This light will call drivers’ attention to fasten
When the ignition key is at position “II”, the Upon any of the following the seat belt.
brake fluid is not sufficient or EBD is with
circumstances, stop the car at a safe Once the ignition key is turned to “II” or “III”, if
malfunctions, this indicator illuminates.
(h) Vehicle brought to the LIFAN service station immediately for check and repair. place immediately and contact the the driver doesn’t buckle up, the indicator will
LIFAN service station. illuminate. Unless the driver buckles up, the
Warning indicator will continue to illuminate.
(i) Water temperature warning for engine coolant. Stop and check. ●This lamp illuminates when the engine is (c) Charging indicator
If the brake fluid level is low, it will be running. Under such circumstance, the The lamp is used to warn for the discharge
dangerous to drive normally and brake probably is in malfunction, which state of battery.
(j) continuously. may result in a longer braking distance.
Fuel warning. Fuel filling is required. If it illuminates in driving, it means that
Step on the brake pedal forcibly to make an something goes wrong in the charge system.
During the operation, the fact that the warning emergency brake. Turn off the electrical equipment like A/C,
(k) Vehicle brought to the LIFAN service station immediately for check and repair. indicator illuminates for a short while doesn’t fan, radio, etc. immediately, and vehicle
mean any problem. ● While the “ABS” warning lamp is brought to the nearest LIFAN service station
illuminating, the warning lamp of brake for check and repair.
system also illuminates.
(d) Oil pressure warning indicator
Under such circumstance, when a braking
The lamp is used to warn for over low oil
is made, the ABS doesn't serve, moreover,
pressure.
the car is extremely unstable as well.
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Owner’s Manual LIFAN
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320
Contact the LIFAN service station for help. (e) OBD indicator If any of the following circumstances occurs, it (g) Door open indicator times or continues lighting. Warning indicator for checking and maintenance
It illuminates when the electronic injection means the part monitored by the warning lamp is ● The lamp illuminates or flickers during driving.
When the engine idles, the lamp may flicker now system of engine is at fault. at fault. It is necessary to Vehicle brought to the The lamp keeps illuminating, till all doors close 1. Pull the parking brake.
and then or it illuminates for a short while after an LIFAN service station for check. completely. (I)Temperature warning indicator of engine The indicator for parking brake system should
emergency brake. During the gradual acceleration When it illuminates, it is necessary to contact ● When the ignition key is turned to “II” position, coolant illuminate.
of engine, if the lamp is out, it is normal. the LIFAN service station for check and the lamp does not illuminate or continues to (h) SRS indicator Used to warning for overheated engine coolant, if
repair as soon as possible. illuminate for about 3s. the lamp flickers or keeps illuminating during 2. Open any of the doors.
●The lamp illuminates in driving. When the ignition key is turned to “II” driving, it is necessary to stop the car at a safe The door open indicator will illuminate.
The oil level should be within the top and bottom
(f) ABS indicator position, SRS indicator will illuminate for place and stop the engine immediately.
limitation of oil dip rod.
When the ignition key is turned to “II” position, During the operation, the fact that the warning about 6 times, which indicates that the air 3. Close doors.
the “ABS” fault indicator will illuminate for lamp illuminates for a short while doesn't mean bag and front seat belt pretensioner work Check the quantity of engine coolant and refill; The door open indicator is out.
about 3s. After that, if the system goes wrong, any problem. normally. meanwhile, check the working state of electronic fan.
the lamp will continue to illuminate. 4. Turn the ignition key to “II”, but not start the
Warning The warning lamp system is used to monitor (j) Low fuel level indicator engine.
Note When the “ABS” fault indicator illuminates (the the air bag ECU, seat belt pretensioner Please fill fuel as soon as possible. All warning lamps except the door open
warning lamp of brake system is out), the ABS While the warning lamp of brake assembly, air charging device, warning lamp, indicator will illuminate. After about 3s, the
No driving when the warning lamp system doesn't work, but the brake system system is illuminating and the “ABS” connection and power supply. (k)Indicator for electronic injection fault of “ABS” fault indicator is out. And after
illuminates,even if just a short distance,or works normally. fault indicator illuminates as well, stop engine illuminating for 6 times, the SRS fault
else the engine will be damaged. the car at a safe place immediately and If any of the following circumstances occurs, It illuminates when the electronic injection system of indicator is out.
When the “ABS” fault indicator illuminates (the contact the LIFAN service station. it means the part monitored by the indicator is engine is at fault.
warning lamp of brake system is out), the wheel Under such circumstance, when a braking at fault or closed down. It is necessary to When any of the indicators for maintenance
may be blocked since the ABS system doesn't is made, the ABS doesn’t serve, moreover, contact the LIFAN service station for check. When it illuminates, it is necessary to contact doesn’t work as per the procedures above, it
work when an emergency brake is made or the LIFAN service station for check and is necessary to Vehicle brought to the LIFAN
the car is extremely unstable as well.
braking on slippery road. ● When the ignition key is turned to the position repair as soon as possible. service station for check.
of “II”, this light does not keep twinkling for six
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Section 1-6
Owner’s Manual LIFAN
320 Owner’s Manual LIFAN
320
Ignition switch
speedometer may move, which doesn’t mean
Operation of instrument and controller something goes wrong.
1 3 5
5
3
PUSH Once the ignition key is turned to “I”, auxiliary equipments 1
R
Ignition switch, transmission and parking brake Ⅰ Ⅱ like radio are powered on, but the engine isn’t.
2
4
2 4 R
B
Ⅲ
Ignition switch……………………………………………………………………61
“B”-The engine is not connected to the power and the
Manual transmission……………………………………………………………62 steering wheel is locked. The key can only be inserted or
Parking brake……………………………………………………………………63 drawn out at this position.
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Owner’s Manual LIFAN
Economical driving
320 Parking brake
Owner’s Manual LIFAN
320
Warning parking brake (position 3). Note
The fuel consumption has close relationship with ●Avoid the full throttle acceleration and try to drive
Don’t shift the gear to the position of reverse personal driving style; application of the following steadily. Unnecessary acceleration or brake will ● Before driving, it is necessary to confirm
For indicating that the parking brake is set, the
in driving so as to prevent the gear box from instructions will decrease the fuel consumption of increase the fuel consumption. if the parking brake is completely released
your car. 1 warning lamp of brake system on the instrument
damage. It is necessary to confirm the vehicle illuminates till the parking brake is released. and the indicator of the parking brake
comes to a full stop before practicing ●Stop the engine in the traffic jam. system goes out.
transmission reverse speed shift. ● It is suggested to choose the high gear low 2
Please do not step your foot on the clutch accelerator but not the low gear long distance ●Regularly check the tyre’s pressure. ●If the parking brake does not be completely
pedal; or the clutch will be worn out or driving in normal driving. Under the same speed, released in driving, the brake will be
damaged. the fuel consumption in gear 2 and gear 3 is two 3 overheated, which will result in poor braking
times and 1.5 times as the gear 4 respectively. or braking failure.
Keep vehicle’s speed within the legal limits. Release: Pull up the parking brake handle
(position 1) gently, press the lock release
button (position 2) and then release the
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Section 1-7
Owner’s Manual LIFAN
320 Owner’s Manual LIFAN
320
CDMD-X functions
Operation of instrument and controller 1. Power switch/Volume control knob
1 2 3 4 5 2. Dispaly screen
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Instruction for plate function
Owner’s Manual LIFAN
320 Instruction for reception of a radio
Owner’s Manual LIFAN
320
Playing USB/SD card Browse play Hunting for designated position Radio station storage 3. In the state of receiving the FM, keeping knob clockwise or counterclockwise can adjust the
pressing down the key of “A.PS”, the radio will sound volume between 0 and 63.
1. Press the power switch on the plate and the When USB/SD card is playing, pressing “21NT” starts When USB/SD card is playing, keep pressing “ ” According to the order you select, 18 FM radio stations automatically scan and store 18 radio stations in 2. Bass pattern (BAS)
mainframe will be turned on. the browse with every song played 10 seconds of its or “ ” can speed or fast reverse. When locating the (six FM1, six FM2 and six FM3) and 12 AM radio this section of band wave with the strongest
beginning; pressing this key again will resume the position needed, press “ ” again and the music will stations (six AM1 and six AM2) can be stored at most. signal. After storing, the stations stored will be In the pattern of BAS, turning the volume control knob
2. Insert the U Disk/SD card into the USB/SD card normal mode and continue playing the current song. continue playing from the current position. browsed according to their order. Repeating the clockwise or counterclockwise can adjust the bass
interface, the display will show “READ” and start 1. In the state of receiving the radio, repeatedly operation mentioned above in the state of receiving volume between -14 and +14 at random.
searching, and then it will play automatically. Repeating play Choosing document file to be read press the key of “BAND” on the plate to choose the AM can store 12 radio stations in this section of
the wave band. The initial state of receiving the band wave with the strongest signal. 3. Treble pattern (TRE)
3. The following will be displayed during playing: When USB/SD card is playing, pressing the key of When playing USB/SD card, shortly pressing the radio is FM1. Every time you press the key, the In the pattern of TRE, turning the volume control knob
“3RPT” will repeat the current song and pressing pre-setting key 5 and 6 can carry out the document band wave will be changed as follows: Receiving the radio station stored clockwise or counterclockwise can adjust the treble
Track Time passed this key again will cancel this function. file selection directly, and the radio will play the FM 1 FM 2 FM 3 AM 1 AM 2 volume between -14 and +14 at random.
music in that document file from the first song on 1. Choose the band wave through the key of “BAND”
4. When USB/SD card is playing, pressing“ ” Random play according to the order. and press the number keys to confirm the station stored. 4. Balance pattern (BAL)
will pause and if pressing this key again, the play 2. In the state of receiving the radio, keeping In the pattern of BAL, turning the volume control knob
will be resumed. When USB/SD card is playing, pressing the key of pressing the key of “ ” or “ ” on the plate will 2. In the state of receiving a radio, shortly pressing the key clockwise or counterclockwise can adjust the volume of
“4RDM” will enter the mode of random play and automatically hunt for the next or the last clear radio of “A.PS” and the radio will skim the radio stations stored the left and right track between L15 and R15 at random.
5. When USB/SD card is playing, drawing out the U pressing this key again will cancel this function and station. Pressing on the “ ” or “ ” on the plate for a in this section of the band wave. Pressing the number
Disk/SD card will withdraw from playing and enter the mode of play according to the order. short time will manually hunt for the next or the last key marked the station can receive the radio station. 5. FAD pattern (FAD)
entering the radio. clear radio station. After receiving the signal, keep In the pattern of FAD, turning the volume control knob
Hunting for designated songs pressing down any number key for two seconds and Sound volume adjustment clockwise or counterclockwise can adjust the volume
this station will be stored on this number key. In case of the front and rear track between L15 and R15 at
When USB/SD card is playing, shortly pressing “ ” this number has been occupied by other station, the 1. Sound volume pattern (VOL) random.
and choose the next song while “ ”, the last song. formation station will be replaced. In the pattern of VOL, turning the volume control
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Other functions
Owner’s Manual LIFAN
320 Owner’s Manual LIFAN
320
Section 1-8
Clock setting (DISP) Note Radio, USB/SB card, audio in switch
1. When active, repeatedly and shortly press the When the radio is in normal operation, if you
After the completion of clock adjustment, it
keep pressing the key of “MODE”, you can
Operation of instrument and controller
key of “DISP” and the radio will display the clock is unnecessary to press any key and the
normal pattern will be resumed after 5 switch patterns of radio, USB/SD card and
display and sound pattern selection according to the
seconds and the clock setting will be the audio play. In case of USB/SD card not
following order: inserted, continuously press “ MODE” and A/C system
stored.
BAS (Bass) TRE (Treble) switch between radio reception and band
DISP (Clock)
only; in case of both USB and SD card
Manual A/C system
inserted, continuously press “MODE”, and
VOL
(Sound volume)
FAD
(Front and rear tra ck balance)
BAL
(Left and rig ht tra ck balance) the radio will switch according to this state:
Control plate………………………………………………………………………70
The normal pattern will be resumed if the Air vent mode setting……………………………………………………………72
key is not pressed for 5 seconds. Radio USB play SD card play Audio in Operating essentials……………………………………………………………72
Vent………………………………………………………………………………74
2. In the pattern of clock display, keeping
If only one device of the USB and SD card is
pressing the key of “DISP” can enter the
inserted, repeatedly press the key of “MODE”
pattern of clock adjustment. When the clock and the radio will switch patterns according to
is flashing, pressing the key of “ ” and “ ” orders as follows:
to adjust the clock; press the key of “DISP” Radio USB play/SD card play Audio in
again and when the minute clock is flashing,
press the keys of “ ” and “ ” to adjust the
minute. After the completion of setting,
press the key of “DISP” again to end the
clock adjustment.
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Manual A/C control plate
Owner’s Manual LIFAN
320 Owner’s Manual LIFAN
320
Recirculation control knob
1. “A/C” switch Fan speed knob Turn the knob to select blow direction
6 5 4 2. Recirculation control knob Turn the knob to adjust the blower speed;: 1. Panel: the air flow blows to the face of
clockwise for increase, counterclockwise for passengers through the central vent at dashboard
3. Defroster switch of rear decrease.
and the side vent.
windshield Temperature control knob
2. Panel/Floor: the air flow blows to both the face and
4. Temperature control knob Turn the knob to adjust the temperature: clockwise
feet of passengers through the central vent at
dashboard, side vent and down vent.
for increase, counterclockwise for decrease. Press keys to select air source
5. Fan speed knob
3. Floor: the air flow blows to the feet of passengers
6. Mode selector knob Mode selector knob through down vent. Press the button and the indicator will be
illuminated to recycle the air in the car. Press
4. Defroster/Floor: the air flow blows to the feet of it again, and the indicator willoff to take in the
passengers and the windshield through the down vent air outside of the car.
and defrost vent.
1 2 3 4 5 “A/C” Switch
Apply when the Recirculation control knob is at To start the A/C system, turn on the fan speed
outer circle position. knob, then press the “A/C” switch, indicator
1 2 3 illuminating. To shut down the A/C system,
5. Defrost and Demist: the air flow blows to the press the “A/C” switch again and reset the fan
windshield through the defrost vent. speed knob to zero.
Apply when the Recirculation control knob is at
outer circle position.
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Air vent mode setting
Owner’s Manual LIFAN
320 Owner’s Manual LIFAN
320
Operating essentials Heating Cooling Demist
In order to gain the perfect effect, please set In order to gain the perfect effect, please set Inside of windshield
● To quickly cool down the car which has parked under hot the controller at: the controller at: In order to gain the perfect effect, please set the
controller at:
sunshine, drive it for several minutes with window open. Air volume adjustment-air volume switch turned on Air volume adjustment-air volume switch turned on
● In wet weather, don’t let cold air blow to the windshield, since Air volume adjustment-air volume switch turned on
Temperature-toward warm zone (red zone) Temperature-towards cold zone (blue zone)
Temperature-towards warm zone (red zone) to raise
the temperature difference inside and outside of it will help mist Inlet-outer circle (air outside) Inlet-outer circle (air outside)
the temperature Towards cold zone (blue zone) to
growing. Air flow-down vent Air flow-top vents decrease the temperature
● The lower part of front seats should be kept as open space A/C-shut downt A/C-start up Inlet-outer circle (air outside)
Air flow- defrost, demist
to ensure full air circulation in the car.
● For a quick temperature increase, turn on the ● For a quick temperature decrease, turn the A/C-start up
● Make sure that the inlet grille in front of the windshield is not inner circle for several minutes. To avoid mist Recirculation control knob at inner circle for several
blocked by things like leaves or snow. Defrosting
growing on windows, after the temperature rises minutes.
● Close all windows when driving the car on the road with to certain degree, turn on the outer circle. Outside of windshield
Venting
much dust. If after doing this, the dust still goes into the car, it is In order to gain the perfect effect, please set the In order to gain the perfect effect, please set
● During defrost or demist of windshield, select controller at: the controller at:
recommended to temporarily set the Recirculation control defrost, demist and down vent for temperature
Air volume adjustment-air volume switch turned on
knob at inner circle and set the rotation speed selector of increase in the car.
Air volume adjustment-air volume switch turned on Temperature-towards warm zone (red zone)
blower at any position except “zero”.
Temperature-towards cold zone (blue zone) Inlet-outer circle (air outside)
● In cold weather, it is necessary to set a high rotation speed
Inlet-outer circle (air outside) Air flow-defrost, demist
of blower for one minute to clean the snow or moisture in the air
Air flow-top vents A/C-shut down
inlet passage, thus to reduce the mist growing on windows.
A/C-shut down
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Vent
Owner’s Manual LIFAN
320 Owner’s Manual LIFAN
320
Section 1-9
Operation of instrument and controller
Other equipments
Cigarette lighter and ashtray……………………………………………………76
Glove box…………………………………………………………………………76
Cup holder…………………………………………………………………………77
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Owner’s Manual LIFAN
320 Owner’s Manual LIFAN
320
Cigarette lighter and ashtray Glove box Cup holder
Cigarette lighter
Press lightly to use the cigarette lighter, which will
then spring out automatically to be at service.
If the engine is not running, the key should be at “I”
position.
It is strictly prohibited to press the cigarette lighter for
long.
When changing for another lighter, use the kind
designated by LIFAN.
Ashtray
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Chapter 2
Run-in time No overloading: The first maintenance
LF320 enjoys an excellent performance. Make sure that the loading weight during the run- The first maintenance during run-in time
Lf320 Driving Guide However, this performance will reach the best in time will not reach the 80% of the maximum should be implemented after the first
state only after a proper run-in time and the first load; otherwise, damage will be caused to those mileage of3000km, to ensure a good using
Run-in time………………………………………………………………………79 maintenance. The effect for this run-in time components which have not been run in well. state of the vehicle. This maintenance is
mainly relies on the driving way within the first available at the LIFAN service station.
Fuel………………………………………………………………………………80 2000km.
No driving for a long distance:
Three-way catalytic converter…………………………………………………80 No high-speed driving: No driving for a long distance during run-in time; Note
otherwise, it will extend the continuous working
Engine exhaust warning……………………………………………………… 81 No driving at full speed within the initial mileage hour of the engine and cause damage to the The first maintenance should be
Oil consumption…………………………………………………………………82 of 2000km. engine parts.
carried out at the LIFAN service station
Brake system……………………………………………………………………83 Maximum driving speed for all gears during run- Avoid emergency brake: to ensure a good maintenance quality
in time: and the best performance of your
Brake pads over-wear alarm……………………………………………………85 Reduce the emergency brake times as possible
vehicle.
Gear Speed (km/h) as you can; otherwise the brake system will be
Notes of luggage loading………………………………………………………86 Gear 1 25 impacted, and the engine will suffer from a bigger
impact load from the chassis. Do not carry out
Suspension and chassis……………………………………………………… 86 Gear 2 40
emergency brake within the initial mileage of
Gear 3 60 300km except for necessary situations.
Gear 4 90
No trailering the vehicle within the first
Gear 5 100 2000km:
The maximum rotation speed allowed for An incorrect trailering may cause damage to the
the engine within the initial mileage of vehicle.
2000km is 4000r/min.
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Fuel Three-way catalytic converter Engine Exhaust Warning
The correct selection of fuel is the base for check, in case of a knock or regular knocking in Warning
Warning Warning
the full performance of the engine. a good road condition at a stable speed under
the condition of using the recommended fuel. Lots of incompletely burnt gas entering the three- pushing. ● Avoid inhaling the exhaust gas from the
way catalytic converter will cause the converter to ● Do not close the ignition switch during engine.
The damage to the engine due to the improper ●Always check the exhaust system and make
be over-heated and even a fire. Please abide by driving.
fuel will not be included in the guarantee scope the following precaution measures to prevent any sure there is no leakage or looseness in the
● Maintain a good operation state of the exhaust system. Immediately check the vehicle
of LF320. danger:
engine. The abnormal function in the electrical in case of a collision during driving or any
system, ignition system or fuel system of the abnormal exhaust sound.
Fuel type ●Only unleaded gasoline can be used. engine will cause an abnormally high ● Do not operate the engine in a garage or a
close place to avoid the danger due to an
●When the engine is working, don’t check the temperature in the three-way catalytic
unsmooth exhaust of the engine.
Warning engine by cutting off the cylinder supply and converter.
Unleaded gasoline In case of engine knock. ●Do not park the vehicle for a long time in case
The three-way catalytic converter is an emission misfiring. ● Immediately check the vehicle, in case of a of a running engine. If necessary, please park it
Forbid using the leaded gasoline. The
control device installed in the emission system ●Do not drive the vehicle with an extremely hard start or frequent running stop of the at an open place to let the fresh air flow into the
utilization of the leaded gasoline will lead
Please contact the LIFAN service station for with an aim to reduce the pollutants in the low oil level; the operation without sufficient oil engine. vehicle.
to inefficiency of the waste gas cleaning
exhaust. will lead to a misfire of the engine and increase ●Pleasecarryoutaregularcheckandmaintenance ● The luggage boot cover should be closed
device and the venting pollution control during driving. An open or unclosed luggage
device as well as increase the the over-load of the three-way catalytic forthevehicleaccordingtothemaintenancescheme
Warning boot will cause a flow of exhaust gas into the
maintenance cost. converter. of LIFAN so as to guarantee the normal operation of vehicle.
When the engine runs, the high- ● Do not run the engine at a high or low idle the three-way catalytic converter and the entire ● Please make sure that there is no snow,
temperature gas will be exhausted. speed for a long time. emissioncontroldevice. leaves or other barriers in the inlet grille, to
Therefore, any person and flammable guarantee a normal ventilation system of the
●Avoid running the engine at over-speed.
vehicle.
materials should be kept away from the ● No starting the vehicle by trailering or ●In case of an exhaust gas smell in the vehicle,
exhaust pipe. please immediately check the cause and correct
it.
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Owner’s Manual LIFAN
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Oil Consumption
Oil function The oil consumption will increase with a high- Warning It is a two-circuit brake system. In case that Note This system is used to prevent the wheel
The oil mainly works for lubricating and cooling the speed driving, frequent acceleration or one brake system loses effect, the other from being locked during braking on a wet
inside of the engine to keep a normal working state. deceleration. If a regular check at the oil level can not be one will still work. Meanwhile, it is harder ● In case of a misfire of the engine, do not and slippery road. It is helpful for ensuring
than usual to step down the brake pedal and
achieved, a severe trouble will be caused step on the brake pedal repeatedly, because the stability and steering function of the
the brake distance will also increase. vehicle under the above-stated situation.
Oil consumption More oil will be consumed due to the piston, piston to the engine due to a relatively low oil every stepping will consume parts of
The engine will consume some oil during a normal ring and cylinder wall of a new engine, all of which level. Note vacuum pressure. Effective ways for stepping on ABS brake pedal:
operation. In a normal case, the engine consumes have not been run in. ● The brake will still be effective even if the When the anti-lock system operates, you can feel
oil due to the following causes: Do not drive the vehicle for a long distance the impulsive motion of the brake pedal and also
vacuum power is entirely lost. However, the
Percentage of oil and fuel: ≤0.3% in case of only a brake circuit working. hear a noise. Under this situation, you can step
force to step on the brake pedal will be much
● Lubricating the piston, piston ring and cylinder: Please immediately repair the ineffective down the brake pedal with bigger force than usual,
When the piston moves down in the cylinder, it will bigger than usual and the brake distance will
Importance for checking the oil level brake system. and then the anti-lock brake system will work. In
leave a layer of oil film. When the vehicle decelerates, also increase.
Keeping the oil level at the best level is one of the case of an emergency brake, do not step on the
the high negative pressure will absorb such oil into key points for the normal maintenance for a brake repeatedly, because that will increase the
the combustion chamber. Like part of oil film left on Vacuum booster If the braking device is immersed in water brake distance.
vehicle, which will not weaken the function of the
the cylinder wall, this oil will be combusted by the oil. Therefore, it is very important to check the oil It is used to assist the braking by the inlet Seeper, heavy rain or cleaning, water film will be When the engine starts or after the vehicle starts, you
high-temperature combustion gas. level regularly. You are recommended to check the negative pressure of engine. In case the formed on the brake drum or brake disc will affect the may hear a click sound or motor noise from the
oil level every time you fill oil. engine stops during driving, a pedal force braking effect. Therefore, if the braking device is engine compartment for several seconds
● Lubricating the intake valve stem: The oil and the bigger than usual is required to stop the immersed in water, please take extra attention to continuously. That means the anti-lock brake
inlet air will be together absorbed into the vehicle. vehicles ahead or at the back, and drive it at low speed system is under self-checking.
combustion chamber and combust with the fuel. and meanwhile lightly step down the brake for times
The high-temperature waste gas will also combust to dry the brake pads until the brake effect resumes to When the anti-lock brake system works, the
the oil used for lubricating the exhaust valve stem. a normal state. following situation may occur. They do not
represent faults in the system.
Anti-lock brake system (with ABS
The consumption of oil is related with its
indicator-optional) ● Hearing the operation sound of the anti-
viscosity, quality and the vehicle use state. lock brake system and feeling the impulsive
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Brake Pads Over-wear Alarm
motion of the brake pedal together with the lock brake system will not work, but the Warning
control to the vehicle if the non-skid
vibration of the vehicle body and steering
performance of the tire exceeds the brake system will still work normally.
wheel. The motor noise from the engine In case of an illuminating warning
compartment will be heard even if the vehicle admissible ability or in case of a wheel spin.
lamp of brake system together with
has been parked. The anti-lock brake system is not used to When ABS indicator illuminates, the anti- illuminating ABS indicator, please
shorten the brake distance. Compared with lock brake system will not work. Therefore, park the vehicle at a safe place and
● The brake pedal may move forward a little at the
end of the operation of the anti-lock brake system. vehicles without anti-lock brake system, a the wheels may be locked in case of an contact LIFAN service station.
longer brake distance may be needed under svs emergency brake or braking on slippery
In this case, the anti-lock brake system
the following situations: roads. will not be effective and the vehicle will
● Driving on a bumpy road and road covered also become extremely unstable during
Note withsmallstonesorsnow. Any of the following cases indicates a faulty braking.
component monitored by the warning lamp system.
Do not overrate the anti-lock brake system: It ● Vehicleswithtirechains.
You must immediately contact the special service
is significant to abide by all notes and keep
● Driving on the steps at the junction of ABS indicator indicator station of LIFAN for check. A disc brake has an in-built over-wear alarm
proper vehicle speed and vehicle spacing, Drum parking brake
roads. which will produce warning sound when the
although this system is helpful for
Install tires with specified specifications on If the ignition key is turned to the position “II”, the light ● In case that the ignition key is turned to the position brake pads are overworn and need to be
controlling the vehicle; because, even if it The vehicle is equipped with a drum parking
performs, the effect for the stability of all wheels: The anti-lock brake system uses will illuminate. If the anti-lock brake system works replaced.
“ON”, the light will not illuminate or illuminate brake. This brake system should be checked
vehicle and the operation of steering wheel the speed sensor to measure the vehicle normally, it will go out after several seconds. Then, it continuously. In case of scream or friction noise during
and adjusted regularly.
is limited. speed to get the rotation speed of each will illuminate again in case of any trouble. driving, please immediately drive to the
wheel. Other undesignated tires can not closest special service station of LIFAN for
When driving in rainy days, the anti-lock ● It will illuminate during driving.
measure the correct rotation speed and will When ABS indicator illuminates, the anti- check or replacing the brake pads. No driving
brake system will be unable to maintain a extend the brake distance. A short illumination of the warning lamp indicates no
the vehicle continuously in case of alarm
trouble.
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Chapter 3
sound. Suspension and Chassis
Notes for Luggage Loading Warning
Starting and Driving
When loading luggage or goods, please abide by Do not refit the suspension or chassis Before starting the engine… … … … … … … … … … … … … … … … … …88
the following instructions: randomly, because that will change the
operation performance and then cause
Engine starting ways… … … … … … … … … … … … … … … … … … … …88
● Put the luggage or goods into the luggage boot
the vehicle to lose control. Safety-check before driving… … … … … … … … … … … … … … … … …89
as possible as you can and make sure that all
objects have been fixed tightly. Driving guidance under different situations… … … … … … … … … … …90
● Keep the balance of the vehicle and put the Driving tips in winter… … … … … … … … … … … … … … … … … … … …91
weight forward as possible as you can to achieve How to save fuel and extend the service life of the vehicle… … … …92
balance.
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Before Starting the Engine Engine Starting Ways Safety-check before Driving
1. Check the situation around the vehicle (a) Before starting (b) Starting the engine You’d better carry out a safety-check before Headlamp, brake lamp, position lamp,
before entering the vehicle. driving the vehicle. A check for minutes will steering indicator lamp and other Battery and cable: Check if there is any
2. Adjust the position of the seat, the angle 1. Check the parking brake. Please make sure that all steps in “(a) be beneficial for your safe and enjoyable illumination all work. Check the aiming of corrosion, looseness or crack at the
the Headlamp. harness connector and check if the cable
of seat backrest, the height of headrest and 2. Turn off all lights and accessory electrical Before starting” have been processed, driving.
and connection is good.
the angle of the steering wheel. equipments. before starting the engine. The inner vehicle
3. Adjust the rearview mirrors inside and 3. Set the shift lever at neutral position.
Note Harness: Check if there is damage or
Spare tire, jack and wrench for wheel looseness to the harness.
outside the vehicle. 4. Release the anti-theft system. Normal starting
In case of a check in a closed garage, nuts: Check the pressure of the spare tires
4. Tighten the seat belt. Turn the key to “Ⅲ ” and start the engine. and make sure there is a jack and wrench Fuel pipe: Check if there is leakage and
make sure that the garage is well
Release the key after the engine starts. for wheel nuts. looseness at the pipeline joint.
If you have set the vehicle anti-theft system, ventilated. The waste gas exhausted
from the engine is harmful. Seat belt: Check if the buckle can be tightly Oil level: Park the vehicle on flat ground
you must cancel this system before starting In case of a misfire of the engine…
fixed and make sure there is no wear nor and check if the oil level is correct.
the engine; otherwise the engine can not be Carry out another starting according to the
scratch on the belt. After the engine starts
started. correct starting process. Check before Starting the Engine
Instrument and controller: Specially make Exhaust system: Check if there is gas
If the engine can not start… The outer vehicle sure that indicator, instrument illumination leakage. In case of a leakage, immediately
Refer to “If the vehicle can not start” in Tire: Check the tire pressure with a tire and defroster work normally. repair it
Chapter 4. pressure gauge and check carefully if there Brake: Make sure that there is enough free
is cut, damage or excessive wear. During driving
clearance for the pedal and ensure a normal
Wheel nuts: Make sure no looseness or braking. Instrument: Make sure that indicators and
loss of nuts. gauges of all kinds in the instrument cluster
The inside of the engine compartment work normally.
Spare fuse: Make sure there are fuses of all
Leakage: Check if there is leakage of oil or specifications for rating carrying capacity in
liquid under the vehicle after the vehicle Brake: Find a safe place and make sure
the fuse box. that the vehicle does not pull to one side
stops for a while. (It is normal in case of
drips from A/C in operation.) Coolant level: Make sure that the coolant when braking.
level is correc Pay attention to the initial stage and check
Illumination: Make sure that the
carefully if there is abnormal noise.
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Driving Guidance under Different Situations Driving tips in winter
1.Stopping the vehicle ●Drive slowly against the wind. It is convenient Note Make sure that the coolant has the right station for assistance. Avoid ice and snow accumulated under
for controlling vehicle. function of freeze protection. the mudguard
The vehicle should not be stopped at once Prevent the door lock from being frozen
when the engine is working, especially at a high ●Drive slowly on the ashlar at the side of street ● Before driving, make sure that the The ice and snow accumulated under the
parking brake has been fully released Only coolant designated by LIFAN can be
rotation speed with high load. It should be and keep the correct angle as possible as you used. Fill the coolant with proper type Spray the deicing agent or glycerin into the mudguard will cause difficulty in steering.
stopped after 3-5 minutes low-speed run. can. Avoid driving on high and sharp-edged and the parking brake indicator has door lockhole to avoid freezing. When driving in cold winter, please always
according to the ambient temperature into
objects or other road barriers; otherwise the tire gone out. check if there is ice and snow under the
the cooling system.
2. Rainy day or wading through water will be damaged abnormally. ●The engine should work at idle speed An improper coolant will damage the Use the washer fluid with antifreeze. mudguard.
for minutes for warm-up. cooling system.
Make sure that the air cleaner has been sealed ● Decelerate when driving on a bumpy road; This kind of product is available at LIFAN
well when running on the road with seeper in
● In case of a long-distance driving Yo u are recommended to take some
otherwise the tire or wheel will be seriously down on a steep hill, please decelerate Note service station. necessary instruments according to different
rainy days or wading through water in normal damaged. driving conditions, such as tire chain, window
the vehicle and shift to a low-speed Warning
times; otherwise, the water may enter the No use of clean water. scraper, a bag of sand or salt, signal flash
engine cylinder and cause damage to the ●If the vehicle is parked on the hillside, rotate gear. Remember that too many times of
the front wheels to make them contact the stepping on the brake will cause over- device, small shovel and connecting cables.
components such as engine connecting rod. Inspect the battery and cable Do not use the antifreeze or other
roadside and use the parking brake to make heating and result in abnormal working
substitute as washer fluid; otherwise the
3. Warming the engine in winter them not slip. If necessary, place a crosstie of the brake. A cold weather will decrease the charge
under the wheels. ● Be careful in case of accelerating, paint of the vehicle will be damaged.
In winter with relatively low temperature, the capacity of the battery. Therefore, the battery
shifting to a high-speed gear or low- should keep a sufficient charge capacity to be
viscosity of oil will increase and its lubrication ● The brake will become damp in case of
speed gear or braking on a slippery helpful for starting in winter. And the
effect is worse than that in summer. Therefore, cleaning or passing by water. Check if the brake
road surface. An abrupt acceleration or inspection of charge level can be carried out
the engine should not work under large load at is normal under a safe condition. If the brake is In winter the parking brake may be frosted.
abnormal due to the dampness, you can lightly braking may cause a skid or spin. at LIFAN service station.
high speed immediately after it is started. It Therefore do not use it in such a case.
should be warmed for minutes at idle speed to step on the brake pedal while driving carefully ● Do not continue to drive the vehicle
normally when the brake is damp. In Make sure that the oil viscosity is suitable
increase the temperature of the oil and coolant. under a condition of using the parking brake. If for driving in winter. When parking in winter, set the shift knob at
Only after the engine is fully lubricated, can you it still can not work normally, please stop the case of a damp brake, a relatively long the first gear or (reverse gear) and block the
drive the vehicle. In case of driving when the vehicle and contact LIFAN service station. brake distance is needed and the In winter, use of summer oil will cause rear wheels. Do not use the parking brake;
engine is not well lubricated, the components of vehicle may be pulled to one side when difficulty in starting the engine. In case of otherwise the parking brake device will be
the engine may suffer from over wear or even braking. Likewise, the parking brake uncertainty about the oil type, please turn to frosted by seeper or snow, and then cause a
be locked. also can not stop the vehicle urgently. the sales service store or LIFAN service hard release to the parking brake.
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How to save fuel and extend the service life of the vehicle Chapter 4
It is simple and easy to save fuel. It is also the engine: Select a proper gear according ●The chassis should be kept clean without
helpful for extending the service life of a to the road conditions. slurry: That will not only ease the load of
vehicle. The following are tips for saving
● Avoid continuous acceleration and
vehicle body but also prevent corrosion. Emergency Trouble Treatment
fuel and repair expense:
deceleration: A driving with frequent stops ●Adjust the vehicle and maintain it under the If the vehicle can not start…………………………………………………………94
● Maintain a correct tire pressure: An will increase the oil consumption. best working state: The performance of the
insufficient tire pressure will cause wear to engine will be affected and the oil If the engine misfires during driving…………………………………………… 97
the tire and waste fuel. Refer to Section 7-2 ● Avoid unnecessary parking or braking: consumption will also be increased by the
for instruction. Keep a stable vehicle speed. Coordinate unclean air cleaner, improper valve clearance, If the vehicle is over-heated………………………………………………………97
with the traffic light to achieve minimum unclean spark plug, oil and lubricant and If the tire leaks…………………………………………………………………… 98
● No unnecessary loads on the vehicle: parking times; or keep space to avoid unadjusted brake. A regular maintenance
Excessive weight will increase the load of the emergency brake when driving on the road should be carried out for a longer service life If the vehicle gets stuck…………………………………………………………103
engine and cause an increase of oil consumption. without traffic light, which will also reduce of all components and a reduction in operation
the wear of brake. expense. In case of frequent driving under If the vehicle needs trailering……………………………………………………103
●Avoid warm-up idling for a long time: Start extreme condition, a more frequent
driving the vehicle once the engine operates ●Avoid passing by area with busy traffic or maintenance should be implemented.
stably, but it must be stable. Be careful, it traffic congestion as possible as you can.
will take a longer time for the warm-up of the Warning
engine in winter. ● Keep proper vehicle speed on the
expressway: The higher the vehicle speed
●Slow and stable acceleration: Avoid rapid is, the more oil will be consumed. No stopping the engine when driving
starting. You should drive at a high-speed down the slope. Once the engine is
gear as quickly as possible. ● Maintain a correct alignment of the front stopped, the power steering and
wheels: Avoid colliding with the road edge
●Avoid engine idling for a long time: In case vacuum booster will not fully display
and drive slowly on bumpy road. An
of parking to wait for someone for a long time incorrect alignment of the front wheels will their performance. Likewise, emission
in a place with no busy traffic, you’d better result in a fast wear to the tires and also control device can work correctly only
stop the engine and restart it later. increase the load of the engine, namely when the engine is running.
●Avoid lug down or over-speed rotation of expand the oil consumption.
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If the vehicle can not start
(a) Simple inspection Note In that case, step down the accelerator (c) Jump-starting
pedal to the bottom and meanwhile turn the continuously on the way to hospital. Booster battery
Before these examinations, make sure if No starting the vehicle by trailering or key to “START”, and retain the accelerator The following instructions must be abode by ● The gas discharged by the battery will
you have started the engine according to pedal and the key and then release them 5 explode in case of flame or spark around.
the correct starting procedures described in
pushing. Otherwise, damage or to avoid serious personal injury as well as
During the jump-starting, you must use
a
seconds later; and then restart the engine damage to vehicle or electrical fittings due
“Engine Starting Ways” in Chapter 3, and collision may be caused to the vehicle standard jumper cable and must not smoke
when the accelerator pedal is under a free to battery explosion, sulphuric acid Discharged battery
check if the fuel is sufficient. At the same when the engine starts. Meanwhile, the state. or light a match.
corrosion and electrical combustion.
time, check whether another key can start three-way catalytic converter will be
the engine. If another key can start the over-heated to cause a fire. If the engine still can not start after 5- Note
engine, it is manifested that the key has second starting, release the key and restart
You are strongly recommended to seek help Positiv e terminal connector
b
from the service station of LIFAN, if you are not (“+”)
been damaged, so please contact the the engine several minutes later. The discharged battery must be 12V. Do Positiv e terminal connector
special service station of LIFAN for check. If clear about the process. Jumper cable
not carry out the jump-starting before (“+”)
all the keys cannot work, the engine must If the engine still can not start, an adjusting confirming the correct discharged
have faults; please contact the special If the engine rotates at a normal speed or repair is needed. You can contact LIFAN Warning battery. 2. If necessary, remove all orifice plugs of
service station of LIFAN. but can not start service station. discharged battery and booster battery. Cover
● The battery contains corrosive and toxic Jump-starting process the open battery orifice with a cloth. (This can
If the engine can not rotate or rotate too 1. Turn the ignition key to “I” or “B”, and then sulphuric fluid. Therefore, you must wear reduce explosive danger, personal injury and
restart the engine. Note burn)
slowly protective goggles during jump-starting. 1. In case that the discharged battery is
2. When the engine can not start, “engine Avoid sulphuric acid spattering on your installed in another vehicle, you must confirm
Each starting period should not exceed 3. In case that the engine of the vehicle with
1. Check if the battery connector is tightly flooding” may be caused due to restarting that the vehicles have no contact with each discharged battery does not rotate, start it and
3 to 5 seconds, otherwise the engine skin, clothes or the vehicle body.
screwed down and clean. repeatedly. other and turn down all unnecessary lights run for several minutes.
3. If the engine still can not start, a repair or ● In case of sulphuric fluid spattering on
2. If the battery connector works normally, and circuit will be over-heated. and accessory equipments. During jump-starting, lightly step on the
adjusting is needed. You may contact LIFAN your body or into eyes due to carelessness, accelerator pedal and operate the engine at a
please turn on the compartment light.
3. The battery has been used up if the light service station. immediately take off the clothes with For battery charging, corresponding battery rotation speed of 2,000 rpm (round/minute).
does not illuminate or illuminate dimly or the (b) Starting “flooded engine” sulphuric fluid and clean the affected part of battery with higher quality shall be
with clear water and then seek medical help. applied. Any other battery can cause 4. Connect the cable according to the process
vehicle can not start. in a, b and c.
If the light illuminates, but the engine can When the engine can not start, “engine If possible, use sponge or clean cloth with difficulty to jump-starting.
a. Connect the clip of the positive terminal (red)
not start, a repair or adjusting is needed. flooding” may be caused due to clean water to wash the affected part of the jumper cable to the equivalent connector
restarting repeatedly. For jump-starting is difficult, charge battery (+) of the booster battery.
Please contact LIFAN service station. for a few minutes.
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Jumper cable
the accelerator pedal and make the engine If the engine misfires during driving If the vehicle is over-heated Warning
d rotate at a speed of 2,000 rpm.
The engine may be over-heated in case of Your hands and clothes should keep a
If the Engine Misfires during Driving
6. Carefully dismantle the cable reverse to water temperature warning lamp lights up, certain distance with the fan and engine
1. Slowly decelerate the vehicle and belt in operation when the engine runs.
the installation procedure; firstly dismantle or loss of power, or a knocking sound or
carefully drive the vehicle off the road to a
the negative terminal cable and then the bang noise. Please take the following
safe place. treatment procedures… 4. Immediately stop the engine in case of a
positive terminal cable. 2. Open the emergency light. leakage of coolant. Contact the special service
c 3. Turn the ignition key to “I”, and restart 1. Drive the vehicle safely off the road, park it station of LIFAN for help.
Booster battery
7. Carefully take off the cloth on the battery the engine. 5. Check the coolant Coolant reservoir in case
and open the emergency light. Set the shift
which may be stuck to by electrolyte knob at neutral position and pull up the parking of no evident leakage. In case that the Coolant
Negative terminal connector Discharged battery
If the engine still can not start, refer to “ If brake. In case of using A/C, close it. reservoir is dry, fill it with coolant to the
(“-”)
In case that the battery discharges due to the Vehicle Can Not Start” of this section. 2. Stop the engine in case of coolant or steam standard scale during the engine runs.
unclear reasons (e.g. the light still ejecting from the radiator or Coolant reservoir. 6. Recheck the coolant level in the Coolant
b. Connect the clip of the other end of the Connection points of engine illuminates), you should contact LIFAN Note Open the engine hood after the steam fades reservoir when its temperature decreases to
positive terminal (red) of the jumper cable to Do not contact the jumper cable to any authorized service station for check. away. Keep engine working and close the normal. If necessary, refill the coolant to half of
the equivalent connector (+) of the movable components during starting the In case that the engine does not run, the ignition switch in case of no coolant or steam the tank. A serious loss of coolant indicates a
discharged battery. engine. power assisting device of the brake and ejection. leakage in the system. In that case, contact
If first starting fails steering gear will not fully work. LIFAN authorized service station for immediate
c. Connect the clip of the negative terminal Check if the clip of jumper cable is fixed Therefore, it is much difficult than usual Warning check.
(black) of the jumper cable to the equivalent 5. Start the engine in the normal way. firmly. Recharge the booster battery for a to carry out the steering and braking.
connector (-) of the discharged battery. Before starting the engine, lightly step on few minutes with the jumper cable To avoid personal injury, keep the engine Warning
d. Connect the clip of the other end of connection method. Then start engine in hood closed until there is no steam any
negative terminal (black) of the jumper normal way. more. The flowing of steam or coolant Do not dismantle the radiator cap when
cable to an unpainted metal fixed point in indicates a rather high pressure. the engine and radiator are in a high-
If the starting still fails, the battery is
the vehicle with a booster battery. temperature state.
indicated to be fully discharged. It shall be
checked by the special service station of 3. Check if there is an evident leakage in the
Connection points are shown as below: LIFAN. radiator, hose and underside of the vehicle.
However, it is normal in case of drips from A/C
in use.
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If the Tire Leaks Tools required and spare tires
1. Slowly decelerates the vehicle and drive Warning Note
it off the road to a safe place far away from
ground, pull up the parking brake tightly
traffic. Avoid parking the vehicle on the Never drive a vehicle with a flat tire, 1
central turnout track. Park the vehicle on a and turn the transmission to the neutral because even a short distance driving
solid and even ground. position. If necessary, set a baffle plate will result in a tire damaged too badly
2. Stop the engine and open the Emergency under the tire in the diagonal direction of to be repaired.
warning lamp. the replaced tire.
3. Pull up the parking brake and turn the ● Make sure that the jack has been set on
shift knob to the neutral position. 1 2
the correct jacking point. An incorrect
4. All persons on the vehicle must get off to
jacking position will cause damage to the
a safe place.
vehicle or make the vehicle drop from the
5. Please read the following instructions
carefully. jack and cause personal injury.
● Any person should not be under the
Warning vehicle supported only by a jack. 1.Take out the tools required and spare Turn the jack joint Screw off the bolts and remove the spare
Please follow the instructions below ●The vehicle can be supported by a jack tires tire, and then take off the spare tire from the
when raising the vehicle by a jack to only when replacing the tire. Removal: Turn the joint according to vehicle.
avoid severe personal injury: ● No jacking the vehicle in case of 1. Spare tires direction 1 until the jack becomes loose.
● Follow the instructions about jacking. anybody in the vehicle. If you have to repair the vehicle by yourself S t o r a g e : Tu r n t h e j o i n t a c c o r d i n g t o Put the spare tire with the outside up into
under an urgent state, you must be familiar direction 2 until the jack is fixed tightly to the storage compartment when storing the
● Do not make any part of your body
with the usage and storage place of the jack prevent the jack from being thrown forward spare tire. And then fix it, reverse to the
under the vehicle supported by a jack to ● Do not place any object on or under the
and various tools. in case of a collision or an emergent brake. above removal procedures to prevent the
avoid personal injury. jack when raising the vehicle.
tire from being thrown forward in case of an
● Do not start or run the engine when the ● Only raise the vehicle to a height at emergent brake or collision.
vehicle is supported by a jack. which the tire can be taken off and
● Park the vehicle on flat and firm replaced.
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Block the wheels Screw off the wheel nuts Jack alignment Lifting the vehicle Replace the wheel
2. Set a baffle plate under the tire in the 3.Screw off all wheel nuts of the flat tires. 4.Put the jack at the correct jacking point 5.Raise the vehicle by a jack to the proper height 6. Remove the wheel nuts and then Brush all the corrosives on the installation
diagonal direction of the replaced tire when according to this fig. at which the spare tire can be installed after replace the tire surface by a wire brush before installing the
using a jack, to avoid vehicle slide. When Screw off the wheel nuts before lifting the ensuring that there is no people in the vehicle. wheels. A bad contact between the metal
blocking the wheel, put the baffle plate in vehicle. Make sure that the jack is put on flat and Roll the spare tire to the installation faces of the installation surface during the
firm ground. Before lifting the vehicle, insert the jack knob into
front of the front wheel or behind the rear the jack (loose contact), and then turn it clockwise. position. Align the bolts to the wheel hole. installation will make the wheel nuts loose
Turn the wheel nuts counter-clockwise and
wheel. screw them off. To get a maximum torque, When the jack contacts the vehicle and starts Then raise the wheel until the bolt at the and cause the wheel to fall off during
put the wrench into the nut according to the rising, recheck if it is at the correct position. uppermost goes through the screw. Rotate driving.
fig. above and make the wrench knob at the tire and push it backwards until other
right. Hold the end of wrench knob and pull Warning bolts go through the screw.
it up. Be noted that the wrench should not
slip out from the nut. Do not remove the nut, Personnel should not be under the
only screw it off for one and a half turns. vehicle supported by a jack only.
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Reinstall the wheel nuts Lower the vehicle After replacing the wheel If the vehicle gets stuck If the vehicle needs trailering
order shown in the fig., and screw them Check the tire pressure after replacement Try to push the vehicle back and forth to
tighter each time. Repeat this process until release it from the trouble if the vehicle is
all nuts are screwed down tightly. Adjust the tire pressure to the value regulated stuck in snow, mud basin and sands. Trailering from the front
in Chapter 8. In case of an air pressure lower
than the regulated value, drive the vehicle
Warning Warning
1 slowly to the close service station for inflation
● When lowering the vehicle, please to make the air pressure reach the correct When driving a stuck vehicle, do not
make sure that all people have left to value. push the vehicle back and forth to let it
4 3 avoid any injury due to the vehicle Remember to install the valve cork, otherwise move if there is people or object near the
descending. the dust and moisture will enter the valve core vehicle, because the vehicle, when it is
2 ● Immediately use a torque wrench with and may cause a leakage. In case the valve being pushed, will suddenly move
120N•m torque to screw down the wheel cork is lost, immediately replace a new one. forwards or backwards after escaping
7. Reinstall all wheel nuts nuts after replacing the wheel. Otherwise, from the trap, which may cause an injury
Store all tools, jack and flat tires properly Trailering from the back
When reinstalling the wheel nuts (the the nuts will become loose and cause the to the people or damage to objects
wheel to fall off, and then cause a serious around.
wedge-shaped end facing inward), screw After wheel replacement, use the torque
8. Completely lower the vehicle and accident.
down the nuts to full, push the wheel inward wrench to screw down the wheel nuts to the
screw down the wheel nuts to fall off and bring severe accidents. In
to see if it can be further screwed down. torque value regulated in Chapter 8. The flat
case of oil or lubricant on the bolt or nut,
Warning Rotate the jack knob counter-clockwise to clean them out. tires should be repaired by the professional
lower the vehicle. personnel.
Do not apply oil or lubricant onto the bolt
or nut, because that may cause the nut to Only the wheel nut wrench can be used to Warning Use a platform truck
be screwed down over-tightly and even
screw down the nuts. No use of other tools
damage the bolt. The nut will become Before driving, make sure that all tools,
loose for that, which will cause the wheel or any other lever except your hands. Make
sure that the wrench has been tightly set jack and flat tires are fixed at the storage
to fall off and bring severe accidents. In place to reduce the possibility of
case of oil or lubricant on the bolt or nut, on the nuts.
personal injury in case of emergent brake
clean them out. or collision.
Screw down the nuts according to the
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The application of proper trailering In case of a need for trailering, the LIFAN
equipments during trailering process will service station are recommended to handle Note Note
Warning
ensure no damage to the vehicle. that for you.
Special care should be taken when Only use the special towing cable or In case that the engine does not run, the
Wrong towing methods will cause damage In case that a trailer company can not be trailering a vehicle. Avoid abrupt starting chain and fasten them at the towing power assisting device of the brake and
to the vehicle. Mistakes may always occur found during an urgent trouble, you can or unstable driving operation, because pothook. steering gear will not work. Therefore, it
although most of towing personnel are fasten the towing cable or chain at the
these will cause huge pressure on the is much difficult than usual to carry out
familiar with the correct methods. urgent towing pothook and trailer the
urgent towing pothook and towing cable Before trailering, release the parking brake and the steering and braking.
Therefore, the following precautions must vehicle temporarily. Extra care must be paid
be abided by to protect the vehicle from during trailering. or chain. The pothook and towing cable turn the shift knob to the neutral position. And
damage. or chain may be broken and then cause the key should be at “I” (engine closed) or “II”
Note severe injury to people or damage to the (engine running).
Front
Precaution measures for trailering: vehicle.
● Only the specified towing pothook can
All trailering should use a safety chain
be used, otherwise the vehicle may be
system and abide by the laws of the damaged.
state/province or municipality and the local
● Do not trailer the vehicle backwards in
government. The wheels and axle case of four wheels on ground; otherwise
contacting the ground should be at a good the vehicle may be damaged.
state. In case of any damage, apply a
platform truck.
The driver must sit in the vehicle for driving
and operating the brake.
This trailering way can be used only on hard
ground at low speed for a short distance.
Meanwhile, the wheel, axles, transmission
system, steering wheel and brake must be
Back at a good state.
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Chapter 5 A correct maintenance of the vehicle can The above shows that it is very important to Check the paint and trims: In case of any
protect it from corrosion for long. keep the vehicle clean as much as possible, fragment or crack on the paint layer, please
especially the bottom of the vehicle body, and immediately go to the service station of LIFAN for
Most common causes for vehicle corrosion:
Anti-corrosive and Outer Maintenance of the Vehicle repair the damaged paint and protection layers repair to prevent corrosion. In case of fragment
as soon as possible. or crack falling off the metal surface, please go to
●The underside of vehicle is covered with salt
the service station of LIFAN for repair.
Anti-corrosive on vehicle body…………………………………………………107 and alkali, dust and moisture. Follow the rules below to prevent LF320
Vehicle cleaning and waxing……………………………………………………108 ● Protective paint cover scratched by a light from corrosion: Check the inner vehicle compartment: The
collision or stone and grit. moisture and dust covering the floor mat will
Inner cleaning……………………………………………………………………109 Always clean the vehicle: A regular cleaning cause corrosion. Please always check the place
It is essential to take an extra care in case of may keep the vehicle body clean. Please abide under the mat and make sure it is dry. Take an
living in a special region or operating the by the following rules to avoid corrosion. extra care during the transportation of chemicals,
vehicle under special environment. cleanser, fertilizer, salt and other materials which
● Clean the running part of the vehicle at least should be transported by proper containers. In
● The salt and alkali or dust with chemical once each month to avoid corrosion in case of case of any spill or leakage, please immediately
materials on the road will accelerate the driving on the road with salt and alkali in winter clean and keep it dry.
corrosion. Even in the coastal area or industrial or at coastal areas.
pollution region, there is still salinity in the air. Application of mudguard: The mudguard can
● High-pressure or steam is very effective for protect the vehicle in case of driving in salty and
●A high humidity will accelerate the corrosion, cleaning the chassis and wheel cover. It is hard alkali region or on gravel roads. It is better if the
especially in case of a temperature barely to see all the slurry and dirt in those two places. mudguard is bigger and closer to the ground.
above zero. Therefore, an extra attention must be paid. It
will cause more serious danger in case of only Park the vehicle in a fully-ventilated garage
● A certain part of the vehicle being wet or roughly moistening but not cleaning the slurry or a place with roof. Do not park it in a damp
damp for a long time will be corroded, although and chips. The drain holes of door lower brim, and airproof garage. The garage will become
other parts keep dry. doorsill plate and the vehicle frame must not be damp due to cleaning vehicle in it or the vehicle
obstructed by dust; otherwise the seeper in driving through a seeper or snow road, resulting
●A high room temperature will cause corrosion in corrosion. Although the garage is very dry,
those parts will cause corrosion;
to the vehicle components which can not get bad ventilation will also cause corrosion to a
dry fast due to the lack of correct ventilation. ●Completely clean the chassis after winter. damp vehicle.
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Cleaning LF320 Note containing abrasive. Warning from the manufacturer carefully; the chrome you should turn the front wheel to make it
plating and paint surface both need contact with the edge of the road, so that the
Clean the car in normal way. Be careful not to hurt your hands when Asphaltum: Clean it by turpentine or the No using organism (petrol, kerosene, polishing and waxing too. vehicle can’t slip. Please use the parking
cleaning the underside of the floor or the cleanser labeled no harm to the paint. naphtha or strong dissolvent);
The following cases will cause the paint chassis. brake. If necessary, a sleeper should be
otherwise, poisoning or damage will be placed under the wheel.
layer to fall off or result in corrosion to the Note
vehicle body and components. Please caused.
1. Wash away the loose dirt by a water pipe,
immediately clean the vehicle and repair and wash away all the slurry on the vehicle Warning In case redoing the waxing and parking ● Cleaning the vehicle or driving through
that. bottom and depressed part of the wheel or the vehicle in a painting workroom at deep water may wet the brake. Check
Do not install the seriously damaged Waxing of LF320 high temperature, take off the plastic
the salt and alkali on the road. whether the brake is normal under a safe
●Driving in the coastal region plastic wheel trims; otherwise, the bumper; otherwise, it will be damaged
Polishing and waxing for the vehicle body is due to the high temperature. condition, if the wet brake causes braking
2. Clean the vehicle with neutral washer wheel trims will fly off the wheel and
recommended for maintaining a shining abnormally, you can use the parking brake,
● Driving on the road covered with fluid. The mixture of washer fluids should be cause an accident during driving.
antifreeze carried out according to the instructions of outlook of the vehicle. drive carefully and tread the brake lightly at
● Please drive slowly against the wind to the same time. If you can’t brake normally
the manufacturer. Dip a soft cloth with
● Stuck by coal tar, resin, ornithocopros washer fluid and wipe away the dirt by suds 3 . Wa s h a w a y t h e s u d s c o m p l e t e l y ; A waxing should be implemented for once control the vehicle easier. still, please stop the vehicle and contact the
and dead insects and clean water. Do not wipe it forcefully. otherwise, it will become speckles when it is each month or anytime when the vehicle
● Be slowly when you drive on the street service station of LIFAN for help.
dry. In case of cleaning in summer, clean surface can not be well water-resistant.
● Driving in a region with a great deal of Plastic wheel trims: The plastic wheel trims each part with clean water correctly. with stones, and if possible, keep the right
soot, coal ash, dust, scrap iron or chemical are easily damaged by organism. In case of 1. Before waxing, do wash the vehicle first angle to avoid driving on the road with
materials any organism spattering on the trim, do 4. Use a clean soft towel to dry the vehicle a n d d r y i t s b o d y, e v e n i f u s i n g t h e sharp-high objects or other obstructions; or
wipe it away by clean water and check if the body to avoid water marks. Do not wipe or compound of cleanser and car wax. the tyre will be damaged abnormally.
●Being evidently dirtied by dust and slurry trim is damaged. press the vehicle forcefully; otherwise the
paint surface will be damaged. 2. Use high-quality polish agent and car ● Please drive slowly when driving at the
Manual cleaning of LF320 Aluminum-quality wheel: Only use
neutral suds or neutral washer fluids. wax. In case that the car polishing has rough roads; or the tyre or wheel will be
Clean the vehicle after its body feels not hot seriously effloresced, use the cleaning damaged badly.
in a shady place. Plastic bumper: Take care of cleaning the polish agent separately from waxing. Follow
bumper. No wiping it with washer fluid the instructions and precaution measures ● If the vehicle is parked on the hillside,
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Note Seat belt A/C control plate, acoustics, dashboard, Leather trims inside the vehicle body Note
control plate and switch
Do not clean the inner floor by water or The seat belt can be cleaned by neutral The leather trims can be cleaned by neutral ● The nylon brush or synthetic fiber
make water flow into the floor when suds or lukewarm water. Clean them with a moist soft cloth. cleanser applied to woolen textiles. cloth will scratch the good texture on
cleaning the inner or outer vehicle. Water the leather surface
Use sponge or soft cloth for cleaning. Do Moisten a clean soft cloth in water or Wipe the dust by a soft cloth immersed with ● Dirty leather trim will produce
may enter the carpet (or mat) or the
check if the belt is excessively worn, lukewarm water, and then wipe away the solution with 5% neutral cleanser applied to mildew. Be extremely careful to avoid
acoustics components or other electrical
frazzled or has shear mark. dust lightly. woolen textiles. And then wipe away the oil stain and always keep the trim clean.
components on and below the carpet and ● A long-time exposure to the
residual cleanser completely by a clean
cause a malfunction, and even result in sunshine will result in surface
Note Note moist cloth.
corrosion on the vehicle. hardening or shrinkage of leather.
●The seat belt should not be cleaned by a ● No using organism (dissolvent, In case of any moistened part of the leather Therefore, park the vehicle at a shady
kerosene, alcohol, petrol etc.) or acid and or after cleaning, clean it with a clean cloth place, especially in summer
staining agent or bleaching agent which
Carpet alkali solution, which will result in fading, and lay it at a ventilated and shady place for ● Since the temperature of the inner
will weaken the strength of the belt.
drying. vehicle becomes high easily in hot
●No using the belt before it is dry. staining or peeling of the surface.
Clean the carpet with high-quality foam summer, you should avoid placing any
washer fluid. ● Confirm that the components do not Note object made of vinyl plastic, plastic or
Door and window have the above-stated materials in case material containing wax, because these
Use a dust collector to wipe away the dust of using cleanser or polish agent. ● In case that the dirt can not be wiped objects will stick to the leather under a
possibly. There is various foam washer The door and window can be cleaned by any ● Do not spatter the fluid into the inner away by the neutral cleanser, a cleanser high temperature.
fluids for use. Some is stored in an aerosol cleanser for home-use surface of the vehicle in case of using a not containing organic solvent can be ● A wrong cleaning of the leather trim
can; others are powder or fluids which new-type washer fluid, because it may applied. will result in color fading or stain.
produce foams when mixed with water. Note contain the above-stated components. ● No using organism such as naphtha,
Clean the carpet by a sponge or brush alcohol, petrol or acid and alkali solution In case of any question about cleaning,
Clean all the spattered fluid immediately
immersed with foams. Wipe it in a circle Take care not to scratch or damage the please contact with the special repair
in the above-stated way. for cleaning the leather, because these
way. heating wire or connectors when station or local sales service store of LIFAN.
materials will result in color fading.
cleaning the inside of rear window.
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Chapter 6 Maintenance Whether the Vehicle Needs to Be Repaired?
Maintenance Instructions It is important and necessary to carry out Where to get maintenance? Pay attention to the change in performance
a regular maintenance. and sound of the vehicle. Some important
Routine maintenance must be done in the cases as below:
Maintenance………………………………………………………………………113 LIFAN strongly advises you to carry out a repair station of LIFAN.
regular maintenance according to the ● The engine misfires, is unstable or
Whether the Vehicle Needs to Be Repaired…………………………………113 maintenance scheme, which will be helpful All the technicians in authorized repair sounds bang noise
for: station of LIFAN have received professional ● Power decreases evidently
trainings in LIFAN Automobile before ● Abnormal noise from engine
● Saving fuel practices. They know about the latest ● Oil and water leakage under the vehicle
● Extending the service life of the vehicle service information of technology (the drip from the A/C is normal)
● Enjoying the fun in driving magazine, maintenance guidance and the ● Change in exhaust sound (That may be
● Safe driving inner training scheme of agents. due to the leakage of dangerous CO. Drive
● Stable traveling with the window open and immediately
● Meeting the guarantee regulation A u t h o r i z e d r e p a i r s t a t i o n o f L I FA N check the exhaust system)
● Conform to the government regulations contributes a great deal of capital to provide ● Leakage of tire; excessive tire noise
special tools and maintenance equipments when turning; uneven tire wear
L I FA N c a r h a s b e e n d e s i g n e d f o r for all styles of LIFAN vehicles. That will be ● The vehicle pulls to one side during a
economical driving and maintenance. Many greatly helpful for accomplishing the straight-line running on flat ground.
maintenance items required before are not maintenance work and reducing the ● Abnormal noise relevant with the
needed now or not needed as much as expense. movement of suspension equipments
before. The maintenance must be carried ● Ineffective brake; stepping on the brake
out according to the maintenance scheme Authorized LIFAN service station provides pedal or clutch pedal feels like on a sponge;
to guarantee the vehicle operating at the reliable and economical maintenance the pedal nearly contacts the floor; the
best running efficiency. service for all vehicles according to the vehicle pulls to one side when braking
maintenance scheme.
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● Continuously high temperature of engine
coolant
Chapter 7
Self-maintenance
In case of any case described above,
immediately contact the authorized repair
station of LIFAN. The vehicle maybe needs Engine Compartment Appearance……………………………………………116
adjusting or repair.
Notes for Maintenance DIY……………………………………………………117
Warning Alignment of Jack………………………………………………………………119
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Engine Compartment Appearance Notes for Maintenance DIY
1. Power steering fluid reservoir To carry out maintenance DIY, it is Warning ignition switch is turned on, if the
1 2 3 4 2. Oil filler cap necessary to do as per correct
temperature of engine coolant rises or
3. Brake fluid reservoir procedures in this section. ● When engine runs, hands, clothes
and tools should be far away from the the A/C is turned on, the electrical
4. Coolant reservoir
running fan and engine belt. (Better to cooling fan of engine will run
5. Fuse and relay box Be careful, incorrect or incomplete
6. Battery maintenance work will lead to operation take off things like ring, watch and automatically.
7. Oil dipstick trouble. tie.) ● When disposing the battery, be
8. Windshiled washer fluid reservoir ● When the car has exactly finished a especially careful, for the battery
This section is just for some maintenance driving, the temperature of engine contains corrosive electrolyte.
work which is easy to carry out for users. As c o m p a r t m e n t — e n g i n e , r a d i a t o r, ●When the car is only jacked by body
mentioned in Chapter 6, some items should exhaust pipe, power-assisted steering jack, people don’t come under the car,
be carried out by professional technicians fluid storage tank, spark plug etc. is do support the car with support frame
using special tools. or other strong strut.
very high. So be careful not to touch.
During maintenance work, be especially ●Whether working above or below the
The temperature of oil, coolant and
careful to avoid incidental injuries. The car, goggles are to be worn, for
spark plug is also very high.
following prevention measures should be avoiding falling or dropping articles
abided by especially. ● If the engine is too heated, then
don’t take off the radiator cap or loose and spattering fluid.
the drainage plug, for avoiding burns.
● Never leave behind such flammable
articles as paper, cloth in the engine
compartment.
● Before working around the grille
plate of cooling fan or radiator, it is
8 7 6 5 necessary to make sure that the
ignition switch is turned off. When the
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Vehicle Lift
Note ● When closing the engine hood, Note
● Both battery and ignition coil bear check whether there is anything like Strictly prohibit from jacking the car at
high current or voltage. Be careful to tools, cloth etc left behind the engine
the place of engine, transmission, rear
prevent accidents resulting in short compartment.
axle or front axle, etc, or it will result in
circuit. serious damage.
● Prevent any miscellany from
dropping into the spark plug hole.
● Strictly prohibit from prying the
outer electrode beside the central
electrode of spark plug.
● Only use the spark plug of
designated model.
● No overfill the power-assisted
steering fluid, or the power-assisted
steering will be damaged.
●If the brake fluid is overflowing, it is
necessary to clean it with water, for
avoiding damaging components or
paint coat. Make sure that the liftadjustable arm locates under the correct position as shown in the
illustration;
● Strictly prohibit from driving when
the air cleaner is taken off, or it will Removable lift
result in excessive wear of engine. Thesupport position should be in accord with the position as shown in the illustration.
● Be careful not to scratch the To avoid damage of body, add rubber attachment, if necessary.
windshield by the wiper.
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Daily Maintenance Chapter 7-2 Check the oil level
Note Check the engine coolant level
Low level High level
Noted that not drop any oil on the When the engine is under cooling state, check
Engine and Chassis the coolant level in the Coolant reservoir, if it is
components of the car.
between the marking lines of “FULL” and
Check the oil level………………………………………………………………121 If the oil level is below or just a little above “LOW”, it conforms to the requirements. If the
Check the engine coolant level………………………………………………121 the low level, it is necessary to fill the oil of oil level is on the low side, it is necessary to fill
the same type. coolant. (For the type of engine coolant, refer to
Check the radiator and condenser……………………………………………122 the “selection of coolant type” below.)
The coolant level in the Coolant reservoir will
Check the tire pressure…………………………………………………………122 To fill Correct Overfilled
Take off the oil filler cap, fill small quantities
change along with the temperature variation,
of oil every time and check the oil rule.
Check and replace the tire………………………………………………………122 however, if the level is at or below the “LOW”
line, it is necessary to fill coolant, to make the
Install tire chain…………………………………………………………………123 When the engine is under working When the oil level reaches the right range,
level reach the “FULL” line.
temperature, shut down the engine, put on the filler cap and screw it down.
After filling coolant, if the level of coolant
Tires replacement………………………………………………………………124 check the oil level with oil rule. declines within a short time, then some leakage
Note
Notes for aluminums alloy wheel………………………………………………126 exists in the system. It is necessary to check
1. To obtain correct reading, it is necessary the radiator, hose, radiator cap, drain plug and
to park the car at flat ground, shut down the ● Avoid overfilling, or the engine will be water pump.
engine and wait for several minutes, let the damaged. If no leakage is found, it is necessary to test the
oil gather at the bottom of engine. ● When the filling is finished, recheck the oil cap pressure and check whether there is any
2. Pull out the oil rule and clean its end. level on the oil rule. leakage at the LIFAN service station.
3. Insert the oil rule again, and try to stick it ●Insufficient oil will cause under-pressure of
to the bottom, or else the reading is engine oil, resulting in poor lubrication,
inaccurate. Warning
bringing about intensified wear and poor
4. Pull out the oil rule and check the oil
cooling of engine, causing frequent troubles To avoid burns, when the engine is at hot
level.
and affecting the service life of engine. condition, don’t take off the radiator cap.
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320
Check the tire pressure Check the tire
Coolant selection Check the radiator and condenser Maintain a correct tire pressure. When checking the tire pressure, it is
Warning
necessary to abide by the following
Only use the coolant designated by LIFAN. When either radiator or condenser has For the recommended cold tire pressure Maintain a correct tire pressure, or instructions:
It is necessary to fill proper type of coolant already extremely dirty or their condition and tire size, refer to Chapter 8. else, the following circumstances or
into the cooling system as per the ambient can’t be made sure, it is necessary to even serious injuries will occur. ●Check the tire pressure only when the car
temperature. Vehicle brought to be checked and repaired It is necessary to check the tire pressure is cold. Only when the car has been parked
at service station of LIFAN. once every two weeks or at least every for at least 3h or drives less than 1.5km, can
Note Low tire pressure (insufficient charge)
month. Don’t forget to check the pressure of the reading of tire pressure be correct.
spare tire. ●Excessive wear
Don’t use clean water. ● Do use tire pressure gauge, since to
Note ●Supernormal wear
judge the tire pressure by experience may
To avoid burns, when the engine is under Incorrect tire pressure will lead to oil waste, ●Hard to control lead to error. Although the variation of tire
Use of improper coolant will damage the
hot condition, be careful not to touch the lowered driving comfort, shortened tire ● Leakage resulting from overheated pressure may be tiny, it will also reduce the
cooling system of engine.
radiator or condenser. service life and lowered driving safety. tire driving comfort and operating stability. Check the tire
For details, contact the service station of
LIFAN. ● Weakened sealing performance at ● After driving, don’t deflate the tire or
If the tire needs to be charged too the hoop of tire reduce the tire pressure randomly. The tire The wear indicating mark is used to help
Note
Warning frequently, it is necessary to demand pressure after driving is always high, which check the tire tread. If it is observed, it is
● Deformed wheel and/or tire
To avoid the damage of radiator and service station of LIFAN for checking. is normal. necessary to replace the tire.
condenser, don’t carry out operation by separation
It is necessary to obtain enough coolant ● Make sure the valve cork is installed.
for the cooling system to ensure the yourself. The tire of LF320 is embedded with wear
Without valve cork, dust or moisture will
normal operation of engine, or “boiling” High tire pressure (overcharge) indicating mark for indicating the time for tire
enter the valve core, and result in leakage.
of car will occur. When the engine is ●Hard to control If the valve cork is lost, it is necessary to replacement. When the wear depth of tire
working under overheated condition, the ● The central of tread pattern is over tread reaches 1.6mm or less, the wear
service life will be affected, so much as install a new one.
worn indicating mark may be seen. If there is wear
resulting in bad accidents like engine
●The hard part of road will more likely indicating mark between two or more adjacent
scraping.
cause tire damage. pattern grooves, it is necessary to replace the
tire. The thinner the tire tread is, the greater
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Owner’s Manual LIFAN
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320
Tires replacement
the risk or slipping and tire burst is. Replacement of tires No using any old tire on Lf320. abnormally worn due to the incorrect tire Warning
pressure, improper wheel alignment and
If damages like cut, rupture, crack which In case of replacing the tire, use a tire of the It is very dangerous to use tires without unbalanced wheel or frequent braking. ● When using tire chain, the driving
is so deep that cord fabric is exposed, same specification and model with the replaced clear identification. speed should not exceed 50km/h or the
and bulging occur to the tire, which one and whose carrying capacity is equal to or Install tire chain lower speed limit specified by the tire
indicates the inner damage of tire, it is larger than that of a common one. You are advised to replace the four tires chain manufacturer.
necessary to replace the tire. at the same time, or two front tires or two Selection of tire chain ● When using tire chain, be careful in
Use of a tire of any other model will cause a driving to note the ridge, hole and sharp
rear ones at least.
If tire leakage is frequently experienced or the serious impact to the vehicle driving and riding, Use the tire chain of correct size. turn of the road, which may result in the
calibration of the speedometer/odometer, jump of car.
size and location of cut and other damages Refer to “If the Tire Leaks” in Chapter 4 for The use rules of tire chain will change
are not proper for correct repair, then it is ground clearance and the space between the ● When using tire chain, avoid sudden
steps of tire replacement. according to different places or roads,
vehicle body and the tire or the tire chain. turn or wheel lock brake, which may
necessary to replace the tire. If you’re not therefore, make sure the local rules before bring about bad effect to the operation of
sure, contact service station of LIFAN. Keep the wheels balanced when installing the tire chain. the car.
If leakage occurs in driving, don’t drive any Warning replacing tires.
Installation of tire chain ● When the car is installed with tire
more, because just a little more driving will You are recommended to exchange the tires
Follow the instructions below; otherwise, a chain, the driver should be careful to
cause unrepairable damages. Unbalanced wheels will effect the vehicle after each mileage of 10,000km so as to decelerate before making a turn, for
serious injury or even death will be caused. maintain the same wear of the tires and Try to install the tire chain at the front tires
operation and the service life of the tires. as tight as possible. Don’t use tire chains at avoiding losing the control over the car,
If any tire serves more than 6 years, ● Radial tire, bias belted tire and The wheels may loose balance in case of a extend their service life. However, the or accident will occur.
proper time for that should be determined rear tires. After driving for 0.5-1.0km, tighten
although no obvious damage is seen, it is diagonal-ply tire can not be mixed in a normal use. Therefore, carry out a regular the tire chain again.
necessary to be checked by professional vehicle; otherwise a typical operation according to the habit of the driver and also
check-up to keep them balanced. the road conditions.
technicians. danger will be resulted in and then cause When installing the tire chain to the tire, be
the vehicle to lose control. The air valves must be replaced with new Refer to “If the Tire Leaks” in Chapter 4 for careful to abide by the guidance of the tire
Although the tire is unused or seldom used, chain manufacturer.
● Do not use any tire with a size not ones in case of a tire replacement. steps of tire replacement.
the aging will lead to quality decline. recommended by LIFAN; otherwise a
Check if there is uneven wear and damage on When the wheel house is used, it may be
These are suitable to spare tires as well. typical operation danger will be resulted in
the tires when exchanging them. The tire will be scratched by the tire chain, so it is necessary to
and then cause the vehicle to lose control. take off the wheel house before installing the
tire chain.
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320
Replace wheel
Chapter 7-3
When to replace the wheel ground and the space between the tire or Notes for aluminum alloy wheel Daily Maintenance
tire chain and the vehicle body and chassis.
If there are damages like twist, crazing or Don’t use old wheels for replacement, because ● The car installed with aluminum wheels,
severe corrosion in the wheel, it is necessary these wheels may be treated or serve a long after the initial 2,000km, it is necessary to
Electrical components
to make a replacement. mileage, and may go wrong without any warning. check whether the nut is screwed.
Meanwhile, the twisted wheels having undergone Check the battery…………………………………………………………………128
If don’t replace the damaged wheel, then alignment always have structural damages, so ● In case of the exchange, repair or
the tire may separate from the wheel or it don’t use them either. Don’t use the inner tube replacement of tires, check whether the nut
Check and replace fuse …………………………………………………………129
will make the car lose control. specially designed for tires without inner tube is screwed after driving for 2,000km.
inside a flat tire.
Selection of wheel ● When using the tire chain, be careful not
to damage the aluminum alloy wheel.
Warning
In case of replacing the wheel, be sure to
use a wheel of the same specification Since wheels of different sizes will cause ● Only use the wheel nut and wrench
and model with the replaced one. typical operation danger which in turn specially designed for aluminum wheel.
makes the car lose control, therefore, do
The service station of LIFAN can carry out not use any wheel with a size not ●When using the tire chain to adjust the wheel
correct wheel replacement. recommended by the manufacturer. balance, only use balancer or tools equal to it
Otherwise, accident will occur. and plastic hammer or rubber hammer.
Wheels of different sizes or types will bring
about bad effect to the control, service life ● Like all vehicles, it is necessary to check
of wheel and bearing, cooling of brake, whether there is damage of aluminum wheels
calibration of the speedometer/odometer, timely. If damages are found, it is necessary
brake performance, Headlamp aiming, to replace it for a new one immediately.
height of bumper, car height above the
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Owner’s Manual LIFAN
320 Check and replace fuse
Owner’s Manual LIFAN
320
Check the battery Check the external part of battery
Notes
If the Headlamp or other electrical Find out which fuse is in trouble. The circuit name for
Warning Note components don’t work, it is necessary each fuse is identified on the cover of the fuse box.
to check the fuse. If the fuse has been See Chapter 8 for the control function of each circuit.
Notes of battery: ● Before carrying out the maintenance, it
blown, replace it for a new one.
Overcharge of battery will produce is necessary to make sure that the engine Pull out type A fuse with a picker.
flammable and volatile oxygen and and all auxiliary equipment have been Shut down the ignition switch and
hydrogen. shut down. If it is impossible to confirm whether the fuse
corresponding components, and
● To check the battery, it is necessary to has been burned or not, replace the fuses
● When using tools around battery, vertically pull out the possible blown
possible in trouble
sparks are to be prevented. take off the ground cable connected to fuse for check.
Good Blow out
● Don’t light a cigarette or fire around the negative terminal (“一 ” marking) Install new fuse for the jacket if the old fuse has
battery. first and install it last. been burned.
● Don’t let children approach to ● Be careful, do not cause short circuit Type A
Install the fuse with the amperage specified on
battery. when using tools.
the cover of the fuse box.
● To clean the battery, be careful not to
Check whether there is any corrosion or let the washing liquid enter the battery If the specified fuse is not available, the fuse with
loose joint, crazing or loose hold-down case. relatively low amperage should be adopted.
of battery.
However, the fuse with lower amperage than the
a. If the battery joint has been corroded, it is specified amperage may be burned again, which
necessary to clean it with the mixture of is not an essential problem. Renew correct fuse
warm water and saleratus. Lubricate the as soon as possible, and place the temporary
Good Blow out
outside of joint with grease to prevent fuse back to the original jacket.
further corrosion.
b. If the connection of joints is loosened, Prepare a set of spare fuse in your car for
screw the nut. emergent application.
Type B
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Chapter 8
The electrical system may have trouble if Maintenance specification
the renewed fuse is burned immediately.
Then, go to the repair station of LIFAN for
maintenance.
Maintenance specification………………………………………………………132
Warning
Using the fuse with overhigh amperage
or making any other subject as the fuse
is forbidden. Otherwise, serious damage
or fire may occur.
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Maintenance Specification
Owner’s Manual LIFAN
320
Type and Amount for Fluid Filled
Oil level
S/N Item Amount Specification & Type API SG level or above
Amount 3.2L
Recommended viscosity
Brak fluid (without ABS) 0.5L
1 DOT4
Brak fluid (ABS) 0.6L
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LIFAN320 Service manual
Foreword
LF7132 Service Manual on common treatment of troubles is to help you correctly use and
maintain your beloved sedan.
This manual, with illustrative figures and easy-going words, thoroughly introduces the
structure features, use and maintenance of LF320 sedan, which will be a good guide for wide
users and maintenance technicians. Meanwhile, LF7132 Spare Parts List will also be referred
if necessary. For any questions and doubts, please do not hesitate to contact the service
stations of Chongqing Lifan Passenger Vehicle Co., Ltd.
The figures, notes, specifications etc. contained in this manual will take effect as of the date
of printing, which can be modified and terminated at any moment by Chongqing Lifan
Passenger Vehicle Co., Ltd. without any notice in advance.
Any comment on anything improper in the manual shall be preferred, and no responsibility on
anything improper shall be undertaken by Chongqing Lifan Passenger Vehicle Co., Ltd.
Without a permit from Chongqing Lifan Passenger Vehicle Co., Ltd., any unit or individual
shall not be allowed to duplicate, store, or distribute any part of the manual in any form or by
any method.
Great appreciation for your support!
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LIFAN320 Service manual
Contents
1
Part I Introduction
Chapter I Vehicle Overview 2
22
Part II Engine Maintenance
Chapter I Mechanical Part 23
246
Part III Chassis Maintenance
Chapter I Suspension 247
Section II Common Problems and Recovery of Axle, Wheel and Tire 262
339
Part IV Electrical System Maintenance
Chapter I Electrical System 340
416
Part V Transmission Maintenance
430
Part VI Vehicle Body Service
Chapter I Vehicle Body 431
Part I Introduction
Chapter I Vehicle Overview
With the advantages of good power nature, commodious internal space and comfortable ride, LF320 sedans
reflect the people-oriented design tenet. Compared with domestic similar vehicles, LF320 sedans have the
advantages of complete vehicle technology and performance leader. It has strong market competitiveness
for its comfortable ride and favorable price.
I. Shape: a new fashion design, smooth appearance, and low air resistance coefficient.
Body: it has a bearing-type body which has passed the frontal crash test and the inspection by state test
institutions.
IV. Chassis
1. The front suspension adopts a Mcpherson independent suspension with a horizontal stabilizer bar, and
the rear suspension adopts a Mcpherson independent suspension with a horizontal stabilizer bar and a
single longitudinal arm.
2. The steering gear adopts hydraulic power gears and racks
3. The front brake is a ventilation disc brake, and the rear brake is a drum brake with proportional valve,
matching ABS and EBD. The brake pedal is of hanging type. The load distribution condition makes
reasonable distribution of front and rear brake force. The parking brake is a mechanical cable drum brake.
4. It adopts 165/70R14 meridian tires, and the wheel rim is 14×5J.
V. Electrical system
The electrical system is designed according to the highest configuration of Lifan, and includes all the
electrical optional parts to cater for the diversified needs of different users, and achieve the control function
of the whole electrical equipment.
Classification of automotive electrical system
1. electronic fan
The electronic fan adopts single-stage and single-fan style.
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2. Power supply start and charge system
The power supply start system mainly includes starter, battery, generator, voltage regulator and so on.
3. Ignition electronic injection system
The electronic injection system uses the multi-point electronic injection system of Sunshine-Tek Company,
and is demarcated by the company. This type has the following components:
Sensor: Intake pressure temperature sensor, throttle position sensor, speed sensor, knock sensor, oxygen
sensor, crankshaft position sensor and water temperature sensor;
Control module: ECU;
Actuator: electric fuel pump, fuel injector, ignition coil and CanCV Canister Control Valve;
Ignition coil: double coil, non-distributor;
Ignition switch: it adopts four-gear combination switch, cooperating with the vehicle door and luggage boot
cover lock.
4. Illumination signal system
Signal system sends the signal of warning and indication to the surrounding environment, mainly including
horns, steering light signal, emergency light switch, reversing and brake light switch, as well as front and
rear fog lights.
5. Instrument system
Instrument cluster includes: engine tachometer, speedometer, fuel gauge and indicator.
Indicators include battery charging indicator, oil pressure indicator, engine fault test indicator, hand brake
indicator, anti-theft indicator, brake shoe abrasion indicator, safety belt indicator, fuel warning indicator,
high bean indicator, steering (emergency) indicator, ABS indicator, door ajar indicator, rear fog light
indicator, and SVS indicator.
Sensors and switches: fuel capacity sensor, oil pressure sensor, speed sensor, hand brake sensor, brake shoe
sensor, safety belt switch, brake fluid level sensor.
6. Auxiliary electrical system
(1) Front and rear windshield wiper system: it is controlled by the combination switch handle, with the
front wiper motor and linkage arranged in the front board panel.
(2) CDMD-X and CD (optional) machine: it is equipped with two speakers and tweeters with regulatory
function. With 4 speakers (installed in the front doors and the retaining plate of column C), the CD is
installed on the instrument board; also it has the functions of radio, disc player and time display. Both
CDMD-X and CD machine have USB interface and accept external player devices.
(3) A cigarette lighter.
(4) Rear windshield defrosting: resistance wire heating style, controlled by switch.
(5) Electric window regulator (optional): four-door layout, and the master control beside the driver and
independent control of right door and window, also the operating switches installed on the handle of the
door.
(6) Central door locks (optional): four-door installed and unified switches, with the remote control function,
mature products to be chosen according to the body structure and shape. The control box is in the central
channel.
(7) Air conditioning system: Otter-86 compressor, with the greatest cooling capacity of 3956Kcal/h. It is
made up of condenser, evaporator, thermostat, sensor, pressure switch, blower and so on. It enjoys good
cooling effect.
7. Safety control system
(1) Air bag (optional);
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LIFAN320 Service manual
Double air bags are arranged on the steering wheel and the dashboard next to the co-driver.
(2) ABS system;
Anti-lock Brake System is called ABS for short. It is a safety device, with the function of preventing
wheels slipping when braking to improve the direction stability, steering control ability and shorten the
braking distance to make braking more safe and effective. And it greatly improves the safety and reliability
on different roads.
(3) Anti-theft system (optional):
The anti-theft system is made up of anti-theft ECU, anti-theft antenna (outside the ignition switch), and
anti-theft chip (installed on the handle of the ignition key). There is a communication wire between
anti-theft ECU and engine ECU. When the ignition key is installed, the antenna will pass the signal of the
ignition key to the anti-theft ECU. If the signal is right, the ignition system will work, or the engine should
not start.
8. Other electrical items
Other electrical items mainly include harness, the central control box, relay, safety gaskets, connectors,
switches, corresponding fixed parts and packs. The use meets the requirements of standard QC/T420-1999
with the function of blown fuse indicator.
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I. Basic parameters
Model LF7132
Two compartments, five seats, four
Basic model doors, one cover, and one rear luggage
boot door
Horizontal engine and front wheel
Drive model
drive
Length mm 3745
Appearance
Width mm 1620
size
High (non-loaded) mm 1430
Wheelbase (non-loaded) mm 2340
Wheelbase (full loaded) mm 2345
Front tread (non-loaded) mm 1385
Tread
Rear tread (non-loaded) mm 1365
Front suspension mm 790
Rear suspension mm 615
Approach angle (°) 20
Passability Departure angle (°) 23
parameters Minimum ground clearance mm 135
Minimum turning radius m ≤4.76
Luggage boot cubage L 300
Oil tank cubage L 37
Whole quality kg 900
Shaft load distribution (front/rear) kg 565/335
Fully loaded quality kg 1250
Quality
Shaft load distribution (front/rear) kg 710/540
parameters
Fully loaded shaft load ratio
% 52.6/47.4
(front/rear)
Centroid height (empty/full) mm 558.2/573.9
Maximum speed km/h 155
Acceleration performance (0-100
s 14.5
Performance km/h)
parameters Fuel consumption under constant
L/100km 4.8
velocity driving (90 km/h)
Maximum gradability (%) ≥30
Passengers Person 5
Structure
parameter
Model LF7132
Assembly
Exhaust system One three-way catalytic converter and two mufflers
Intake system Intake manifold, air cleaner
Including fuel pump, fuel filter, pressure regulator and accelerator
Fuel supply system
pedal
Cooling system Pipe radiator, electronic fan
Clutch
Monolithic, dry-type, diaphragm spring
Maximum clutch pedal play 116 mm~130mm
Clutch pedal force Clutch pedal force should be less than 300N ruled by GB7258
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ABS
Driving brake Front wheels with disc brake, rear wheels with drum brake
Assembly
Bearing body, two compartments, five seats, four doors, one
Body model
cover, and one rear luggage boot door
All-metal closed structure, hidden A column, undercurrent
White body
launder
Overall frame, 4 doors opened in the same direction, buckle
Body
Door assembly
door locks, anti-collision door beam
Engine hood Open backwards, curved-arm hinge
Cubage about 300 liters, leaf-joined hinge with pneumatic
Luggage boot and hood
support
Front and rear bumpers Injection molded parts
Inner trim Intenerated structure
Intenerated structure, injection molded structure with exterior
Dash board
veins
A, B, C pillar and inner-door shield Injection molded structure with exterior veins
5. Lubricants, fuel, steering fluid, brake fluid, cooling fluid, A/C refrigerant and capability
Structure
parameter
LF7132
Model
System
Circuit Mongline, negative pole earthing, direct current 12V
Power supply, start and
12V/80A
Starter Magnetic operation (in engine), power 1kW
Front-rear fog lights and reversing lights Rear fog light/reversing light (21W, red/white, I), switch
on the dashboard
Steering light (21W, amber, 2, combination switch)
Rear combination lamps Brake lamp (21W, red, 2, closing contact switch)
Rear position light (5w, white, 2)
(Continued)
Structure
parameter
LF7132
Model
System
Auxiliary electric
(1) Lubricant
(2) Fuel
Engine model
LF479Q3
Performance index
Fuel type 93# or higher number vehicle-used unleaded gasoline
Fuel tank capability s(L) 37
(3) Steering fluid, brake fluid, cooling fluid, and A/C refrigerant.
(Continued 1)
Checking and
Items Order Measures Notice
maintenance content
Check the oil before the If the oil level ★Do not inject oil higher than
engine starts or stops for line is lower the high level line, because it
Engine at least 5 minutes. or a little may bring bad effect to the
Engine oil
compartment higher than engine.
After pulling out the oil the low oil ★Do not put impurity into
dipstick, rub it clean and level, inject engine from the oil filler, or it
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LIFAN320 Service manual
put it to the end and then oil of the may bring bad effect to engine
pull it out. Check same model and damage the engine.
whether the high oil into the ★Do not let oil leak, because
level line and the low engine. it may cause the oil burning
level line is stained with when the temperature of the
oil. engine is high. Rub it
completely in case of leakage.
★Except changing coolant and
renewing coolant when the
engine is too hot; please do not
open the cap of the radiator.
★Don’t let coolant level line
higher than F (upper limit) of
expansion tank. It will bring
After the coolant is bad effect to the engine if the
cooled, check the coolant is not between F and L.
When coolant
coolant quantity of the If the fluid level is lower than
is lacking,
radiator and expansion L, please refill coolant after
renew it with
tank. checking whether the cooling
Coolant antifreeze
Check whether the system is leaking.
quantity G11 to the
coolant measure is ★Please do not refill water, or
upper limit of
between the F(upper the melting point of the coolant
expansion
limit) and L(lower limit) will rise, and the anti-rust
tank.
beside the expansion ability will fall. It will make
tank the coolant ice up and rust
easily.
★Do not make the coolant
leakage in the engine
compartment, or it will damage
the accessories and paint. Even
the hot engine compartment
would be on fire.
(Continued 2)
Checking and maintenance
Items Order Measures Notice
content
★Do not use suds
If all the cleaners can’t
instead of cleaning
work, the cleaner tank may
Add cleaning solution, or the paint
be empty. Please check the
Engine Cleaning solution in case will be damaged.
cleaning solution level on
compartment solution of insufficient ★Don’t only add
the liquidometer. Fill
amount. water, or it will ice up
cleaning solution in case of
in winter; the cleaning
level lower than LOW.
solution can’t erupt.
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LIFAN320 Service manual
.
(Continued 3)
Checking and maintenance
Items Order Measures Notice
content
If the wearing
limit sign
emerges, please
change the tire.
Check whether the wearing If the tire is ★If the wearing limit
limit sign of the contact wearing sign emerges, please
Tire groove
condition between tire and extremely or change the tire. The
face is
Around the ground the wearing use of tire over
wearing
vehicle emerges; check whether condition is wearing limit sign may
deeply and
there is wearing part of the very different cause accidents such
abnormally.
contact part between tire from other tires, as skid.
and ground. you can
consider the air
pressure is too
low, or the tire
top is incorrect,
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LIFAN320 Service manual
so please
contact the
repair service
center of
LIFAN.
Please clean the
lamps when
they are
Damage to smudgy. Please
Check whether the
light contact the
lampshades are stained or
equipments repair service
broken. Check if all lamps
and signal center of
are installed stably by hand.
indicators LIFAN when
they are broken,
cracking or not
installed stably.
(Continued 4)
Checking and
Items Order Measures Notice
maintenance content
If the times of
Pull up the parking brake ratting sound
Parking handle by hand; check are more than
Sitting on the
brake the times of ratting ruled times,
driver seat
operation sound from the ratchet please carry
wheel. out
adjustment.
Check whether there is
abnormal sound or the
When engine
engine working
starts up, such
condition is good when
condition will
Engine starting;
cause damage
working
to engine and
condition In addition, check
even hidden
and whether there is
troubles.
abnormal abnormal sound of
Please contact
sound engine working
the repair
condition, when at idle
service center
speed condition or the
of LIFAN.
rotation speed is added a
little.
Brake pedal Start the engine, and step ★Brake fluid leakage, and
stepping on the pedal to the interfused with air will cause
condition bottom to check whether worsening braking effect.
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LIFAN320 Service manual
the distance between the Please contact the repair
pedal and bottom is service center of LIFAN
small, and whether the instead of self-check in case of
feeling of stepping on the below conditions.
the pedal is normal.
★Check the condition of pedal
sinking when stepping on the
pedal continuously. It feels
softened when the pedal is
trampled to the end.
(Continued 5)
Checking and
Items Order Measures Notice
maintenance content
Do change the
wiper rubber
Put the ignition switch to
and clean the
“on”. Start the cleaner,
windshield
and check after wetting
when the
Wiper the windshield.
wiping
condition Start the wiper; check if
condition is
the wiping condition is
not good.
normal at low speed,
Please contact
high speed, and
the repair
intermission.
service center
of LIFAN.
Headlight: Visually
check whether it can be
Sitting on the illuminated or the
driver seat luminance is insufficient
under the condition of
headlight on.
Please contact
Work Steering light: turn on
the repair
condition of the left and right steering When the bulbs are
service center
lighting light control lever, and open-circuited, the glittering
of LIFAN, if
system and check whether all the speed would be faster.
they are not
steering steering lights glitter.
on or
light Brake lamp: step on the
glittering.
brake pedal lightly and
repeatedly, and check
whether the brake light
is on.
Other lamps: check the
working condition of the
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LIFAN320 Service manual
taillight, hazard warning
light and reversing light.
(Continued 6)
Checking and
Items Order Measures Notice
maintenance content
Pay attention to the traffic
Please contact the
condition around, please check
When driving normally, repair service
in a safe place, especially brake
Braking check whether the brake center of LIFAN,
In driving checking; please ensure
effect is effective, or there is if the braking
whether there are vehicles
one-side brake. effect is not good.
around.
If you continue
driving when the
low speed and
speedup condition
is not good, it will
During normal driving,
cause accidents
when stopping for the
Low like engine
traffic signal, please Pay attention to the traffic
speed and wearing, drive
check whether the condition around, and please
speedup uncontrolled, and
engine stops, and check check in a safe place.
condition worsening braking
whether you can speed
of engine effect. It is very
up placidly with
dangerous, so
stepping on the pedal.
please refer to
repair service
center of LIFAN
as soon as
possible.
Please refer to the
repair service
Check the
Ensure whether there are center of LIFAN
abnormal
problems in the as soon as
part last
abnormal parts last day. possible, if there
day.
is continuous
abnormality.
Replacing the
1.1 engine oil & R R R R R R R R R R R R
the oil filter
Replacing the
1.2 R R R R R
fuel filter
Replacing the
1.3 power steering R R
fluid
Replacing the
1.4 It should be replaced every 40,000 km or 2 years
brake fluid
Replacing the
1.5 It should be replaced every 40,000 km or 2 years
coolant
Replacing the
transmission
1.6 R It should be replaced every 40,000 km or 2 years
oil (MT)& rear
axle gear oil
Fluid Level
Add As The Case May Be
Check
Inspecting the
fluid level &
add (including
brake fluid,
1.7 I I I I I I I I I I I I
coolant, glass
cleaning fluid
etc.) to the
proper level.
Inspecting &
Adjust As Necessary
Adjustment
Inspecting the
lighting system
1.8 I I I I I I I I I I I I
of the whole
vehicle
Inspecting the
clutch pedal &
1.9 its position as I I I I I I I I I I I I
well as the
parking brake
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LIFAN320 Service manual
Odometer Readings Or Months, Whichever Is First
13,000k 18,000k 23,000k 28,000k 33 ,000k 38 ,000k 43 ,000k 48,000 53,000k 58,000k
Maintenance 3,000km 8,000km
NO. m m m m m m m km m m
Item
15Month 21Month 27Month 33Month 39Month 45Month 51Month 57 63Month 69Month
3Months 9Months
s s s s s s s Months s s
handle position
Inspecting the
1.10 I I I I I I I I I I I I
ABS system
Inspecting the
parking brake
1.13 mechanism I I I I I I I I I I I I
working
performance
Inspecting the
brake system
1.14 I I I I I I I I I I I I
working
performance
Inspecting the
steering system
1.15 I I I I I I I I I I I I
working
performance
Inspecting the
A/C & HVAC
1.06 I I I I I I I I I I I I
working
condition
Cleaning throttle
1.17 & injection C C C C C
nozzle
Inspecting the
engine timing
1.18 I I I I I I
chain
(VVT-engine)
13,000k 18,000k 23,000k 28,000k 33 ,000k 38 ,000k 43 ,000k 48,000 53,000k 58,000k
Maintenance 3,000km 8,000km
NO. m m m m m m m km m m
Item
15Month 21Month 27Month 33Month 39Month 45Month 51Month 57 63Month 69Month
3Months 9Months
s s s s s s s Months s s
exhaust
emission
condition
Inspecting &
Replace As Necessary
Replacement
Inspecting the
glass cleaning
1.20 system & I I I I I I I I I I I I
windshield
wiper system
Inspecting or
replacing the
1.21 I It should be replaced every 40,000 km or 2 years
high-tension
cable
Replacing the
drive belt
1.22 (generator, It should be replaced every 80,000 km or 2 years
A/C
compressor)
Inspecting or I I I I I I
replacing the
1.23
engine timing It should be replaced every 60,000 km or 3 years
belt
Replacing the
three-way
1.24 It should be replaced every 80,000 km
catalytic
converter
Cleaning or
1.25 replacing the C C R C R C R C R C R C
air filter
Cleaning or
replacing the
interior
1.26 C C R C R C R C R C R C
ventilation
system air
filter
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Odometer Readings Or Months, Whichever Is First
13,000k 18,000k 23,000k 28,000k 33 ,000k 38 ,000k 43 ,000k 48,000 53,000k 58,000k
Maintenance 3,000km 8,000km
NO. m m m m m m m km m m
Item
15Month 21Month 27Month 33Month 39Month 45Month 51Month 57 63Month 69Month
3Months 9Months
s s s s s s s Months s s
Inspecting if
1.27 there is oil I I I I I I I I I I I I
leakage
Inspecting the
1.28 radio, CD or I I I I I I I I I I I I
DVD
Inspecting the
instrument
1.29 I I I I I I I I I I I I
cluster &
speaker
Inspecting or
1.30 replacing the I I I R I I I R I I I R
spark plug
Inspecting the
1.31 suspension I I I I I I I I I I I I
system
Inspecting the
brake system
condition
(including pipe
line leakage,
mechanism
performance,
1.32 I I I I I I I I I I I I
friction
condition of
brake pads or
brake shoes),
dust boot &n
rubber boot
condition
Inspecting the
dust boot & the
rubber boot
1.33 I I I I I I I I I I I I
condition
(leakage &
damage) of the
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Odometer Readings Or Months, Whichever Is First
13,000k 18,000k 23,000k 28,000k 33 ,000k 38 ,000k 43 ,000k 48,000 53,000k 58,000k
Maintenance 3,000km 8,000km
NO. m m m m m m m km m m
Item
15Month 21Month 27Month 33Month 39Month 45Month 51Month 57 63Month 69Month
3Months 9Months
s s s s s s s Months s s
whole vehicle
Inspecting the
cooling system
1.34 & fuel system I I I I I I I I I I I I
(leakage &
damage)
Inspecting the
related control
units (ECU,
immobilizer
control unit,
A/C control
1.35 I I I I I I I I I I I I
unit, TCU,
EPS,TCU,EPS,
ABS control
unit, etc.)
working
condition
Inspecting the
vehicle body
1.36 (dent, paint off, I I I I I I I I I I I I
discoloration,
etc. )
Inspecting the
lubrication of
1.37 I I I I I I I I I I I I
the lock, hinge,
etc.
Road Test
Part II
Engine Maintenance
Chapter I Mechanical Part
Section I Check and Adjustment of Carbon Monoxide Concentration
Tips: The check can only be used for emission regulation conformity at fixed idle speed.
1. Initial condition:
(a) Engine in normal work temperature.
(b) With air filter.
(c) Ready connection of all piles and houses of pipes and hoses.
(d) All auxiliary facilities in off condition.
(e) Correct connection of all vacuum line.
(f) Ready connection of wire connector of electronic fuel injection (EFI) system.
(g) Correct ignition time setting
(h) Transmission in natural position
(i) Air conditioner in off condition.
(j) Tachometer and carbon monoxide tester with manual alignment
2. Check and adjust carbon monoxide concentration of carbon monoxide of idle speed
Note: Carbon monoxide tester must be applied for idle speed gas mixture adjustment. Must not adjust idle
speed gas mixture without a carbon monoxide tester.
(a) Apply special service tool to connect the two terminals, TE1 and E1 of check connector. Refer to Fig.
2-1.
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Fig. 2-1
(b) Make engine speed to 2,500 rpm for about 3 minutes.
(c) Put tester probe into tailpipe for at least 40cm.
(d) 1 minute is needed for concentration stability before test, and test shall be finished within 3 minutes.
Refer to Fig. 2-2.
Fig. 2-2
Idle speed carbon monoxide concentration: 0.5%.
Failure searching
Table 2-1
Carbon
Phenomenon Cause
monoxide
1. Blockage of air filter
2. Failure of electronic fuel injection (EFI) system
Failure of fuel pressure regulator
Unstable idle speed
Failure of water temperature sensor
High (black smoke in
Failure of intake air temperature pressure sensor
exhaust)
Failure of electronic control unit (ECU)
Failure of fuel injection nozzle
Failure of throttle position sensor
Tips: For insufficient engine power, too much fuel consumption or bad fuel economical efficiency, cylinder
compression pressure shall be tested.
Dismantle high voltage wire at rubber boot cap, do not pull wire. Refer to Fig. 2-3.
Fig. 2-3
Fig. 2-4
(b) Open throttle completely.
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(c) Test compression pressure when starting engine.
Tips: Must apply fully charged battery and make engine speed to over 250 rpm.
(d) Repeat from procedure (a) to (c) for every cylinder
Note: The test must be finished in time as short as possible.
Compression pressure: 1,100Kpa (11.0 kgf/cm2) or higher.
Minimum pressure: 981Kpa (10.0kgf/cm2).
Pressure difference between cylinders: 100Kpa (1.0kgf/cm2) or less.
(e) If one or more cylinders have relatively lower compression pressure, inject little engine to cylinder
through spark plug opening. Repeat from procedure (a) to (c) for cylinders with low compression pressure.
· If engine oil can improve compression pressure, it indicates wear or damage on piston ring and cylinder
wall.
· If compression pressure is still low, it could be the blockage or unsealed closeness of throttle, or gas
leakage at cylinder ring.
Fig. 2-5
(c) Dismantle 2 positive crankcase ventilation (PCV) hoses from cylinder head.
(d) Dismantle 4 retaining nuts, gasket seal, cylinder head and washer.
3. Set No. 1 cylinder as the compression stroke top dead center (TDC)
(a) Turn crankshaft pulley, make the groove of crankshaft pulley aiming at the timing mark of No. 1 timing
belt housing.
(b) Check whether mark “K” of camshaft timing pulley is aiming at the timing mark of bearing cap. If not,
turn crankshaft a circle. Refer to Fig. 2-6.
Fig. 2-6
· Measure the clearance between valve tappet and camshaft by feeler gauge.
· Record valve clearance measuring structure with stipulation disconformity. All the data are used to
specify the filling piece needed in replacement.
Valve clearance (cold):
Intake air: 0.20-0.25mm
Exhaust: 0.25-0.30mm
(b) Turn crankshaft pulley a circle, make groove of crankshaft pulley aim at the timing mark of No. 1
timing belt housing.
(c) Only check valves indicated in the figure, measure valves (refer to method in procedure (a)). Refer to
Fig. 2-8.
Fig. 2-8
5. Intake air
Adjust valve clearance
Fig. 2-9
Tips: Conditions above allow that No. 1 and No. 3 cylinder camshaft nose bits of intake camshaft to press
their valve tappets evenly.
(b) Dismantle 2 bolts and No. 1 bearing cap.
(c) Use 1 service bolt to fix intake camshaft pinions on drive and driven gears. Refer to Fig. 2-10.
Fig. 2-10
(d) Loose and dismantle 8 bearing cap bolts step by step according to order indicated in the figure. Refer to
Fig. 2-11.
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Fig. 2-11
Fig. 2-12
(a) Measure the thickness of filling piece taken off by micrometer screw gauge.
(b) Calculate thickness of new filling piece; make valve clearance within prescribed scope.
Cold clearance value: 0.20-0.25mm
(c) Choose new filling piece with possible thickness close to calculated valve.
Tips: There are filling pieces with 20 kinds of thickness. The size varies from 2.35mm to 3.30mm, with the
level difference of 0.05mm.
Fig. 2-13
Note: As shown in Fig. 2-14, each gear has the timing mark (for TDC), do not use these marks.
Fig. 2-14
(d) Tighten intake camshaft to bearing pivot and make occlusion between gears.
Tips: Above angles allow No. 1 and No. 3 cylinder camshaft nose bits of intake camshaft to press their
valve tappets evenly.
(e) Install 4 bearing caps on their positions.
(f) Coat thin engine oil on F surface of bolt head and thread of bearing cap.
(g) Tighten 8 bearing cap bolts step by step with order indicated in Fig. 2-15.
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Torque: 11N·m
Fig. 2-15
6. Exhaust:
Adjust valve clearance
Fig. 2-16
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(c) Use special service tool (A) to press valve tappet down, and place special service tool (B) between
camshaft and valve tappet. Refer to Fig. 2-17. Dismantle special service tool (A).
Fig. 2-17
Tips:
· Apply service tool (B) in a little angle at the side with mark “9”. The position is shown in Fig. 2-18.
Fig. 2-18
· When special service tool (B) is inserted too deep, it may be blocked by filling piece. To avoid that, it
must be put in at the air intake side in a small angle.
· For the shape of camshaft, it is difficult to make special service tool (B) to reach the rear part of No. 3. It
is better to put filling piece in from the exhaust side.
(d) Use screwdriver and magnetic stick to dismantle filling piece. Refer to Fig. 2-19.
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Fig. 2-19
Fig. 2-20
Tips: There are filling pieces with 20 kinds of thickness. The size vary from 2.35mm to 3.30mm, with the
level difference of 0.05mm.
Fig. 2-21
1. Initial condition
(a) Engine in normal work temperature.
(b) With air filter.
(c) Ready connection of all piles and hoses of pipes and hoses.
(d) Correct connection of all vacuum line.
(e) Electronic fuel injection (Well connection of wire connector of electronic fuel injection (EFI) system).
(f) Turn off all working auxiliary facilities.
(g) Transmission in neutral position.
2. Connect tachometer
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3. Check idle speed
Idle speed (cooling fan off: 800±50rpm.If idle speed is not in conformity with prescribed value, check idle
speed control (ISC) system.
4. Remove tachometer
I. Remove
Fig. 2-23
Fig. 2-24
Fig. 2-25
4. Set No. 1 cylinder as the compression stroke top dead center (TDC)
(a) Turn crankshaft pulley, make the groove of crankshaft pulley aim at the timing mark “O” of No. 1
timing belt housing. Refer to Fig. 2-26.
Fig. 2-26
(b) Check whether mark “K” of camshaft timing pulley is aiming at the timing mark of No. 2 bearing cap.
If not, turn crankshaft a circle (360°).
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Fig. 2-27
Fig. 2-28
(b) Use special service tool to remove belt pulley. Refer to Fig. 2-29.
Fig. 2-29
Fig. 2-30
Fig. 2-31
(a) Loosen install belts of belt tension wheel and push belt pulley towards left as much as possible; then fix
it temporarily.
(b) Remove belt.
Fig. 2-32
Fig. 2-33
Note: Put a piece of cloth as shown in the figure to prevent part damage.
Fig. 2-34
II. Check
Fig. 2-35
Fig. 2-36
Fig. 2-37
Free length: 36.9mm
If free length is not in conformity with prescribed value, replace the tension spring.
(b) Measure the tension power of spring at prescribed installation length
Installation tension power: at length of 43.6mm, tension power is 34-38N.
If installation tension power is not in conformity with prescribed value, replace the tension spring
III. Installation
Fig. 2-38
Tips: There are two types of camshaft timing pulley, with 1 or 2 alignment pins respectively.
(b) Temporarily install bolts of timing belt pulley.
(c) Use wrench to fix the hexagon part of camshaft, and screw down bolts of timing belt pulley.
Torque: 59±2N·m
Fig. 2-39
3. Temporarily install belt tension wheel and tension spring
(a) Use bolt install belt tension wheel, but not tighten it.
(b) Install tension spring.
(c) Push belt pulley to left as much as possible, then screw down bolts tightly. Refer to Fig. 2-40.
Fig. 2-40
4. Set No. 1 cylinder as the compression stroke top dead center (TDC)
(a) Turn the hexagon part of camshaft, and make mark “K” of camshaft timing pulley aim at the timing
mark of bearing cap. Refer to Fig. 2-41.
Fig. 2-41
(b) Turn crankshaft with crankshaft pulley bolt, and make the timing mark of crankshaft timing pulley aim
at oil pump body. Refer to Fig. 2-42.
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Fig. 2-42
5. Install timing belt
Note: Engine in cold condition.
Tips: If use removed timing belt, keep marks made in remove with correct alignment; when installing belt,
arrow shall aim at the running direction of engine. Refer to Fig. 2-43. For timing belt installation, check the
tension power between crankshaft timing pulley and camshaft timing pulley.
Fig. 2-43
6. Check valve timing
(a) Loosen belt tension wheel bolts.
(b) Turn crankshaft for 2 circles slowly, from TDC to TDC. Refer to Fig. 2-44.
Fig. 2-44
Tips: Must turn crankshaft in clockwise direction.
(c) Check whether every belt pulley is aiming at timing mark as shown in the figure. If not, remove timing
belt and install it again. Refer to Fig. 2-45.
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Fig. 2-45
(d) Screw down belt tension wheel bolt.
Torque: 33N·m
(e) Remove the temporarily installed crankshaft pulley bolt.
7. Reference:
Check timing belt flexivity.
Check whether a certain flexivity exists at the position shown in Fig. 2-46.
Fig. 2-46
Belt flexivity:
5-6mm at 20N
If flexivity is not in conformity with prescribed value, adjust belt tension wheel again. Refer to Fig. 2-47.
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Fig. 2-47
8. Install timing belt guide wheel
Install timing belt guide wheel and make outer ring towards outside. Refer to Fig. 2-48.
Fig. 2-48
图2-49
Fig. 2-49
Fig. 2-50
The breakdown drawing of cylinder head parts are shown in Fig. 2-51.
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Fig. 2-51
I. Remove
Fig. 2-52
4. Remove AC-generator
Fig. 2-53
6. Remove outlet pipe. Remove 2 bolts and outlet pipe as shown in Fig. 2-54.
Fig. 2-54
Fig. 2-55
Remove 7 bolts, 2 nuts, earth wire blade, intake manifold and washer.
Fig. 2-56
(a) Remove 2 nuts fixing intake pipe of water pump on cylinder head.
(b) Disconnect intake hose and water pump; remove intake pipe of water pump and the washer.
Fig. 2-57
Fig. 2-58
(b) Remove rubber seal ring from No.1 timing belt housing. Refer to Fig. 2-59.
Fig. 2-59
(c) Loosen fix bolts of belt tension wheel and push to left as much as possible, then fix it temporarily.
(d) Remove belt from camshaft timing belt.
Note:
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Support timing belt, make crankshaft timing pulley match with timing belt and do not move.
Be cautious and keep anything from falling into No. 1 timing belt housing.
Do not make belt contact with oil, water or dust.
Fig. 2-60
25. Remove camshaft timing belt wheel
Use wrench to fix hexagon part of the camshaft and remove bolts and timing belt wheel. Refer to Fig. 2-61.
Fig. 2-61
Note: Be carefully and do not damage cylinder head with wrench.
Fig. 2-62
Tips: For above situations, No.1 and No.3 cylinder camshaft nose bits are allowed to press their valve
tappets evenly.(b) Remove 2 bolts and No.1 bearing cap. Refer to Fig. 2-63.
Fig. 2-63
(c) Use a service bolt to make the auxiliary gear of intake camshaft back against the drive gear. Refer to Fig.
2-64.
Fig. 2-64
Fig. 2-65
(e) Remove 4 bearing caps and intake camshaft. Refer to Fig. 2-66.
Fig. 2-66
Tips: If camshaft is not lifted levelly in straight direction, use 2 bolts to reinstall bearing cap. Then lift
camshaft gear and alternately loosen and remove bearing cap bolts.
Note: Do not use tool or other things to move or try to take camshaft off by great force.
Fig. 2-67
Tips: For above angle, No. 1 and No. 3 cylinder camshaft nose bits of intake camshaft to press their valve
tappets evenly.
(b) Remove 2 bolts, No.1 bearing cap and oil seal. Refer to Fig. 2-68.
Fig. 2-68
Note: If No.1 bearing cap can not be removed by hand, do not remove by force, but leave it there without
bolt.
(c) According to order indicated in Fig. 2-69, evenly loosen and remove 8 bearing cap bolts in several
times.
Fig. 2-69
(d) Remove 4 bearing caps and exhaust camshafts. Refer to Fig. 2-70.
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Fig. 2-70
Tips: If camshaft is not lifted at level and in straight direction, use 2 bolts to reinstall No. 3 bearing cap.
Then loosen and remove 2 bearing cap bolts when lifting camshaft gear.
Note: Do not use tool or other things to move or try to remove camshaft by force.
Fig. 2-71
(c) Take snap ring off by snap ring plier. Refer to Fig. 2-72.
Fig. 2-72
Fig. 2-73
Note: Incorrect order of bolt removing can cause twisting or fracture of cylinder head.
(b) Remove 10 plate washers.
(c) Lift cylinder head from the cylinder alignment pin; put cylinder head on the wood block of the
workbench.
Tips: If cylinder head is hard to lift, a screwdriver can be applied to prize between cylinder head and
cylinder lug boss.
Note: Please be careful. Do not damage the contact surface between cylinder head and cylinder body.
II. Remove
1. Remove valve tappet
Tips: Should place valve tappets in correct order.
2. Remove valve
(a) Use special service tool, compress valve spring and remove 2 alignment lock blades. Refer to Fig. 2-74.
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Fig. 2-74
Fig. 2-75
(d) Use compressed air and magnetic stick to blow removed spring seat. Refer to Fig. 2-76.
Fig. 2-76
Tips: Place valve, valve spring, spring seat and spring pedestal in correct order.
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III. Check
1. Clean piston top and cylinder body
(a) Turn crankshaft and make each piston rise to top dead center (TDC). Use bushing scraper to clear all
carbon deposit on piston top. Refer to Fig. 2-77.
Fig. 2-77
(b) Use bushing scraper to eliminate all bushing materials on cylinder surface.
(c) Use compressed air to blow carbon deposit and engine oil in bolt hole. Refer to Fig. 2-78.
Fig. 2-78
Caution: Please protect your eyes when using high pressure compressed air.
Fig. 2-79
Fig. 2-80
Fig. 2-82
Fig. 2-83
Maximum twisting:
Cylinder body side: 0.05mm
Manifold side: 0.10mm
If twisting exceeds maximum twisting value, cylinder head should be replaced.
Fig. 2-84
4. Clean valve
(a) Use bushing scraper to clean carbon deposit on valve end.
(b) Use wire brush to clean valve thoroughly. Refer to Fig. 2-85.
Fig. 2-85
Fig. 2-86
Bushing inside diameter: 6.010-6.030mm
(b) Use micrometer screw gauge to measure diameter of valve tappet. Refer to Fig. 2-87.
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Fig. 2-87
Fig. 2-88
(a) Grind valve until pockmarks and carbon deposit are all eliminated.
(b) Check whether valve grinding is with correct face angle.
Fig. 2-89
Fig. 2-90
Fig. 2-91
Fig. 2-92
Fig. 2-93
Fig. 2-94
2) If pedestal is too close to valve surface, modify pedestal with 60° and 45° cutting tools. Refer to Fig.
2-95.
Fig. 2-95
(d) Use grinding material to grind valve and valve pedestal by hand.
(e) After hand grinding, clear valve and valve pedestal.
Fig. 2-96
If the deviation is more than maximum value, valve spring should be replaced.
(b) Use vernier caliper to the free length of valve spring. Free length: 38.57mm. Refer to Fig. 2-98.
Fig. 2-99
If installation stretching force is not in conformity with prescribed value, valve spring should be replaced.
Fig. 2-100
Fig. 2-101
Standard camshaft nose bit height:
Intake: 41.76±0.05mm
Exhaust: 42.01±0.05mm
If camshaft nose bit height is not in conformity with prescribed valve, camshaft should be replaced.
Fig. 2-103
Fig. 2-104
Fig. 2-105
Fig. 2-106
Torque: 11N·m
Note: Do not turn camshaft.
Fig. 2-108
Fig. 2-110
Fig. 2-111
Fig. 2-112
Maximum twisting
Intake manifold: 0.20mm
Exhaust manifold: 0.30mm
If twisting value exceeds maximum value, manifold should be replaced.
Fig. 2-113
IV. Replace
Fig. 2-114
(b) Use special service tool and hummer to knock out guide bushing slightly. Refer to Fig. 2-115.
Fig. 2-115
(c) Use caliper gauge to measure cylinder head bushing internal diameter. Refer to Fig. 2-116.
Fig. 2-116
Standard valve guide pore diameter (cold):
11.000-11.027mm
(d) Select new guide bushing (standard value or with enlarged size of 0.05)
If cylinder head bushing internal diameter exceeds 11.027mm, process bushing internal diameter to
following size:
11.050-11.077mm
If bushing internal diameter of cylinder head exceeds 11.077mm, cylinder head should be replaced.
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(e) Gradually heat cylinder head to 80-100℃.
(f) Use special service tool and hummer to knock new guide bushing until it stretches 12.7-13.1mm out of
cylinder head. Refer to Fig. 2-118.
Fib. 2-118
(g) Use sharp 6mm reamer to cut guide bushing to make the clearance between guiding bushing and valve
tappet meet the prescribed clearance value (please refer above step c). Refer to Fig. 2-119.
Fig. 2-119
2. Replace cylinder head oil seal
(a) Upwards bend little tongue piece of wind screen; the little tongue piece is to prevent oil seal sliding.
(c) Use special service tool and hummer to knock new oil seal as shown in Fig. 2-121.
Fig. 2-121
V. Reassembly
Tips:
Clean and wash all parts thoroughly; all the parts are prepared for installation.
Before part installation, coat new engine oil on all sliding and turning surfaces.
Replace all washers and oil seals with new ones.
Fig. 2-122
Fig. 2-123
(c) Use punch to press in new spark plug pipe until it stretches 46.8-47.6mm out of installation platform of
cylinder head camshaft bearing cap. Refer to Fig. 2-124.
Fig. 2-124
Note: Measure stretching length when pressing to avoid too much stretching length of new spark plug pipe.
2. Install valve
(a) Use special service tool to press in new valve oil seal. Refer to 2-125.
Fig. 2-125
Note: Intake valve oil seal is gray while exhaust valve oil seal is black. Refer to Fig. 2-126.
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Fig. 2-126
(b) Install following parts. Refer to Fig. 2-127.
Fig. 2-127
1) Valve
2) Spring pedestal
3) Valve spring
4) Spring seat
(c) Use special service tool to compress valve spring, place 2 lock blades around valve tappet. Refer to Fig.
2-128.
Fig. 2-128
(d) Use plastics-coated hummer to knock the valve rod top slightly to make sure the perfect matching.
Refer to Fig. 2-129.
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Fig. 2-129
Fig. 2-130
Fig. 2-131
Fig. 2-132
Fig. 2-133
1) Camshaft gear snap spring
2) Camshaft auxiliary gear
3) Wave washer
Note: Make pin on gear aim at the end of gear snap spring.
(c) Use snap ring plier to install snap ring. Refer to Fig. 2-134.
Fig. 2-134
(d) Use special service tool to turn camshaft auxiliary gear in clockwise direction, make camshaft drive
gear aim at the pore of auxiliary gear and install service bolts. Refer to Fig. 2-135.
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Fig. 2-135
Fig. 2-136
Tips: Above angles make the nose bits of No. 1 and No. 3 cylinders of exhaust camshaft evenly press valve
tappet.
(c) Eliminate all old filling materials.
Fig. 2-137
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Fig. 2-138
Fig. 2-139
Torque: 13N·m
(h) Coat multipurpose grease to new oil seal edge.
(i) Use special service tool to knock oil seal slightly. Refer to Fig. 2-140.
Fig. 2-140
Note:
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· Do not make mistake on edge direction when installing oil seal.
· Put oil seal to the deepest part of cylinder cap.
Fig. 2-141
Fig. 2-142
Note: As shown in the figure, each gear also has timing mark (for TDC). Do not use these marks.
(d) For mutual occlusion of gear, make intake camshaft locate on the bearing journal.
Note: Above angles allow No. 1 and No. 3 cylinder camshaft nose bits of intake camshaft to press their
valve tappets evenly
(e) Install 4 bearing caps at proper positions. Refer to Fig. 2-143.
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Fig. 2-143
(f) A thin layer of engine oil should be coated on thread and under the bearing cap bolt head.
(g) Evenly install and screw down 8 bearing cap bolts in several times with order indicated in Fig. 2-144.
Torque: 11N·m
Fig. 2-144
Fig. 2-145
Note: If No. 1 bearing cap can not match perfectly, use screwdriver to move and separate cylinder head and
camshaft gear; then push camshaft gear backwards.
(j) A thin layer of engine oil should be coated on thread and under the bearing cap bolt head.
(k) Install and alternately screw down 2 bolts in several steps. Torque: 11N·m
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(l) Turn exhaust camshaft in clockwise direction and make alignment pin face upwards. Refer to Fig.
2-146.
Fig. 2-146
(m) Check for the correct alignment of timing mark of camshaft gear.
Tips: Installation mark is at upper part. Refer to Fig. 2-147.
Fig. 2-147
Fig. 2-148
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(b) Temporarily install timing belt pulley bolt.
(c) Use wrench to fix the hexagon head part of camshaft and screw down timing belt pulley bolt.
Torque: 59N·m
Fig. 2-149
Torque: 23N·m
Fig. 2-150
Aim at the match marks of timing belt and camshaft timing pulley.
(a) Clean oil or water of camshaft timing pulley and keep clean.
(b) Install timing belt, check the tension force between crankshaft timing pulley and camshaft timing
pulley.
Fig. 2-151
Fig. 2-152
(d) Screw down belt tension wheel bolt. Torque: 33N·m
(e) Install rubber seal ring for No. 1 timing belt housing.
9. Reference:
Check timing belt flexivity
Check belt fexivity of position shown in Fig. 2-153.
Fig. 2-153
Flexivity: 20N: 5-6mm. If flexivity is not in conformity with prescribed value, readjust belt tension wheel.
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Fig. 2-156
(c) Install semicircular plug on cylinder head.
Fig. 2-157
(c) Install cylinder head gasket seal on cylinder head cover.
(d) Use 4 wave seal ring and lock nut to install cylinder head cover.
Torque: 11N·m
Fig. 2-158
Fig. 2-159
Torque: 11N·m
Fig. 2-160
Torque: 11N·m
Fig. 2-161
Torque: 23N·m
(b) Use 5 bolts to install new washer and exhaust manifold. Evenly screw down nut in several times. Refer
to Fig. 2-162.
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Fig. 2-162
Torque: 33N·m
(c) Use 2 bolts to install manifold support bar and alternately tighten bolts.
Torque: 23N·m
(d) Use 4 bolts to install upper heat shield.
力矩:11N·m
Torque: 11N·m
30. Install water pump belt pulley and AC-generator drive belt
(a) Use 4 bolts to install water pump belt pulley temporarily.
(b) Use adjustment bolt and pivot bolt to install drive belt.
(c) Screw down 4 water pump belt pulley bolts tightly.
I. Disassembly
1. Remove flywheel
Remove 6 bolts and flywheel. Refer to Fig. 2-164.
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Fig. 2-164
Fig. 2-165
Fig. 2-166
7. Remove right engine installation support
Remove 3 bolts and right engine installation support
Fig. 2-167
Fig. 2-168
Fig. 2-169
(b) Remove connecting rod cap nut
(c) Use plastics-coated hummer to knock connecting rod bolt and lift connecting rod cap. Refer to Fig.
2-170.
Fig. 2-170
Tips: Keep lower bearing shell embedded in connecting rod cap.
(d) Use short hose to cover connecting rod bolt to protect crankshaft from damage.
Fig. 2-171
(e) Clean crank pin and bearing shell
(f) Check crank pin and bearing shell for existence of pockmark and scratch. Refer to Fig. 2-172.
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Fig. 2-172
If damage exists for crank pin or bearing shell, bearing shell should be replaced. When necessary, crank pin
can be polished or replaced.
(g) Put a section of plastic oil clearance gauge through crank pin. Refer to Fig. 2-173.
Fig. 2-173
Fig. 2-174
Torque: 60N·m
Note: Do not turn crankshaft.
(i) Remove connecting rod cap.
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(j) Apply plastic oil clearance gauge at the widest part. Refer to Fig. 2-175.
Fig. 2-175
Fig. 2-176
Center wall thickness of standard size bearing shell:
Number “1”:
1.486-1.490mm
Number “2”:
1.490-1.494mm
Number “3”:
1.494-1.498mm
(k) Take out all plastic oil clearance gauges.
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Fig. 2-177
(b) Use short hose to cover connecting rod bolt to protect crankshaft from damage.
(c) Push piston, connecting component and upper bearing shell through cylinder body top.
Tips:
· Place bearing shell, connecting rod and connecting rod cap together.
· Place piston and connecting rod components in correct order.
Fig. 2-178
Fig. 2-179
(b) Use removed main bearing cap bolt to move main bearing cap forward and backward, and remove main
bearing cap, lower main bearing shell and lower thrust washer (only for No. 3 main bearing cap). Refer to
Fig. 2-180.
Fig. 2-180
Tips:
Place lower mian bearing shell and main bearing cap together.
Place main bearing cap and lower thrust washer in correct order.
(c) Take out crankshaft upwards. Refer to Fig. 2-181.
Fig. 2-181
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Tips: Place upper main bearing shell, upper thrust washer and cylinder body together.
(d) Clean all main bearing journal and main bearing shell.
(e) Check all main bearing journal and main bearing shell for existence of pockmark and scratch. If any
damage exists for main bearing journal or main bearing shell, bearing shell should be replaced. When
necessary, crankshaft can be polished or replaced. Refer to Fig. 2-182.
Fig. 2-182
Fig. 2-183
(h) Install main bearing cap. Refer to Fig. 2-184.
Fig. 2-184
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Torque: 78±2N·m
Note: Do not turn crankshaft.
(i) Remove main bearing cap.
(j) Measure plastic oil clearance gauge at the widest part. Refer to Fig. 2-185.
Fig. 2-185
Fig. 2-186
If bearing shell number can not be confirmed, add the numbers on cylinder body and crankshaft. The sum
number that is same to the number of bearing shell should be chosen. Then the correctness of bearing shell
selection can be guaranteed. Standard bearing shell has 5 sizes with relevant number of “1”, “2”, “3”, “4”
and “5”.
Number
Cylinder
1 2 3
body
Crankshaft 0 1 2 0 1 2 0 1 2
Matching
bearing 1 2 3 1 2 3 1 2 3
shell
e.g. No. 3 cylinder body’s number “2” + crankshaft number “1” = sum number “3” (Then apply No. 3
bearing shell)
Reference table of standard bearing shell
‐ Number mm
“1” 52.025‐52.031
Internal diameter of cylinder body main bearing journal “2” 52.032‐52.037
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“3” 52.038‐52.043
“0” 47.993‐48.000
Diameter o crankshaft bearing journal “1” 47.987‐47.994
“2” 47.982‐47.988
“1” 2.002‐2.005
“2” 2.006‐2.008
Center wall thickness of bearing shell of standard type “3” 2.009‐2.011
“4” 2.012‐2.014
“5” 2.015‐2.017
Fig. 2-187
(b) Remove main bearing shell and upper thrust washer from cylinder body.
Tips:
Place main bearing cap, main bearing shell and thrust washer in correct order.
II. Check
Fig. 2-188
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Fig. 2-189
Fig. 2-191
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Use cylinder diameter gauge to measure the diameters of thrust direction and axis direction at 3 positions A,
B and C. Refer to Fig. 2-192.
Fig. 2-192
Standard diameter:
Standard type:
Number “1”
78.700-78.710mm
Number “2”
78.710-78.720mm
Number “3”
78.720-78.730mm
Maximum diameter:
Standard type: 78.93mm
Enlarged size 0.50: 79.43mm
If diameter exceeds maximum value, 4 cylinders should be rebored. When necessary, cylinder body should
be replaced.
Fig. 2-193
6. Check the coordination between connecting rod and piston pin
Try and see whether piston can move forward and backward on piston pin. Refer to Fig. 2-194. If any
movement is felt, the entire set of connecting rod and piston pin should be replaced.
Fig. 2-194
Fig. 2-195
Fig. 2-196
Tips:
Connecting rod, pin and piston form a matched set.
Place piston, pin, ring, connecting rod and bearing in correct order.
9. Clean piston
(a) Use bushing scraper to eliminate carbon deposit on piston top. Refer to Fig. 2-197.
Fig. 2-197
(b) Use ring groove cleaning tool or broken ring to clean piston ring groove. Refer to Fig. 2-198.
Fig. 2-198
(c) Use solvent and brush to clean piston thoroughly. Refer to Fig. 2-199.
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Fig. 2-199
Fig. 2-200
(a) At 44.5mm to piston top, use micrometer screw gauge to measure the piston diameter at right angle to
piston pin centerline. Refer to Fig. 2-201.
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Fig. 2-201
Piston diameter
Standard type:
Number “1”: 78.655-78.665mm
Number “2”: 78.665-78.675mm
Number “3”: 78.675-78.685mm
Enlarged size 0.50 type:
79.175-79.185mm
(b) Measure internal diameter of cylinder hole at thrust direction (refer to page EM.60)
(c) Measured internal diameter of cylinder hole minus measured piston diameter.
Standard oil clearance:
0.035—0.055毫米
0.035-0.055mm
Maximum oil clearance:
0.075毫米
0.075mm
If oil clearance exceeds maximum value, all of 4 pistons should be replaced and be rebored. When
necessary, cylinder body can be replaced.
Tips (when applying new cylinder body): Apply piston with number mark equal to cylinder pore diameter
on cylinder body. Refer to Fig. 2-202.
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Fig. 2-202
Fig. 2-203
Fig. 2-204
(c) Use finger gauge to measure gap clearance. Refer to Fig. 2-205.
Fig. 2-205
Fig. 2-206
Check nonstraightness
Maximum nonstraightness: 0.05mm/100mm. If nonstraightness exceeds maximum value, connecting rod
components should be replaced.
Check torsion resistance as shown in Fig. 2-207.
Fig. 2-207
Maximum torsion resistance: 0.05mm/100mm. If torsion resistance exceeds maximum value, connecting
rod components should be replaced.
Fig. 2-20
(b) If lock nut can not be rotated freely, use vernier caliper to measure the external diameter of connecting
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rod bolt. Refer to Fig. 2-209.
Fig. 2-209
12. Bore
Tips:
Piston external diameter of 4 cylinders enlarged with matching size.
Use pistons enlarged with matching size to replace all piston rings.
A. Keep piston with enlarged size
Piston diameter with enlarged size:
Enlarged size 0.50:
79.115-79.145mm
Fig. 2-210
(b) Calculate rebore amount of each cylinder with following formula: Rebore size=P+C-H
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P= Piston diameter
C= Piston oil clearance: 0.035-0.055mm
H= Honing amount: 0.02mm or less
C. Bore and hone cylinder to calculated size
Maximum honing amount: 0.02mm
Note: Over honing can damage the roundness of finished pieces.
Fig. 2-211
Fig. 2-212
15. Grind and bone main bearing journal and/or connecting rod neck when necessary
Grind and bone main bearing journal and/or connecting rod neck to relatively smaller diameter of finished
piece size (refer to method in step 14). Install bearing shell with new size matching main bearing journal
and/or connecting rod neck.
III. Replacement
Tips: Oil seal replacement has 2 methods (A and B) as indicated in following statement:
1. Replace crankshaft front seal
A. If oil pump has been removed from cylinder body
(a) Use screwdriver to remove oil seal. Refer to Fig. 2-213.
Fig. 2-213
(b) Use special service tool and hummer to knock new oil seal slightly until its surface and oil pump
housing edge are at the same level. Refer to Fig. 2-214.
Fig. 2-214
Fig. 2-215
Note: Be careful, do not damage crankshaft. Use adhesive tape to cover the sharp end of screwdriver.
(c) Coat new oil seal edge with lubricant grease.
(d) Use special service tool and hummer to knock oil seal slightly until its surface and pump housing edge
are at the same level. Refer to Fig. 2-216.
Fig. 2-216
2. Replace crankshaft rear end cap
A. If crankshaft rear end cap has been removed from cylinder body
(a) Use screwdriver and hummer to knock out oil seal slightly. Refer to Fig. 2-217.
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Fig. 2-217
(b) Use special service tool and hummer to knock new oil seal slightly until its surface and rear oil seal
edge are at the same level. Refer to Fig. 2-218.
Fig. 2-218
Fig. 2-219
Note: Be careful, do not damage crankshaft. Use adhesive tape to cover the sharp end of screwdriver.
(c) Coat new oil seal edge with lubricant grease.
(d) Use special service tool and hummer to knock new oil seal until its surface and crankshaft rear end cap
edge are at the same level. Refer to Fig. 2-220.
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Fig. 2-220
IV. Reassembly
Tips:
Clean all parts to be installed thoroughly.
Before part installation, coat new engine oil on all sliding and turning surfaces.
Replace all washers, O rings and oil seals with new ones.
Fig. 2-221
(c) Use special service tool to press in piston pin. Refer to Fig. 2-222.
图2-222
Fig. 2-222
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2. Install piston ring
(a) Install film loop and lined ring by hand.
(b) Use piston ring expander to install 2 compression rings, and make their code mark toward upwards.
Refer to Fig. 2-223.
Fig. 2-223
Code mark (only for 2 compression rings)
(c) Position of placing piston ring should make open end as shown in Fig. 2-224.
Fig. 2-224
Note: Ring openings should not on the same line.
Fig. 2-225
(b) Put bearing shell into connecting rod and connecting rod cap.
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Fig. 2-226
(a) Make projection of main bearing shell aim at the groove of cylinder body; then push 5 upper main
bearing shells in. Refer to Fig. 2-227.
Fig. 2-227
(b) Make projection of main bearing shell aim at the groove of main bearing cap; then push 5 lower main
bearing shells in.
Fig. 2-229
Fig. 2-230
(b) Install 5 main bearing caps to proper position. Refer to Fig. 2-231.
Fig. 2-231
(c) A thin layer of engine oil should be coated on thread and under the main bearing cap bolt head.
(d) Install and evenly screw down 10 main bearing bolts in the order shown in Fig. 2-232.
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Fig. 2-232
Torque: 78±2N·m
(e) Check whether crankshaft can be turned easily.
Fig. 2-233
(b) Use piston ring compressor to push piston and connecting rod group into relevant cylinders and make
front mark of piston toward forward. The piston and connecting rod group should have matching numbers
with cylinders. Refer to Fig. 2-234.
Fig. 2-234
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Fig. 2-235
(b) Install and alternately screw down lock nut in several times. Refer to Fig. 2-236. Torque: 60N·m
Fig. 2-236
If any lock nut can not meet the prescribed torque requirement, the entire set of connecting rod bolts and
lock nuts should be replaced.
(c) Use paint to mark on connecting rod bolts and lock nuts. Refer to Fig. 2-237 and Fig. 2-238.
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Fig. 2-237 Fig. 2-238
(d) Check whether crankshaft can rotate freely.
11. Check connecting rod axial clearance
Fig. 2-239
Torque: 11N·m
13. Install oil pump and oil pan
Fig. 2-240
Torque: 23N·m
15. Install oil pressure switch
(a) Coat the second or third thread of oil pressure switch with adhesive.
(b) Use special service tool to install oil pressure switch.
Fig. 2-241
Torque: 23N·m
Fig. 2-242
Torque: 23N·m
Fig. 2-243
Torque: 78±2.5N·m
Section I Coolant
I. Check
II. Replacement
Fig. 2-244
I. Removal
2. Remove the driving belt of alternator and belt pulley of water pump
Fig. 2-245
Fig. 2-246
(b) Remove the 2 nuts connecting water pump pipe to the cylinder head. See Fig. 2-247.
Fig. 2-247
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(c) Remove 3 bolts, water pump and water pump intake pipe.
(d) Take out the O ring from the cylinder body.
8. Disconnect the water pump and its intake pipe. See Fig. 2-248.
Fig. 2-248
II. Check
III. Removal
Fig. 2-249
2. Remove the belt pulley seat
Press down the shaft of the bearing by a special service tool and a punch, and then dismantle the belt pulley
seat. See Fig. 2-250.
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Fig. 2-250
Fig. 2-251
Fig. 2-252
(d) Take out the seal receptacle.
Note: Do not damage the water pump body.
Fig. 2-253
IV. Reinstallation
Note: During reassembly of water pump, new seal parts, rotors and bearing should be used.
1. Install water pump bearing
(a) Gradually warm the water pump to 85℃.
(b) Press down the bearing outer ring by a special service tool and punch to make the surface flush with
water pump body surface. See Fig. 2-254.
Fig. 2-254
Fig. 2-255
(b) Press the seal part by a special service tool and punch. See Fig. 2-256.
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Fig. 2-256
Fig. 2-257
4. Install rotor
(a) Install new filling and seat into the rotor. See Fig. 2-258.
Fig. 2-258
(b) Smear little silicone fluid on the contact surface of the wheel seat and rotor. See Fig. 2-259.
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Fig. 2-259
(c) Press down the new rotor onto the shaft of water pump bearing by a punch and let it away from the
pump installation surface for 7.8 mm. See Fig. 2-260.
Fig. 2-260
Fig. 2-261
Torque: 11N·m
6. Check if the water pump can rotate smoothly. See Fig. 2-262.
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Fig. 2-262
V. Installation
Fig. 2-263
(c) Temporarily install the water pump and its intake pipe by 3 bolts and 2 nuts. See Fig. 2-264.
Fig, 2-264
(d) Screw down the bolts and nuts. See Fig. 2-265.
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Fig. 2-265
Torque: bolt: 23N·m
Nut: 23N·m
Fig. 2-266
Fig. 2-267
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6. Install cylinder head cover
I. Removal
Note: The removal of thermostat will bring about adverse effects and lower the cooling efficiency. Even
though the engine is too hot, the thermostat should not be removed.
1. Drain the engine coolant
II. Check
Fig. 2-269
(a) Immerge the thermostat into water. Warm the water slowly. See Fig. 2-270.
Fig. 2-270
Fig. 2-271
If the valve lift does not reach the regulation, please replace the thermostat.
(d) When the thermostat is at a lower temperature (less than 40℃), please check if the valve is completely
closed.
If it is not closed, please replace the thermostat.
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III. Installation
Fig. 2-272
(b) Align the bypass valve of thermostat with the top of double-head bolt. Insert the thermostat into the
water inlet housing.
Tips: The bypass valve can be installed within 10 degrees at the two sides of the regulated position. See Fig.
2-273.
Fig. 2-273
I. Inspection on vehicle
1. Check the rotation of cooling fan at low temperature (lower than 83℃)
(a) Turn on the ignition switch (ON). See Fig. 2-274.
Fig. 2-274
(b) Connect the battery, ammeter and cooling fan connector. See Fig. 2-276.
Fig. 2-276
(c) Check if the cooling fan rotates smoothly and check the reading of ammeter.
Standard current intensity: 5.7-7.7A
(d) Reconnect the cooling fan connector.
II. Removal
Fig. 2-277
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2. Removal fan motor
Disconnect the wire from the cooling cover and remove 3 bolts and fan motor. See Fig. 2-278.
Fig. 2-278
III. Reassembly
1. Install fan motor
(a) Install fan motor with 3 bolts. See Fig. 2-278. Torque: 26N·m.
(b) Connect the wire to fan cover. See Fig. 2-277.
2. Install fan
Install fan by nuts. Torque: 6.2N·m.
Fig. 2-279
(c) Check the conductivity of cooling fan relay:
1) Check it by an ohmmeter. Terminal 1 and 3 should be conducted. If not, please check the relay.
2) Check the conductivity of Terminal 2 and 4, which should not be conducted. If conducted, please replace
the replay. See Fig. 2-280.
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Fig. 2-280
(d) Check the working condition of cooling fan relay:
1) Connect the positive voltage of battery to Terminal 1 and 3.
2) Check the conductivity between Terminal 2 and 4 by an ohmmeter, which should be conducted. If not,
please replace the relay. See Fig. 2-281.
Fig. 2-281
(e) Reinstall cooling fan relay.
(f) Reinstall relay box cover.
I. Inspection
1. Check the engine oil quality
Check if the engine oil is deteriorated, with water, faded or diluted. If it evidently goes bad, please replace
engine oil. Recommended viscidity is shown in Fig. 2-282.
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Fig. 2-282
2. Check engine oil level
After the engine warms up and stops for 5 minutes, the engine oil level should be between oil dipstick L
and F. If too low, please check if there is leakage and refill the engine oil to mark F.
Note: Do not refill the engine oil above mark F.
3. Remove the oil pressure switch and install the oil pressure gauge
(a) Take off the oil pressure switch by a special service tool. See Fig. 2-283.
Fig. 2-283
Fig. 2-284
4. Engine warm-up
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Warm up the engine to normal working temperature.
5. Check the oil pressure
Oil pressure: no less than 80 kilopascal at idle speed
300-480 kilopascal in case of 3,000rpm
6. Remove the oil pressure gauge and reinstall oil pressure switch
(a) Remove the oil pressure gauge
(b) Smear bond onto the 2 or 3 screw threads of the oil pressure switch. See Fig. 2-285.
Fig. 2-285
(c) Install the oil pressure switch by a special service tool.
Torque: 18N·m
7. Start engine and check if there is leakage
II. Replacement
Notes:
Long-time contact with the mineral oil will eliminate the natural fat of skin and cause dryness, stimulus and
dermatitis. Besides, the used engine oil contains harmful pollutants that may result in skin cancer.
Please be careful and reduce the time and frequency of contact with the used engine oil as possible as you
can. Please wear the blue protective suite and gloves. Completely clean your skin by soap and water or
hand cleaner without water to clean all used engine oil. Do not use petroleum, thinner or solvent.
For environmental protection, please dispose the used engine oil and fuel filter at specified place.
1. Drain the engine oil
(a) Dismantle the engine oil charger cap. See Fig. 2-286.
Fig. 2-286
(b) Dismantle the engine oil drain plug and drain the engine oil into a container.
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2. Replacement of engine oil filter
(a) Remove the engine oil filter by a special service tool.
(b) Check and clean the installation surface of the filter.
(c) Check if the part number of the new oil filter is the same with that of the original one.
(d) Smear clean engine oil on the washer of the new oil filter.
(e) Slightly screw the oil filter and screw it down when the washer contacts the pedestal.
(f) Screw it down again for 3/4 turn by a special service tool. See Fig. 2-287.
Fig. 2-287
I. Removal
Tips: Remove the oil pan and oil rough filter first for cleaning when repairing the oil pump.
1. Drain the engine oil.
2. Dismantle the timing belt.
3. Dismantle tension wheel and tension spring.
4. Dismantle the crankshaft timing belt pulley.
5. Remove the oil dipstick and pipe.
(a) Remove the installation bolt. See Fig. 2-288.
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Fig. 2-288
Fig. 2-289
(b) Install a special knife blade for servicing between the cylinder body and oil pan. Cut the sealant and
remove the oil pan. See Fig. 2-290.
Fig. 2-290
Note:
Do not apply the special service tool to the side of oil pump body and rear receptacle.
Do not damage the oil pan flange.
7. Dismantle oil rough filter
Remove 2 bolts, 2 nuts, rough filter and washer. See Fig. 2-291.
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Fig. 2-291
8. Remove the oil pump
(a) Remove 7 bolts. See Fig. 2-292.
Fig. 2-292
(b) Slightly knock the oil pump body by a hammer with plastic surface, and remove the oil pump. See Fig.
2-293.
Fig. 2-293
(c) Remove the washer.
II. Removal
1. Remove the reducing valve
(a) Take out the snap ring by clip. See Fig. 2-294.
Fig. 2-294
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(b) Remove the limiter and driven rotor
2. Remove the drive and driven rotors
Remove 5 bolts, pump housing, O ringand drive and driven rotors
III. Inspection
1. Check the reducing valve
Smear the engine oil onto the reducing valve. Check if it can fall into the valve hole successfully by its
body weight. See Fig. 2-295.
Fig. 2-295
If not, please replace the reducing valve. Replace the oil pump components as necessary.
2. Check the drive and driven rotors
A. Check the clearance of rotor body.
Measure the clearance between the driven rotor and main body by a thickness meter. See Fig. 2-296.
Fig. 2-296
Standard main body clearance: 0.10-0.18mm
Max main body clearance: 0.20mm
In case of a clearance over the max value, please replace the whole set of rotor. Replace the oil pump
components as necessary.
B. Check the rotor tip clearance.
Measure the clearance between the tips of driven and drive rotors by a thickness meter. See Fig. 2-297.
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Fig. 2-297
Standard tip clearance: 0.060-0.180mm
Max tip clearance: 0.35mm
In case of tip clearance over the max value, replace the whole set of rotor.
Fig. 2-298
Standard side clearance: 0.025-0.075mm
Max side clearance: 0.10mm
In case of a side clearance over the max value, replace the whole set of rotor. Replace the oil pump
components as necessary.
IV. Replacement
Replace the crankshaft front oil seal
V. Reinstallation
1. Install the driven and drive rotors
(a) Rotate the driven and drive rotors into the pump body to make the mark towards the pump body cap.
See Fig. 2-299.
Fig. 2-229
(b) Install the oil pump body cap by 5 bolts.
Torque: 11N·m
Fig. 2-300
(b) Make the key slot of oil pump driven rotor occlude with the crankshaft and roll in the oil pump.
(c) Install the oil pump by 7 bolts. See Fig. 2-301.
Fig. 2-301
Torque: 23N·m
Stay bolt: 35mm
Other bolts: 25mm
2. Install engine oil rough filter
Install the new washer and engine oil rough filter by 2 bolts and 2 nuts.
Torque: 11N·m
Fig. 2-302
Install a filler with a diameter of 3-5mm.
Assemble the parts within 5 minutes after smearing fillings, otherwise clean all fillings and re-smear oil.
Remove the filler from the pipe immediately and reinstall the cap.
(c) Install the oil drip pan by 19 bolts and 2 nuts.
Torque: 11N·m
4. Install oil dipstick and pipe
(a) Install the new O ring onto the pipe of oil dipstick.
(b) Smear soap water on the O ring.
(c) Push into the oil dipstick and the pipe together and install them by bolts. See Fig. 2-303.
Fig. 2-303
Torque: 11N.m
5. Install crankshaft timing gear
6. Install the tension wheel and tension spring temporarily
7. Install timing belt
8. Fill engine oil
9. Start engine and check if there is oil leakage
10. Recheck the engine oil level
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Purpose
The exhaust gas emission control system is to reduce the CO and hydrocarbon discharged by the engine so
as to prevent the leaked gas containing hydrocarbon to the air and the fuel steam containing hydrocarbon
emitted by the petroleum tank to the air.
System functions shown as below:
Table 2-3
System Abbreviation Purpose
(1) Positive crankcase PCV Reduce gas leakage (hydrocarbon)
ventilation EVAP Reduce the evaporation of hydrocarbon
(2) Evaporation circulation EFI Adjust the working of all parts of engine to
(3) Electronic fuel injection reduce exhaust gas
Schematic diagram:
Fig. 2-304
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Inspection
1. Remove PCV valve
(a) Remove PCV hose from PCV valve.
(b) Remove PCV valve.
2. Install clean hose on the PCV valve
3. Check the work of PCV valve
(a) Blow air into PCV valve from one side of cylinder cap and check if the air path is smooth. See Fig.
2-305.
Fig. 2-305
Note:
Do not blow air through the PCV valve.
Petroleum content in PCV valve is harmful.
(b) Blow air into the PCV valve from one side of the air intake and check if the air path is smooth. See Fig.
2-306.
Fig. 2-306
In case the working situation does not reach the regulations, please replace the PCV valve.
4. Remove the clean hose from PCV valve
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5. Reinstall PCV valve
6. Visually check the hose, connector and washer. Check if there is a crack, leakage or damage. See
Fig. 2-307.
Fig. 2-307
Inspection
1. Visually check the pipe and connector
Check if there is loose connector, sudden bent or damage.
2. Visually check the fuel tank
Check if there is distortion, crack or fuel leakage. See Fig. 2-308.
Fig. 2-308
Fig. 2-309
Fig. 2-310
(b) Blow the air into the steam pipeline and check if the air flows out smoothly from the pipeline.
In case of any question, replace the activated charcoal canister.
D. Clean the filter inside the activated charcoal canister
Close other pipelines on the upper part of the activated charcoal canister. Blow air into the canister through
fuel tank pipeline to clean the filter. See Fig. 2-311.
Fig. 2-311
Tips: Do not try to clean the activated charcoal canister and do not let charcoal leak.
E. Install activated charcoal canister.
5. Check the EVAP vacuum valve
1. Note:
Disconnect the wire from the negative pole of the battery before repairing the fuel system.
Note: Each DTC stored in the computer will be deleted when the wire of the negative pole (-) of the battery
is disconnected. Therefore, please read the DTC before the wire of the negative pole (-) of the battery is
disconnected when necessary.
(a) Do not smoke or repair it in the vicinity of obvious flame;
(b) Do not let the rubber or leather part contact the gasoline;
(c) Repair one set of parts at one time to avoid confusing of parts with similar shapes;
(d) Keep the repair ground clean to avoid polluting the other parts;
(e) Do not mistakenly install or miss any clamp or spring.
2. Notes before repairing:
(a) The battery should supply power for timing light, revolution meter, etc.
(b) If the engine can not ignite, diagnose it with reference to the following notes:
1) Check if the wires on the terminals of the battery are connected correctly.
2) Remove the high voltage coil carefully as shown in Fig. 2-312.
Fig. 2-312
3) Check if the terminals of ignition coil are tightly connected to the wires of other ignition systems.
4) Prevent specially water seepage of electronic systems when cleaning the engine compartment.
(c) Notes to removal of oxygen sensor
1) Do not let the oxygen sensor drop or collide with other objects.
2) Do not let the oxygen sensor contact with water.
(d) Connect the wire harness to adapting piece plug.
1) Insert the wire harness terminal to socket connector, and lock it safely in the bayonet of socket
connector.
2) Pull out the wire harness to check if it is tightly locked.
3. Air inlet system
(a) If the engine oil level meter, engine oil filler cover, PCV (positive crankcase ventilation) and other parts
drop off, the engine may work abnormally.
(b) If the parts of air inlet system between throttle valve section and cylinder head drop off, loose or crack,
the air will be taken in, and the engine will work abnormally.
Fig. 2-313
2) As shown in Fig. 2-314, the socket connector should be totally inserted and locked up when installing.
Fig. 2-314
(i) When checking the connector with voltmeter/ohmmeter
1) Pull out the waterproof plug carefully if it is waterproof socket connector.
2) Insert the test probe from one side of the wire harness into the socket connector to check the conduction,
current and voltage.
3) Do not apply unnecessary strong force on the terminal head.
4) Install the waterproof plug onto the wire harness socket connector and fix it after finishing checking.
(j) Check and test the oil injection nozzle or wire connector with special tools.
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2. Check engine alarm light
(a) The engine alarm light should be on when the ignition switch is in the ON position and the engine is not
started.
(b) After the engine is started, the engine alarm light should be off. As shown in Fig. 2-315, if the alarm
light is not off, there should be fault in the engine electrical system.
Fig. 2-315
3. Check the DTC with hand-held diagnostic equipment (diagnostic equipment type: OBD II)
(a) Connect the hand-held diagnostic equipment to the diagnosis socket.
(b) Read the DTC displayed on the screen of diagnostic equipment. For more detailed information please
refer to the instruction manual of the hand-held diagnostic equipment.
4. Clear the DTC
(a) The DTC still remains in the ECM storage after fixing the fault area. To clear these codes, the ignition
switch should be in the OFF position, disconnect the electronic fuel injection fuse (15A), or disconnect the
negative pole of the battery at least for 10 seconds so as to clear the DTC by cutting off the system power.
The duration is determined by the environmental temperature (The temperature is lower, the duration for
cutting off power is longer.).
Note:
The DTC can also be cleared by disconnecting the negative pole (-). However, this will also clear the
information in other storage systems (like timing system).
If the DTC is not cleared, it will be stored in ECM and appear together with the new DTC as past DTC in
the future fault diagnosis.
First check if the DTC is recorded during necessary maintenance for terminals on engine assembly without
power supply.
(b) Check if the engine alarm light works normally through road testing after clearing the DTC. If the same
DTC appears, it means that the fault area is not completely repaired.
Fig. 2-316
Diagnose with hand-held tester and read its value.
(1) Turn the ignition switch to ON position.
(2) Start the hand-held tester and operate according to the instructions. Read the values displayed on the
tester (Pressure and temperature are the same with atmospheric pressure and intake air temperature.) and
relevant fault (if there is). If normal, check if there is intermittent fault; if abnormal, proceed to the next
procedure.
(3) Check voltage of ECM Terminal J104.
a. Turn the ignition switch to ON position.
b. Measure the voltage between Terminal J104 and J121 of ECM connector. The normal value should be
between 4.5-5.5V.
If abnormal, check and replace ECM; if normal, proceed to the next procedure.
(4) Check voltage of Terminal J142 of ECM connector.
a. Turn the ignition switch to ON position.
b. Measure the voltage between Terminal J142 and J121 of ECM connector. The normal value should be
between 3.4-3.8V.
If abnormal, check and replace ECM; if normal, proceed to the next procedure.
(5) Check voltage of Terminal J127 of ECM connector.
Measure the voltage between Terminal J127 and J121 of ECM connector. The voltage should be 0.5-3.4V
when the intake air temperature is 20℃; and the voltage should be 0.2-1.0V when the intake air
temperature is 60℃. If normal, check and replace ECM; if abnormal, proceed to the next procedure.
(6) Check wire harness and connector (ECM-intake air temperature and pressure sensor):
a. Disconnect ECM connector and intake air temperature and pressure sensor connector.
b. Measure the electric resistances between ECM connector Terminal J104, J121, J142, J127 and sensor
connector Terminal B, D, A, C. The resistance value should not be more than 1Ω.
c. Measure the electric resistances between ECM connector Terminal JI04, J121, J127, J142 and vehicle
body earth wire. The resistance value should not be more than 1Ω.
If abnormal, repair or replace wire harness or connector; if normal replace intake air temperature and
pressure sensor.
8. Fault diagnosis for water temperature sensor
The schematic diagram is as following:
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Fig. 2-317
Diagnose fault with hand-held tester.
(a) Read the value of hand-held tester (engine coolant temperature).
1) Turn the ignition switch to ON position.
2) Start the hand-held tester, and operate according to the instructions. Read the value displayed on the
tester (engine coolant temperature) and relevant DTC (if there is). If normal, check if there is intermittent
fault; if abnormal, proceed to the next procedure.
(b) Check the connection condition of the wire harness.
1) Turn the ignition switch to ON position.
2) Disconnect the water temperature sensor connector. Measure the voltage between Terminal 3 and 1 of
water temperature sensor connector. The value should be 4.5-5.5V. If normal, replace sensor; if abnormal,
proceed to the next procedure.
3) Turn the ignition switch to OFF position, and disconnect the water temperature sensor and ECM
connector. Measure the electric resistance between ECM connector Terminal J143 and sensor Terminal 3
and between Terminal J105 and sensor Terminal 1. The value should not be more than 1Ω. Measure the
electric resistance between sensor terminal and vehicle body earth wire. The value should not be more than
1Ω. If abnormal, replace the wire harness; if normal, replace the sensor.
If there is still fault or abnormal display value after replacing sensor, replace ECM.
Fig. 2-319
Read the stable data with a hand-held tester. The stable data records the engine condition when a fault is
detected. It can be used to judge that if the sedan is running or stopped when a fault occurred, if the engine
is preheated, and if the air-fuel percentage is too high or too low, etc.
(a) Check wire harness and connector:
Check the connection condition of the wire harness between ECM and knock sensor. Disconnect ECM and
sensor connector, measure the electric resistance between ECM connector terminal and vehicle body earth
wire, which should be more than 1MΩ. If abnormal, replace the wire harness.
(b) Check knock sensor: If the oscillation frequency is not 8.1kHz under normal condition, the sensor is
abnormal, and the conduction condition between the terminal and vehicle body should be checked. If not
normal, replace knock sensor; if normal, proceed to the next procedure.
(c) Check wire harness and connector (ECM-knock sensor)
1) Disconnect ECM connector.
2) Disconnect knock sensor connector.
3) Measure the electric resistance between Terminal J169 of ECM connector and terminal of knock sensor
connector. The resistance value should be less than lMΩ.
4) Measure the electric resistance between Terminal J169 of ECM connector and vehicle body earth wire.
The value should not be less than 1MΩ. If electric resistance value is abnormal, repair or replace wire
harness or connector; if normal, proceed to the next procedure.
(d) Confirm that the circuit fault disappears after installing new knock sensor.
1) Replace with new knock sensor.
2) Conduct road testing after eliminating the fault.
3) Read the DTC. If there is no new DTC output, the knock sensor should be replaced; if there is new DTC
output, check and replace ECM.
12. The schematic diagram for diagnosing the fault of circuit of crankshaft position sensor
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Fig. 2-320
Read the stable data with the hand-held tester. The stable data records the engine condition when a fault is
detected. It can be used to judge that if the sedan is running or stopped when a fault occurred, if the engine
is preheated, and if the air-fuel percentage is too high or too low, etc. First check the fault with DTC. If
there is no fault detected, diagnose and eliminate the mechanical system faults.
(a) Check crankshaft position sensor (including electric resistance)
Measure the electric resistance between Terminal A and B of crankshaft position sensor connector. The
value should be 560Ω±10% (25Ω)
(b) Check wire harness and connector (ECM-crankshaft position sensor):
1) Disconnect ECM connector.
2) Disconnect the connector of crankshaft position sensor.
3) Measure the electric resistance Terminal J112 of ECM connector and Terminal A of crankshaft position
sensor connector. The resistance value should not be more than 1Ω.
4) Measure the electric resistance between Terminal J128 of ECM connector and Terminal B of crankshaft
position sensor connector. The resistance value should not be more than 1Ω.
5) Measure the electric resistance between Terminal J112 and J128 of ECM connector. The value should
not be less than 1MΩ.
6) Measure the electric resistance between Terminal J128 of ECM connector and vehicle body earth wire.
The value should not be less than 1MΩ.
7) Measure the electric resistance between Terminal J112 of ECM connector and vehicle body earth wire.
The value should not be less than 1MΩ.
If the electric resistance is abnormal, repair or replace the wire harness or connector. If normal, proceed to
the next procedure.
(c) Check the installation condition of crankshaft position sensor. If abnormal, tighten the sensor; if normal,
proceed to the next procedure.
(d) Check the timing belt pulley (signal plate) of the crankshaft:
1) Remove the timing belt pulley of the crankshaft
2) Check signal plate tooth. If abnormal, repair or replace timing belt pulley of the crankshaft; if abnormal,
check and replace ECM.
13. The schematic diagram for diagnosing the fault of circuit of idle speed control system:
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Fig. 2-321
Fig. 2-322
Electric resistance: 12-16Ω at 20℃ (68°F)
If the electric resistance is out of the range, replace the injector.
3) Reconnect the injector connector.
Note:
1. Connect a revolution meter in ignition system, and connect the test wire of revolution meter to the
Terminal IG (-) of diagnosis connector.
2. As some revolution meter are not compatible with the ignition system, it is advised to confirm the
compatibility of the revolution meter and ignition system to be diagnosed.
3. Do not connect the earth terminal of revolution meter with the earth wire. Otherwise, the lighter and (or)
ignition coil may be damaged.
4. Do not disconnect with the battery when the engine is running.
5. The vehicle body earth wire should be connected correctly when checking the lighter.
Check on vehicle
1. Spark test
A. Check the generation of spark
(a) Disconnect high voltage damping wire from spark plug.
(b) Remove the spark plug.
(c) Install spark plug to each high voltage damping wire.
(d) Connect the spark plug to the earth.
(e) Check if there is spark when the engine is started.
Note: In order to prevent the gasoline spray out from the injector during test, the engine start duration should not
exceed 1-2 seconds. If there is no spark, proceed to the following test.
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Fig. 2-323
Maximum electric resistance: 25KΩ for each damping wire
If the electric resistance of damping wire is over the maximum electric resistance, check the terminal. And
replace the high voltage damping wire.
(d) Reconnect the high voltage damping wire to the spark plug.
Make sure the high voltage damping wire and clip are correctly installed.
3. Check the spark plug
(a) Disconnect the high voltage damping wire from the spark plug.
(Refer to the first step of checking of high voltage damping wire.)
(b) Remove the spark plug
As shown in Fig. 2-324, remove the spark plug with 16mm spark plug special wrench.
Fig. 2-324
(c) Wash the spark plug
As shown in Fig. 2-325, wash the spark plug with spark plug cleaner or wire brush.
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Fig. 2-325
(d) Visually check the spark plug
Check the electrode abrasion, screw thread damage and insulator damage condition of spark plug.
If an abnormal condition is detected, replace the spark plug.
Recommended spark plug: CHAMPION
(e) Adjust electrode space
As shown in Fig. 2-326, bend the out electrode carefully to correct the electrode space.
Fig. 2-326
Correct electrode space: 0.8mm
(f) Install spark plug
Install spark plug with 16mm spark plug special wrench.
Torque: 18N·m
(g) Reconnect the high voltage damping wire to spark plug.
(Refer to the (c) 3 steps of checking the high voltage damping wire.)
Check on vehicle
Note: Recheck the following items before operating the starter:
(1) Connection condition of connector
(2) Accessory installation, like anti-theft system
A. Removal and installation of starter
(a) Remove the magnetic switch
1) Remove the nut, cut the wire of magnetic switch terminal.
2) Loosen 2 nuts fasten on starter house by magnetic switch.
3) Pull on the magnetic switch, and loosen the plunger piston couple on drive rod at the same time. Then
loosen the magnetic switch.
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4) Remove plunger piston cover.
B. Remove magnetic pole frame and armature
1) Remove the connection wire between solenoid switch and motor; remove the nut; and cut the wire from
the terminal.
Torque: 5.9 N·m
2) Remove 2 through bolts. Torque: 5.9N·m; model: 1.2KW
3) Remove magnetic pole frame and armature from solenoid switch assembly.
4) Remove the O ring.
Assembly notes:
Use new O ring.
Match the scab of magnetic pole frame and notch of solenoid switch.
C. Remove starter house, clutch assembly and gear
1) Remove 2 screws. Torque:
Model 1.2KW: 5.9 N·m
Model 1.4KW: 5.9 N·m
Model 2.0KW: 9.3 N·m
2) Remove the following parts from solenoid switch assembly:
Starter house, reverse spring, bearing, idler wheel and clutch assembly.
3) Remove the steel ball: aspirate the ball with magnetic needle from clutch bearing hole.
D. Remove brush carrier
1) Remove the 2 screws and the cover in magnetic pole frame.
Torque:
Model 1.2KW: 1.5 N·m
Model 1.4KW: 1.5 N·m
Model 2.0KW: 3.8 N·m
2) Remove the O ring from the magnetic pole frame. Assembly note: use new O ring.
3) Press down the spring with screwdriver and remove brush from brush carrier. Disconnect 4 brushes and
remove the brush carrier.
E. Remove armature from magnetic pole frame
F. Armature coil
1) Check the conduction condition of commutator
As shown in Fig. 2-327, the 2 bars on commutator to be checked with ohmmeter should be conductive. If
one bar is not conductive, replace the armature winding.
2) Check earth connection condition of commutator
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Fig. 2-327
As shown in Fig. 2-328, check with ohmmeter. It should not be conductive between commutator and
armature coil core. If it is conductive, replace the armature winding.
Fig. 2-328
G. Commutator
(a) Check the surface burn and pollution condition of commutator
If the surface is polluted or burnt, process it with sand paper or on lathe.
(b) Check gear ring difference of commutator
1) Lay the commutator on V shape stow-wood.
2) Measure gear ring difference with dial indicator gauge.
Maximum gear ring difference: 0.05mm
If the gear ring difference exceeds the maximum value, correct it on lathe.
(c) Check commutator diameter
As shown in Fig. 2-329, measure the diameter of commutator with vernier caliper.
Fig. 2-329
Standard diameter:
Model 1.2KW: 30mm
Model 1.4KW: 30mm
Model 2.0KW: 35mm
Minimum diameter:
Model 1.2KW: 29mm
Model 1.4KW: 29mm
Model 2.0KW: 34mm
If the diameter is smaller than the minimum value, replace the armature.
(d) As shown in Fig. 2-330, check under cut depth.
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Fig. 2-330
Make sure that the under cut part is clean and without foreign material. And the fringe should be smooth.
Standard under cut depth:
Model 1.2KW: 0.6mm
Model 1.4KW: 0.6mm
Model 2.0KW: 0.7mm
Minimum under cut depth:
0.2mm
If the under cut depth is smaller than the minimum value, correct it with hacksaw blade.
H. Magnetic pole frame (magnet exciting coil)
(a) Check the open circuit condition of magnet exciting coil
As shown in Fig. 2-331, check with ohmmeter. It should be conductive between the wire and carbon brush
of magnet exciting coil. If not conductive, replace the magnetic pole frame.
Fig. 2-331
(b) Check the earth connection condition of magnet exciting coil
As shown in Fig. 2-332, check with ohmmeter. And it should not be conductive between the end of magnet
exciting coil and magnetic pole frame. If conductive, repair or replace the magnetic pole frame.
Fig. 2-332
Model 2.0kW
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Check electric resistance of commutating coil
Check the electric resistance with ohmmeter between Terminal A and Terminal B of commutator.
Standard electric resistance:
1.5-1.9Ω at 20℃
I. Brush
Check brush length
As shown in Fig. 2-333, measure the brush length with vernier caliper.
Fig. 2-333
Standard length:
Model 1.2kW: 15.5mm
Model 1.4kW: 15.5mm
Model 2.0kW: 15.0mm
Minimum length:
Model 1.2kW: 10.0mm
Model 1.4kW: 10.0mm
Model 2.0kW: 9.0mm
If the length is smaller than the minimum value, replace the brush carrier and magnetic pole frame.
J. Brush spring. As shown in Fig. 2-334
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Fig. 2-334
K. Brush carrier
检查电刷架绝缘情况
Check the insulation condition of brush
As shown in Fig. 2-335, check with ohmmeter. It should not be conductive between the positive pole (+)
and negative pole (-) of brush carrier. If conductive, repair or replace the brush carrier.
Fig. 2-335
L. Clutch and gear
(a) Check gear tooth
Check the abrasion or damage condition of gear tooth of small planet gear, idler wheel and clutch
assembly.
If there is damage, replace the gear or clutch assembly.
If there is damage, check the abrasion or damage condition of ring gear of fly wheel.
(b) Check small planet gear of clutch
As shown in Fig. 2-336, hold the starter clutch and rotate the small planet gear in clockwise direction. The
small gear should be able to rotate freely. And then try to turn the small planet gear in counter-clockwise
direction, which should not be able to rotate. If necessary, replace the clutch assembly.
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Fig. 2-336
Precaution items------CH-2
Preparation--------------CH-2
Checking on vehicle---CH-3
AC-generator----------CH-7
Repair regulation------CH-1
Precaution items
1. Check if the battery wire is correctly connected to the terminals.
2. Disconnect the battery wire, and discharge the battery quickly.
3. Do not use high voltage insulation resistance detector when testing.
4. Do not disconnect the battery when the engine is rotating.
Special tools (special service tools)
Table 2-6
Jet pump camshaft taper bearing inner ring replacer Rotator rear bearing cap
Replacer 26
Replacer 50
Adapter
Equipment
Table 2-7
Ammeter (A)
Battery weight meter
Belt tension meter
Torque spanner
Vernier caliper Rotator (slip ring), brush
I. Check on vehicle
Check battery electrolyte position
Check the electrolysis amounts of all batteries.
1. Maintenance free battery
If lower than the lower level, replace the battery (or add distilled water if possible). Check the discharge
system. As shown in Fig. 2-337.
Fig. 2-337
2. Non-maintenance free battery
(a) Check electrolyte density
As shown in Fig. 2-338, check the electrolyte density of each battery. If lower than the lower level, add
distilled water.
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Fig. 2-338
Standard density: 20℃: 1.25-1.29
If the density is smaller than the standard density, discharge the battery.
(b) Check battery voltage
1) After the vehicle is driven, within 20 minutes after engine stop, the ignition switch in ON position and
electrical system (headlight, blower fan rotator, rear defroster, etc.) 60 seconds so as to remove the surface
charge.
2) Turn the ignition switch to OFF position and turn off the electrical system.
3) As shown in Fig. 2-339, measure the voltage between positive pole (+) and negative pole (-) of battery.
Fig. 2-339
Standard voltage:
20℃ (68°F): 12.5-12.9V
If the voltage is below the standard value, discharge the battery.
Note: As shown in Fig. 2-340, check indicator.
Fig. 2-340
(c) Check battery electrode, fusible wire or fuse.
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1) As shown in Fig. 2-341, check if the battery electrode is loose or corrupted.
Fig. 2-341
If the electrode is corrupted, clean the electrode.
2) Check the conduction conditions of fusible wire and fuse
3. Check drive belt
(a) As shown in Fig. 2-342, visually check if there is excessive wear, inhaul cable break and other problems
in the belt. And replace the drive belt if any problem is detected.
Fig. 2-342
Note: Crack is allowed in the surface of drive belt. If there is no gear rib, replace the drive belt.
(b) As shown in Fig. 2-343, press on the position shown in the figurewith the force of 98N to check the
deviation of drive belt.
Fig. 2-343
Drive belt deviation
New drive belt 7-9mm (0.28-0.35 inch)
Old drive belt 11.5-13.5mm (0.45-0.53 inch)
Adjust the drive belt deviation if necessary
Reference
Check the tension degree of drive belt with tension meter.
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Tension degree of drive belt:
New drive belt 685-785N
Old drive belt 295-440N
If the tension degree of drive belt is too poor, adjust it.
Note:
“New belt” means drive belt that not used for over 5 minutes in rotating engine.
“Old belt” means drive belt that used for 5 minutes or above in rotating engine.
As shown in Fig. 2-344, check if the drive belt matches the gear groove after installing the drive belt.
Fig. 2-344
Check with hand to confirm the belt does not roll out of the groove.
Run the engine for about 5min after installing a new belt, and recheck the tension degree of the belt.
(c) Visually check the AC-generator wire and listen for the noise.
1) Check if the wire is in good condition.
2) Check if there is abnormal noise in AC-generator when engine is running.
(d) Check discharge alarm light circuit
1) Ignition switch should be in ON position, and the discharge alarm light should be turned on.
2) Start engine, and the discharge alarm light should be turned off.
If the discharge alarm light does not work as described above, check and repair the DTC of circuit of
discharge alarm light.
(e) Check idle load charge circuit
Note: If use battery/AC-generator tester, connect the tester and indicator according to the manufacturer’s
instructions.
If there is no tester, connect the voltmeter and ammeter with charge circuit:
Disconnect the circuit from the Terminal B of AC-generator, and connect it to the contact clip of negative
pole (-) of ammeter
Connect the contact clip of positive pole (+) of ammeter to the Terminal B of AC-generator.
Connect the wire of positive pole (+) of voltmeter to Terminal B of AC-generator.
As shown in Fig. 2-345, connect the negative pole (-) of voltmeter to the ground.
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Fig. 2-345
(f) Check the charge circuit according to the following regulations:
Rotate the engine at 2,000rpm, and check and read the number on the ammeter and voltmeter.
Standard current: 10A or less
Standard voltage: 14.0-14.8V (25℃)
13.5-14.3V (115℃)
If the number displayed on voltmeter is larger than standard voltage, replace IC regulator.
As shown in Fig. 2-346, if the number displayed on voltmeter is smaller than standard voltage, check the IC
regulator and AC-generator in the following order: earth connection condition of Terminal F, and start
engine and check the number displayed on voltmeter of Terminal B.
Fig. 2-346
If the number displayed on voltmeter is larger than the standard voltage, replace the IC regulator.
If the number displayed on voltmeter is smaller than the standard voltage, check the AC-generator.
(g) Check loaded discharge circuit
1) When the engine is rotating at 2,000rpm, turn on the high beam and set the heater switch in HI position.
2) Check the number displayed on ammeter.
Standard current: 30A or larger
If the number displayed on ammeter is smaller than the standard current, replace the AC-generator.
Note: If the battery is completely discharged, sometimes the number displayed on ammeter will be smaller
than the standard current.
Removed and installed parts of AC-generator
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Fig. 2-347
II. AC-generator removal
1. Remove the rear end cap
(a)As shown in Fig. 2-348, remove nut and terminal insulated sleeve.
Fig. 2-348
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(b) M/T:
As shown in Fig. 2-349, remove 3 nuts and the end cap.
Fig. 2-349
2. Remove brush
(a) M/T:
1) As shown in Fig. 2-350, remove 2 screws and brush carrier.
Fig. 2-350
2) Remove brush carrier cover from brush carrier.
3. Remove IC regulator
As shown in Fig. 2-351, remove 3 screws and IC regulator.
Fig. 2-351
4. Remove rectifier bracket
(a) As shown in Fig. 2-352, remove 4 screws and rectifier bracket.
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Fig. 2-352
(b) Remove 4 rubber insulators.
5. Remove pulley
As shown in Fig. 2-353, hold the special tool (A) with torque wrench, and screw down the special tool (B)
in clockwise direction to appointed torque.
Fig. 2-353
Torque: 39N·m
Special tool (A) should be tightly fastened to rotator bearing.
(b) As shown in Fig. 2-354, put special tool (C) in punch pliers.
Fig. 2-354
(c) Install generator to special tool (C).
(d) As shown in Fig. 2-355, loosen the belt pulley nut, and turn special tool (A) in direction shown in the
figure.
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Fig. 2-355
Note: In order to prevent rotator bearing, do not loosen the pulley nut for over half-turn.
(e) Remove generator from special tool (C).
(f) As shown in Fig. 2-356, turn special tool (B) and remove special tool (A and B).
Fig. 2-356
(g) Remove belt pulley nut and belt pulley.
6. Remove rectifier end bracket
(a) As shown in Fig. 2-357, remove 4 nuts.
Fig. 2-357
(b) As shown in Fig. 2-358, remove rectifier end bracket with special tool.
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Fig. 2-358
7. Remove rotator from drive end bracket.
Check and repair the AC-generator
(a) Check and repair the rotator.
1) Check the conduction condition of rotator.
As shown in Fig. 2-359, check the conduction condition between slip rings with ohmmeter.
Fig. 2-359
Standard electric resistance (cold condition): M/T: 2.1-2.5Ω
As shown in Fig. 2-360, replace rotator.
Fig. 2-360
2) Check the earth connection condition of rotator.
As shown in Fig. 2-361, check with ohmmeter. And it should not be conductive between the slip ring and
rotator.
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Fig. 2-361
As shown in Fig. 2-362, if not conductive, replace rotator.
Fig. 2-362
3) Check slip ring
a. Check roughness or scratch on slip ring.
If it is too rough or there is scratch, replace rotator.
b. Measure diameter of slip ring with vernier caliper.
Standard diameter: 14.2-14.4mm
Minimum diameter: 12.8mm
As shown in Fig. 2-363, if the diameter measured is smaller than the minimum diameter, replace rotator.
Fig. 2-363
(b) Check and repair stator (drive end bracket)
1) Check if the circuit of stator is open.
Check with ohmmeter, and it should be conductive between coil and wire.
If not conductive, replace drive end bracket assembly.
2) Check earth connection condition of stator.
Check coil wire and drive end frame with ohmmeter, and it should not be conductive between them.
If conductive, replace drive end bracket assembly.
(c) Check and repair brush
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1) Check exposed length of brush.
Measure the exposed length of brush with vernier caliper.
Standard exposed length: 10.5mm
Minimum exposed length: 1.5mm
If exposed length is less than the minimum exposed length, replace brush (M/T).
M/T: If necessary, replace brush.
2) As shown in Fig. 2-364, cut and remove brush and spring.
Fig. 2-364
3)As shown in Fig. 2-365, insert a new brush wire harness in the brush hole, and then insert the spring and
brush.
Fig. 2-365
4) Weld the brush on brush carrier in accordance with regulated exposed length.
End. Exposed length: 10.5mm
5) Check the brush which should be able to move smoothly on brush carrier.
6) Cut spare wire harness. Coat insulated paint on welding area.
(d) Check and repair rectifier (rectifier bracket)
1) Check positive direction rectification of rectifier
As shown in Fig. 2-366, connect one probe of ohmmeter to positive pole (+), and the other to each rectifier
terminal.
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Fig. 2-366
Exchange the pole of tester probe and repeat Step (a).
Check the ohmmeter. One should be conductive and the other should not be conductive.
If the conduction condition is not the same as described above, replace rectifier.
2) Check negative pole of rectifier
As shown in Fig. 2-367, connect a probe of ohmmeter to each positive pole, and the other probe to the
terminal of rectifier.
Fig. 2-367
Exchange the pole of tester probe and repeat step (a).
One should be conductive and the other should not be conductive. If the conduction condition is not the
same as described above, replace rectifier.
(e) Check and repair bearing
1) Check front bearing
Check roughness degree or wear condition of bearing.
2) Replace front bearing if necessary
As shown in Fig. 2-368, remove 4 bolts, bearing bearer and bearing.
Fig. 2-368
As shown in Fig. 2-369, press out the bearing with special tool and holding-down device.
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Fig. 2-369
Press in a new bearing with special tool and holding-down device.
As shown in Fig. 2-370, install bearing bearer and 4 bolts.
Fig. 2-370
Fig. 2-371
Note: Do not damage the fan.
Place the bearing cap on rotator.
As shown in Fig. 2-372, press down a new bearing with special tool and holding-down device.
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Fig. 2-372
As shown in Fig. 2-373, push in bearing cap with special tool.
Fig. 2-373
(f) AC-generator assembly
1) Place drive end bracket to belt pulley.
2) As shown in Fig. 2-374, install the rotator to drive end bracket.
Fig. 2-374
3) Install rectifier end bracket.
As shown in Fig. 2-375, slowly press down the rectifier end bracket with a 29mm socket wrench and
holding-down device.
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Fig. 2-375
Install 4 nuts.
Torque: 4.5 N·m
4) Install belt pulley
Screw down the belt pulley nut with your hand, and install the belt pulley to stator bearing.
As shown in Fig. 2-376, hold special tool (A) with torque wrench, and tighten special tool (b) to appointed
torque in clockwise direction.
Fig. 2-376
Torque: 39N·m
Special tool (A) should be fastened on belt pulley bearing.
As shown in Fig. 2-377, put special tool (C) in punch pliers.
Fig. 2-377
As shown in Fig. 2-378, install AC-generator to special tool (C).
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Fig. 2-378
As shown in Fig. 2-379, turn special tool (A) in the direction shown in the figure so as to screw the belt
pulley nut.
Fig. 2-379
Torque: 110.5 N·m
Remove AC-generator from special tool (C).
Use special tool (B) and remove special tool (A and B).
Fig. 2-380
Note: Pay attention to the installation direction of rubber insulators.
Install rectifier bracket and 4 screws.
Torque: M/T: 2.0N·m
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6) As shown in Fig. 2-381, install IC regulator and brush carrier.
Fig. 2-381
M/T:
As shown in Fig. 2-382, install brush carrier cover to brush carrier.
Fig. 2-382
Note: Pay attention to the installation direction of brush carrier.
As shown in Fig. 2-383, put together the IC regulator and brush carrier on the same level.
Fig. 2-383
As shown in Fig. 2-384, install 5 screws, and the space between brush and socket connector should be
about 1mm (0.04in).
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Fig. 2-384
Torque: 2.0N·m
Install brush carrier cover
7) Install rear end cap
A. M/T:
Install end cap and 3 nuts.
Torque: 4.4N·m
B. Install terminal insulated sleeve and nut.
Torque: 4.1N·m
7. Check if the rotator rotates smoothly
Repair data
Table 2-6
Battery Proportion At 20℃ (68°F) 1.25-1.29
Skewness degree New 5-7mm
Old 7-8mm
Drive belt
Tension degree New 685-785N
Old 295-440N
Rated output M/T 12 V 7A
Electric resistance of rotator coil M/T 2.1-2.5Ω
Slip ring diameter STD 14.2-14.4mm
AC-generator
Minimum value 12.8mm
Brush exposed length STD 10.5mm
Minimum value 1.5mm
IC regulator Calibration voltage 13.2-14.8V
Torque range
Table 2-7
Parts to be tightened N·m
Bearing bearer×drive end bracket M/T 2.6
Rectifier end bracket×driven end bracket 4.5
AC-generator belt×rotator 110.5
Rectifier end bracket×brush carrier, IC regulator 2.0
Rectifier bracket×rectifier end bracket coil wire M/T 2.0
Rear end cap×rectifier bracket 4.4
Plate electrode terminal×rectifier bracket bolt 3.8
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Terminal insulator×rectifier bracket 4.1
Section I Introduction
I. Fundamentals
The electronic injection system is a multi-point fuel injection system with electronic control unit (ECU).
With various sensors installed on different parts of the engine to measure each working parameter of the
engine, the ECU can precisely control the fuel injection volume by controlling the fuel injector according to
the pre-set control program in the computer, and achieve the most favorable air-fuel mixture for the engine
under any working condition. With the control program in the ECU and relevant actuator, such functions as
fuel increase at start, fuel increase at warm-up, fuel increase at acceleration, fuel increase at full load, fuel
decrease at deceleration, fuel cut at idle speed, and automatic idle speed control are available in this system,
which can achieve special air-fuel mixture for the engine under the special working condition. Therefore,
the engine enjoys good performances in fuel efficiency and exhaust emission, and the service performance
of the vehicle is improved at the same time. Besides, the trouble diagnostic modes in the ECU can make the
researching of troubles much easier.
II. Structure of electronic control system
The electronic control system is divided into the following three parts:
1. (1) Sensor---Convert various non-electrics physical quantities of the engine into electrics physical
quantities, and then send them to the ECU. The sensors on ECU of Lifan 320 (LF479Q3 engine, close
coupling catalytic converter, aluminous intake manifold) include:
① Intake pressure and temperature sensor
②Throttle position sensor
③Coolant temperature sensor
④ Heated oxygen sensor (front and rear oxygen sensor, only front oxygen senor available under National
III Emission Standard, front and rear oxygen sensor available under National III Emission Standard
(Simplified) + EOBD and in National IV Emission Standard)
⑤ Knock sensor
⑥ Crankshaft position sensor
Weak acceleration sensor (unavailable under National III Emission Standard (Simplified), available under
National III Emission Standard +EOBD and under National IV Emission Standard).
2. Electronic control unit (ECU) is the “brain” for the whole electronic control system, which analyses and
processes all the information from sensors, sends orders to actuator, and makes the engine work under the
best condition.
3. Actuator is to perform the orders from the ECU. The actuator is the “hand” and “leg” of the electronic
control system, which include: ① Fuel pump, ② Fuel injector, ③ Ignition coil, ④ Idle speed actuator with
stepper motor, ⑤ Canister control valve.
III. Four stroke engine multi-point electronic fuel injection
1. Simultaneous injection: Injectors in all cylinders inject fuel simultaneously, with 2 times of fuel
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injection at each circle in each cylinder.
2. Group injection: Even number cylinders ignite in succession, and two cylinders inject fuel
simultaneously. For example, Cylinder 1 and 3 in the 4 cylinders inject fuel simultaneously; and Cylinder 2
and 4 inject fuel after the crankshaft turn over 360°. Each cylinder injects one time in each circle.
3. Orderly injection: Injector in each cylinder injects fuel in fixed phase, and injects one time at each
circle in each cylinder.
As the gas mixtures in all the cylinders are different during simultaneous injection, it is the worst situation
for the engine to work. And the gas mixtures in all cylinders are the same during orderly injection, which is
the best situation for the engine to work. Group injection is between the former two.
IV. Basic functions of gasoline engine ECU
1. Electronic fuel quantitative control
As the most important function in gasoline engine ECU, it plays an key role in power, energy saving and
exhaust of the engine and mobility and comfort degree of the whole vehicle, which involves O2 closed-loop
control, start control, after-start control, engine warming control, idle speed control (idle speed rotation
control), full load control, acceleration and deceleration control, overspeed fuel cut control, towing astern
fuel cut control and evaporative emission control (canister control), etc.
2. Electronic control on electronic ignition timing and ignition close angle
As an important function next to fuel quantity in ECU, it also plays an important role in power, energy
saving and exhaust of the engine and mobility and comfort degree of the whole vehicle, including
electronic knock control.
V. Air-fuel ratio in gasoline engine
Air-fuel ratio is the quality proportion of air and fuel in air-fuel gas mixture (gas mixture).
Theoretical air-fuel ratio is the quality proportion of air and fuel in gas mixture when both air and fuel are
completely burnt out. As a constant, theoretical air-fuel ratio changes with different fuels, and the ratio for
gasoline and diesel oil is about 14.7:1.
The ratio between actual air-fuel ratio and theoretical air-fuel ratio is excess air coefficient (λ).
λ=1 means that the actual ratio equals theoretical ratio;
λ>1 means that the actual ratio is larger than the theoretical ratio, the gas mixture is dilute;
λ<1 means that the actual ratio is smaller than the theoretical ratio, the gas mixture is thick.
VI. Fundamentals of electronic control of gasoline engine ignition timing
1. Key aspect of electronic control of ignition timing
The key aspect of electronic control of ignition timing is to control the ignition advance angle. And the
ignition advance angle should be adjusted to achieve the largest power, torque and lowest fuel consumption
result under the condition of no knock and no excess of emission limitation.
2. Knock and knock control
Knock is the spontaneous combustion phenomenon of unburned gas mixture in the cylinder. Knock harms
the engine greatly, and severe knock will damage the engine. And because of this knock, the traditional
carburetter engine has to choose a small ignition advance angle at the cost of low torque and power and
high fuel consumption. While the engine with electronic fuel injection control can prevent knock through
adjusting the ignition advance angle to a smaller angle. As a result, a comparatively large ignition advance
angle in usual time can obviously improve the power and torque and decrease the fuel consumption.
The knock control function of fuel injection engine with electronic control is based on the knock signal
from the knock sensor. As the signals from knock sensor include other vibration signals caused by other
mechanical reasons, ECU has to process and analyze these signals and choose the right one. If necessary
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ECU will also adjust the ignition advance angle to a smaller angle to avoid knock, and resume to the
previous ignition angle gradually when there is no knock signal.
Fig. 2-2 Circuit diagram of intake air temperature and pressure sensor
6. Trouble diagnosis: The electronic devices of the intake air pressure sensor can diagnose such troubles
as open/short circuit and the damage of senor. When the ECU detects that the signal output by the sensor is
beyond its normal signal curve, the sensor will be in trouble. For example, when the intake air pressure is
higher or lower than its limit, the ECU will confirm that the sensor is in trouble (The pressure lower than
the limit at start will be excluded by the ECU.), then the engine MIL will be lighted and the operation under
trouble mode will be applied.
II. Throttle valve position sensor
1
2
1. Function: To provide throttle-alternator position information to the ECU. According to this information,
the ECU can obtain other information on engine load, working condition (start, idle speed, backing, partial
load, and full load), acceleration and deceleration. With the three-wire sensor, the ECU can detect the
opening of throttle through the change of pressure
2. Structure and principle: As an angle sensor with linear output, the sensor is made by two arc sliding
contact resistances and two sliding contact arms. The turning shaft of the sliding contact arm shares the
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same axis with the throttle shaft. Power supply voltage (US) of 5V is added to the both ends of the sliding
contact resistance. When the throttle turns, the arm turns and moves on the sliding contact resistance. Then,
the electric potential (UP) at the contact point will be led out as an output voltage. Actually, it is an angle
sensor and the real value adopted by the ECU is the value of Up/Us, and the value fluctuation of the sensor
caused by the fluctuation of the generator voltage will be avoided.
3. Connection circuit: As shown in the following circuit diagram of throttle valve position sensor.
4. Trouble diagnosis: By monitoring the throttle-alternator position, when the signal higher or lower than
its limit, the ECU will confirm that the throttle position sensor is in trouble, then the engine operation under
trouble mode will be applied, and the engine MIL will be lighted (Knock on sensor and internal dirt will
contribute to engine troubles.)
5. Installation: Allowed fastening torque for fastening screw is 1.5N.m-2.5N.m. (Fastening torque for
installation screw is 1.5N.m~2.5N.m.)
III. Coolant temperature sensor
1. Function: To provide information on coolant temperature. To provide water temperature signal for the
ECU, and to control ignition timing and fuel injection pulse width at start, idle speed, and normal operation.
2. Structure and principle: Made by a thermistance with NTC. The resistance value will decrease with the
increase of the coolant temperature (not a linear relation). The thermistance with NTC is installed within a
copper sleeve. With a voltage division circuit, the resistance value of the thermistance is converted into a
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changing voltage and then provided to the ECU, and then the change of water temperature can be
monitored (internal structure of ECU).
3. Connection circuit
4. Trouble diagnosis: When the coolant temperature is higher than its upper limit, or lower than its bottom
limit, the engine MIL will be lighted and the engine operation under trouble mode will be applied. Then,
the ECU will carry out the ignition and fuel injection control as per the water temperature set under the
engine water temperature trouble mode, and make the fan run at a high speed at the same time.
5. Limit data: 2.5±5%KΩ
6. Installation note: Tightening torque is 15±2N.m.
c b a
a - Water temperature signal pin of electronic injection system b - Meter water temperature pin c-
Signal earth connection
a - Water temperature signal of electronic injection system b - Meter water temperature signal
J1-05
1 2 1 2
J1-69
4. Trouble diagnosis: The ECU will monitor the sensors, actuators, power amplifying circuit and detecting
circuit. In case of any of the following situations, like shock sensor trouble, shock control data process
circuit trouble, unreliable cylinder judgment signal, incorrect shock sensor trouble mark level, and shock
closed loop control closed, the ignition advance angle stored in the ECU will be decreased for a safety
angle. When the trouble frequency is lower than the set value, the trouble mark level will be repositioned.
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5. Installation notes: Tightening torque is 20±5N·m. There is a hole in the middle of knock sensor, which
can be used to fasten it on the cylinder block with a M8 bolt. And use 25mm long bolt for cast-iron cylinder
block. Installation position should be easy for sensor to receive vibration signal from all cylinders, which
should be decided by modal analysis of cylinder block. Usually the knock sensor should be installed
between Cylinder 2 and 3 for an engine with 4 cylinders. Do not let engine oil, coolant, brake fluid, water
and other materials contact the sensor for a long time. Do not use any kind of washer when installing. The
metal surface of sensor must contact the cylinder block. Avoid resonance vibration of signal wire for
rupture prevention when installing the signal wire. And high voltage current between Pin 1 and 2 is not
allowed because this may damage piezoelectric element.
V. Oxygen sensor
1. Function: To provide the information that whether oxygen in the cylinder is too high after the fuel is
burned with the air in the cylinder. With this information, the ECU can carry out closed loop control for the
fuel ration. Therefore, the three main toxic elements (HC, CO, and NOX) of the engine exhaust can be best
converted and purified in the three-way catalytic converter.
2. Structure and principle: The sense element of the oxygen sensor is a ceramic pipe with holes and gaps.
The pipe is surrounded by engine exhaust and the air flows within the pipe. The ceramic pipe wall is a kind
of solid electrolyte with electric heating tube inside, which begins work when the ceramic pipe has been
heated to 300 0C (a feature of a solid electrolyte). With such a special material, the oxygen ions can freely
go through the ceramic pipe. Then, the concentration difference of the mixture will be converted into
potential difference, which will be put out in the form of electric signal. If the concentration of the mixture
is relatively high, the concentration difference of the oxygen ions inside and outside the ceramic pipe will
be relatively high, and the potential difference will be relatively high as well. At the same time, a lot of
oxygen ions will move to the outside from the inside, and the voltage output will be relatively high. If the
concentration of the mixture is relatively low, the concentration difference of the oxygen ions inside and
outside the ceramic pipe will be relatively low, and the potential difference will be relatively low as well.
At the same time, little oxygen ions will move to the outside from the inside, and the voltage output will be
relatively low. The working voltage of the oxygen sensor fluctuates from 0.1V to 0.9V, which will be
changed for 5-8 times within 10 seconds. In case of lower than the changing frequency, the oxygen sensor
shall be renewed, as it can not be repaired.
3. Connection circuit
1 - Main relay output 2 - Oxygen sensor heating control 3 - Signal low 4 - Signal high
4. Trouble diagnosis: The ECU will monitor the sensors, actuators, power amplifying circuit and detecting
circuit. In case of any of the following situations, like unreliable battery voltage, unreliable air intake
manifold absolute pressure singal, unreliable engine coolant temperature signal, fuel injector driving stage
trouble, incorrect oxygen sensor trouble mark level, and fuel ration closed loop control closed, the fuel
ration will be confirmed according to the basic fuel injection time stored in the ECU.
5. Installation notes: The tightening torque of the oxygen sensor is 50~60N.m. Apply anti-rust oil to the
renewed oxygen sensor to prevent difficult removal due to rust. Oxygen sensor should be installed on
exhaust pipe where can represent the exhaust gas composition and meet the temperature limit, which means
that the position should be at the nearest position to the engine.
VI. Electronic control unit (ECU)
1. Function: The ECU is the key part of the electronic control system of the engine. The sensors provide
various signals to the ECU, and the ECU calculates the signals and sends orders to the actuators like fuel
injector, ignition coil etc to control the engine.
2. Structure: Made by a shielded housing and printed circuit board, many electronic control units
integrated on the board to control the electronic injection system.
3. Installation: Fixed under the instrument panel sundries box with bolt, the double interfaces ECU is
adopted.
4. Definition of LF479Q3 engine controller pin
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1 16
17 32 73
33 52
53 72
1
2
3. Connection circuit
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4. Trouble diagnosis: The short and open circuit of the two coils of the idle speed stepper motor will be
monitored by the ECU. When such troubles occur, the engine MIL will be lighted and the engine will be
operated under trouble mode. If the engine fails to work normally after check the steps of the stepper motor
with a diagnostic instrument, the intake air pressure should be checked to ensure the normal operation of
the piston of the stepper motor.
X. Ignition coil
1. Function: To convert primary winding low voltage electricity into secondary winding high voltage
electricity, to produce spark to burn the mixture of fuel and air in the cylinder.
2. Grouped ignition: Based on the signal from the crankshaft/camshaft position sensor, the ECU controls
the low signal of ignition coil for the ignition of the engine according to crankshaft position sensor.
3. Structure and principle: Consists of primary winding, secondary winding, iron core, housing, etc.
When the battery is connected with the primary winding, the primary winding will be charged. When the
circuit of the primary winding is cut down by the ECU, the charge will stop. Meanwhile, the high voltage
electricity will be induced in the secondary winding.
3. Shock sensor
Diagnostic Trouble Code (DTC) Trouble Location or Type
P0325 Shock sensor 1 circuit trouble
Test
S/N Operation Actions
Results
1 Turn off the ignition switch, and stop the engine. Next step
Disconnect the shock sensor from the harness. Measure the Yes Next step
resistance between pin (1) and pin (2) with a multimeter. Is
2
the resistance greater than 1MΩ? No Renew sensor
Gently knock around the shock sensor with a small hammer. Yes Next step
3 Check for AC signal output between pin (1) and pin (2)
No Replace sensor
with a multimeter.
4 Turn on the ignition switch, and do not start the engine. Next step
Connect an adapter between the ECU and the harness. Repair or replace
Yes
5 Check for open or short circuit between pin J1-05, J1-69 of harness
the ECU and the pin (1), (2) of the sensor with a multimeter. No Replace ECU
5. Oxygen sensor
Diagnostic Trouble Code (DTC) Trouble Location or Type
P0031 Heated oxygen sensor heater control circuit low (front)
P0032 Heated oxygen sensor heater control circuit high (front)
P0037 Heated oxygen sensor heater control circuit low (rear)
P0038 Heated oxygen sensor heater control circuit high (rear)
P0130 Oxygen sensor circuit trouble (front)
P0131 Oxygen sensor circuit voltage low (front)
P0132 Oxygen sensor circuit voltage high (front)
P0134 Unactivated oxygen sensor (front)
P0136 Oxygen sensor circuit trouble (rear)
P0137 Oxygen sensor circuit voltage low (rear)
P0138 Oxygen sensor circuit voltage high (rear)
P0140 Unactivated oxygen sensor (rear)
P1166 Oxygen sensor controller self-adaptive trouble diagnosis
Test
S/N Operation Actions
Results
1 Ignition switch in position ON. Next step
2 Disconnect the oxygen sensor from the harness. Measure Yes Next step
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the voltage between pin (1) (+) and pin (2) (-) with a
No 4
multimeter. Is the voltage about 12V?
Yes Replace ECU
Measure the resistance between pin (1) and pin (2) with a
3 Next step
multimeter. Is the resistance between 6k and 25k? No
Replace sensor
Check the fuse for the oxygen sensor heated circuit. Is the Yes Replace fuse
4
fuse OK? No Next step
Check for open or short circuit between pin (1) of the Repair or replace
Yes
oxygen sensor and the pin J1-02 of the main relay, as well harness
5
as between pin (2) of the oxygen sensor and the pin J1-61
No Next step
(front)/J1-64 (rear) of the ECU with a multimeter.
Connect the oxygen sensor, keep neutral position, start the
6 engine, and keep idle speed until the coolant reaches normal Next step
temperatue.
Disconnect the oxygen sensor from the harness. Measure Yes Next step
the voltage between pin (4) (+) and pin (3) (-) with a
7
multimeter. Is the voltage between 0V and 0.9V? No Replace sensor
Connect an adapter between the ECU and the harness. Repair or replace
Yes
Check for open or short circuit between pin J1-06, pin J1-62 harness
8
(front)/ J1-38 (rear) of the ECU and pin (3), pin (4) of the
No Replace ECU
sensor with a multimeter.
8. Fuel injector
Diagnostic Trouble Code (DTC) Trouble Location or Type
P0261 Cylinder 1 fuel injector circuit low
P0264 Cylinder 2 fuel injector circuit low
P0267 Cylinder 3 fuel injector circuit low
P0270 Cylinder 4 fuel injector circuit low
P0262 Cylinder 1 fuel injector circuit high
P0265 Cylinder 2 fuel injector circuit high
P0268 Cylinder 3 fuel injector circuit high
P0271 Cylinder 4 fuel injector circuit high
Test
S/N Operation Actions
Results
1 Ignition switch in position ON, do not start the engine. Next step
Disconnect the electromagnetic fuel injector from the
2 harness. Connect the two pins of the multimeter with the Next step
pin (1) (+) and the engine respectively.
Yes Repeat 2
Ignition switch in position ON. Check if the voltage of 12V
3 Yes (all) As per S/N 6
can be read in the multimeter for about 1 second.
No Next step
Check for open or short circuit between pin J1-02 of the Repair or replace
Yes
4 main relay and pin (1) of solenoid fuel injector with a harness
multimeter. No Next step
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Repair or replace the fuel pump relay/main relay and Repair or replace
5 Yes
relevant circuit. harness
Connect an adapter between the ECU and the harness.
Check for open or short circuit between pin J1-55, pin
6 No Next step
J1-70, J1-56, J1-71 of the ECU and pin (2) of the solenoid
fuel injector with a multimeter.
Yes Repeat 7
Measure the resistance between pin (1) and pin (2) of the Yes (all) Next step
7 solenoid fuel injector with a multimeter. Is the resistance Replace
between 12Ω and 16Ω under the temperature of 200C? No electro-magnetic
fuel injector
Connect the solenoid fuel injector, keep neutral position, Yes Repeat 8
start the engine and keep idle speed. Disconnect the
8
electromagnetic fuel injector in sequence. Check the engine No Replace ECU
for vibration when each connector is removed.
Before the steps for trouble diagnosis based on engine symptom, carry out the following primary checks at
first:
1. Check the ECU and MIL for abnormal condition (for vehicles without MIL, skip this step);
2. To confirm no trouble information record found with a trouble diagnostic instrument or flasher;
3. Check the idle speed data after warm-up of the electronic control system with a trouble diagnostic
instrument for normal range;
4. Confirm the concern of the user and the actual location of the symptom.
Then, check the appearance:
1. Check the harness grounding for cleanness and tightness;
2. Check the vacuum pipe for break, twist and correct connection;
3. Check if the pipe is blocked; check if the inlet pipe is extruded or damaged;
4. Check the sealing between the throttle body and the intake manifold for damage;
5. Check the high voltage wire of the ignition system for break, aging and wrong connection;
6. Check the lead for correct connection and check the connector for looseness.
Key note: In case of the above-mentioned conditions, repair these troubles at first. Otherwise, the following
trouble diagnosis and maintenance will be affected.
Diagnosis help:
1. To confirm no trouble record found for the engine;
2. To confirm the concern of the user;
3. No abnormal condition is found after check following the above-mentioned steps;
4. During check and maintenance, do not ignore the impact on the system from the vehicle maintenance,
cylinder pressure, mechanical ignition timing, fuel condition, and so on.
5. Replace the ECU, and then carry out tests.
If the trouble is removed at this moment, the trouble is produced within the ECU. If the trouble can not be
removed at this moment, replace the original ECU, and repeat the steps.
1. Engine fails to run or runs slowly at start
Test
Operation Actions
S/N Results
Measure the voltage between the two terminals of the Yes Next step
1 battery with a multimeter. Is the voltage about Repair or replace
No
10-12.5V? battery
Turn the ignition switch to ON. Measure the voltage Yes Next step
2 between the ignition switch and the terminal of the Repair terminal or
No
battery positive pole. Is the voltage about 10-12.5V? replace lead
Turn the ignition switch to START. Measure the Yes Next step
voltage of the terminal of the ignition switch to connect
3 Repair or replace
with the positive pole of the start motor with a No
ignition switch
multimeter. Is the voltage greater than 8V?
Keep the ignition switch in START. Measure voltage of Yes Next step
4 the terminal of the positive pole of the start motor with Repair terminal or
No
a multimeter. Is the voltage greater than 8V? replace lead
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Repair or replace start
Check the start motor for open or short circuit with a Yes
5 motor
multimeter.
No Next step
Yes Remove the trouble
6 Check if the engine is locked for lack of lubrication.
No Next step
In winter, check if the start motor is affected by high Yes Replace the oil
7 resistance as improper engine lubricant and gear box Repair or replace timing
No
oil is applied. belt
Test
S/N Operation Actions
Results
Yes Next step
6 Check the ignition coil for normal operation.
No replace
Check if the interfaces of the high pressure coil are Yes Next step
7
well connected. No Connect
Turn the ignition switch to ON. Check if the fuel pump Yes Next step
8 relay and the fuel pump can keep running for 3 Check and repair fuel
No
seconds. pump circuit
Connect the fuel pressure gauge valve. Short-circuit the Yes Next step
pin J1-47 and the pin J1-73 of the fuel bump relay, and
9
run the fuel pump. Check if the fuel pressure is about No 13
300kPa.
Take out the fuel distribution pipe together with the Yes 12
10
fuel injector. Disconnect the fuel injector from the No Next step
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harness. Check the fuel injector for fuel injection with
the voltage of 12V directly from the battery.
Clean the fuel injector and check the fuel injector for Yes Next step
11
fuel injection. No Replace fuel injector
Yes Replace fuel
12 Check if the fuel is wrong or contains water.
No 18
Yes Next step
13 Check if the fuel pressure is lower than 300kPa.
No 17
Close the fuel gauge valve. Turn on the ignition switch Yes Next step
14 again and keep the fuel pump working for 3 seconds. No
16
Check if fuel pressure can be produced.
Yes Replace or repair fuel
16 Check the fuel intake pipe for leakage or blockage. intake pipe
No Replace fuel pump
Yes Repair or replace fuel
return pipe
17 Check if the fuel return pipe is blocked or bent.
No Replace fuel pressure
regulator
Connect an adapter between the ECU and the harness. Yes Next step
Check the pin J1-73 of the ECU for voltage. Check the
18 positive power supply line of the above-mentioned Repair or replace
No
ECU pin and the earth wire of the pin J1-01, J1-17, harness
J1-18 connected to the ECU for normal operation.
Check the parts and components of the intake system Yes Repair
19
for leakage. No Next step
Check if the intake manifold absolute pressure and Yes Repair or replace
20
temperature sensor is blocked. No Next step
Check if the coolant temperature sensor for normal Yes Next step
21
operation. No Repair or replace
Remove mechanical
Check if the gap between the piston and the cylinder is Yes
22 trouble
too wide. Check the cylinder for leakage.
No Replace ECU
Gently step on the throttle, and check if the Check and replace throttle and
4 Yes
vehicle can be started easily. idle speed passage
Connect the fuel pressure gauge valve. Yes Next step
Short-circuit the pin 30 and the pin 87 of the
5
fuel bump relay, and run the fuel pump. Check No 9
if the fuel pressure is about 380kPa.
Test
S/N Operation Actions
Results
Connect the battery and the fuel injector with a special Yes 8
6 connector. With the voltage supply of 12V, check the
No Next step
fuel injector for normal operation.
Wash the fuel injector and check the fuel injector again Yes Next step
7
for normal operation. No Replace fuel injector
Replace the fuel. Check if the fuel is wrong or contains Yes Replace fuel
8
water. No 14
Yes Next step
9 Check if the fuel pressure is lower than 250kPa.
No 13
Close the fuel gauge valve. Turn on the ignition switch Yes Next step
10 again and keep the fuel pump working for 3 seconds.
No 12
Check if fuel pressure can be produced.
Replace fuel pressure
Yes
Turn on the fuel gauge valve, and block the fuel return regulator
11
pipe. Check if the fuel pressure is quickly produced. Repair or replace fuel
No
injector or fuel pipe
Repair or replace fuel
Yes
12 Check the fuel intake pipe for leakage or blockage. intake pipe
No Replace fuel pump
Repair or replace fuel
return pipe
Yes
Repair or replace fuel
13 Check if the fuel return pipe is blocked or bent.
return pipe
Replace fuel pressure
No
regulator
Before the engine coolant reaches 35°C, take out the Yes Next step
14 idle speed actuator connector, and check if the rotation Replace idle speed
No
speed of the engine is decreased. actuator
Turn the ignition switch to ON. Check the voltage of Yes Next step
the following pins of the ECU. Is the voltage of the pin
15 J1-12 (crankshaft position sensor) is about 12V? Is the Check harness and
empty pin and the pin J1-54 (idle speed stepper motor No
interface
A+) is 0V?
16 Check if the compressed pressure of the engine Yes Next step
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cylinder is normal. No Remove the trouble
Check if the intake air manifold absolute pressure and Yes Repair or replace
17
temperature sensor is blocked. No Next step
Check if the coolant temperature sensor for normal Yes Replace ECU
18
operation. No Repair or replace
Test
S/N Operation Actions
Results
Yes Replace fuel
8 Check if the fuel is wrong or contains water.
No 14
Yes Next step
9 Check if the fuel pressure is lower than 300kPa.
No 13
Close the fuel gauge valve. Turn on the ignition switch Yes Next step
10 again and keep the fuel pump working for 3 seconds.
No 12
Check if fuel pressure can be produced.
Replace fuel pressure
Yes
Turn on the fuel gauge valve, and block the fuel return regulator
11
pipe. Check if the fuel pressure is quickly produced. Repair or replace fuel
No
injector or fuel pipe
Repair or replace fuel
Yes
12 Check the fuel intake pipe for leakage or blockage. intake pipe
No Replace fuel pump
Repair or replace fuel
Yes
return pipe
13 Check if the fuel return pipe is blocked or bent.
Replace fuel pressure
No
regulator
Replace coolant
Take out the coolant temperature sensor, and check the Yes
15 temperature sensor
engine for normal operation.
No Next step
Yes Next step
16 Check the compressed pressure.
No Remove the trouble
Check the resistance of the high voltage wire for each Yes Next step
17
cylinder. Is the resistance OK? No Replace
Yes Replace
18 Check the ignition coil for damage or crack.
No Next step
Yes Replace ECU
19 Check the spark plug for normal operation.。
No Replace spark plug
9. Unstable idle speed or flameout under load (A/C etc)
11. Idle speed too high (self-learning after power cutoff of the ECU)
Test
S/N Operation Actions
Results
Turn the ignition switch to ON. Check if there is Yes Remove the trouble
1 trouble information records with a diagnostic
No Next step
instrument.
Check if the cable connected the accelerator pedal is Yes Adjust or replace
2
locked or tightened. No Next step
Check the canister control valve, fuel pressure Yes Adjust or replace
regulator, crankcase compulsory ventilation vacuum
3
pipe, and the vacuum booster tube of the brake system No Next step
for reliable installation or damage.
Run the engine at an idle speed, keep neutral position, Yes Next step
4 step on the brake pedal, and check if the idle speed is
No 6
too high.
Repair or replace
Clamp the vacuum booster tube. Check if the idle Yes
5 vacuum booster
speed becomes normal.
No Next step
Replace the PVC valve. Clamp the crankcase Yes Replace PVC valve
6 compulsory ventilation vacuum tube. Check if the idle
No Next step
speed becomes normal.
Replace canister control
Clamp the canister control valve tube. Check if the idle Yes
7 valve
speed becomes normal.
No Next step
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Yes Repair or replace
8 Check if the idle speed actuator is blocked or locked.
No Next step
Repair or replace. Check the other parts of the intake Yes Repair or replace
9
air pipe for leakage. No Next step
Yes Next step
10 Check the fuel injector seal ring for damage.
No Replace seal ring
Check the intake air manifold absolute pressure and Yes Replace ECU
11
intake air temperature sensor for damage. No Replace sensor
Test
S/N Operation Actions
Results
Repair or replace fuel
Yes
return pipe
15 Check if the fuel return pipe is blocked or bent.
Replace pressure
No
regulator
Check the data of the intake air manifold absolute pressure Yes Next step
16
and intake air temperature sensor. Is it OK? No Replace sensor
Check the spark plug, high voltage wire, distributor, No Next step
17
ignition coil for normal operation. No Replace or adjust
18 Does it caused by A/C system? Yes Check A/C system
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No ECU Replace ECU
Test
S/N Operation Actions
Results
Install all the removed parts. Release the fuel pressure Yes Next step
8 to 0. Install fuel pressure gauge. Check if the pressure is Check as per fuel pressure
No
normal. test method
Check the ignition time (-5°-20°BTDC). The target idle Yes Next step
9
speed is M/T: 750±50rpm. No Basic check
Start the engine for warm-up. After the engine reaches
normal operation speed, measure the voltage between Yes Next step
the pin J1-62 (front oxygen sensor high signal) or J1-06
(front oxygen sensor low signal) of the ECU and the
10
ground. Under the rotation speed of 2000rpm, the
changes between 0V-0.3V and 0.6V-1.0V should be no Renew front oxygen
No
less than 5 times, at least one time higher than 0.6V, at sensor
least one time lower than 0.3V, an no higher than 1V.
Yes Replace ECU
Check the intake air sensor signal with a diagnostic Check the connector of the
11 instrument. (2.0-6.0gm/sec, at idle speed, air intake temperature
No
7.0-20.0gm/sec, at 2500rpm) sensor circuit for rust or
looseness.
Test
Actions
S/N Operation Results
Yes Next step
1 Visually check if the exhaust pipe and muffle is normal.
No Repair or replace
Start engine and run at idle speed; and listen if there is Yes Next step
2 sound of exhaust gas leak before heating three way
No Repair or replace
catalyzer.
Listen if there is leak from the exhaust pipe behind intake Yes Next step
3
air sensor. No Repair or replace
Check if ignition time is -5°-20°BTDC; and check if target Yes Next step
4
idle speed is M/T: 750±50rpm. No Basic check
Injector check: Stop engine and turn ignition switch to ON Yes Next step
position, and check if the voltage between Pin J1-55, J1-70,
5 Execute injector
J1-56 and J1-71 of ECU and earth output voltage is No
normal. diagnosis procedure
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Turn ignition switch to OFF position; remove ignition coil
Yes Next step
and connect with a normal spark plug; and face the end
6
with the ground and rotate the engine to check if the spark
No Check ignition coil
plug is normal.
Turn ignition switch to OFF position; remove injector, Replace three way
Yes
remove fuel injection pipe and all injection connectors, catalyzer
7 remove connector of fuel injection coil; turn ignition
Replace injector with
switch to ON position; and make sure there is no gasoline No
fuel leak
runs out of the injector.
I. Security items for the diagnosis and maintenance of the fuel injection
Repair:
Check throttling of catalytic converter: Visually check the catalytic converter core with endoscope. And if
there is no endoscope, check if there is crack or dissolved matrix with flashlight.
Note:
(1) As the operation temperature of exhaust system is very high, do not work or maintain part around it
before it cool down. Be especially careful when operating around the catalytic converter, because the
temperature of converter will increase to the highest point in a short period after the engine is started.
(2) Original part (or equivalent part) should be used when replacing any part in exhaust system.
(3) Confirm the source of fault before replacing the catalytic converter, because most malfunctions of
converter are caused by gas, fuel or ignition problem.
(4) As the shapes of catalytic converter and exhaust assembly are similar, be careful when replacing a part.
For some regions (especially vehicles for regions with strict exhaust standards) and models, the converts
are quite different.
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Chapter I Suspension
Section I Introduction
Side‐slip amount/(mm/mm) ±3
The upper end of the telescopic shock damper 2 of the front suspension is mounted on the body through
rubber mount of the front suspension and its lower end is fixed on the steering knuckle which is connected
to the lateral oscillating arm by ball chain. For the suspension of this type, most of the side force
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undertaken by the wheel is shared by the front oscillating arm through steering knuckle, while the left force
by the shock damper. Because the two ends of the stablizer bar are connected with the front oscillating arm,
the stabilizer works as the vertical track bar meantime.
(1) Front oscillating bar. The structure of front oscillating bar is shown in Fig. 4-3. The lateral oscillating
arm 3 made through forging and presenting shape of “I” boasts high degree of stiffness and strength. The
inner end of the front oscillating arm 3 hinges with carrying shaft of front oscillating arm 11 on the front
oscillating arm bracket 10 through the rubber bushing 4. Two sides of the rubber bushing are equipped with
gaskets 5 and 8, the end of which is tightened by nut 7. The carrying shaft of front oscillating arm 11 is
jointed with braket 10 which is fixed on the bottom of the body through bolts.
The position and structure of the connecting hole of lateral oscillating arm and stablizer bar are shown in
Fig. 3-4 (a) and the structure of ball pin in Fig. 3-4 (b). The ball pin 1 is mounted on the integral type ball
cup 3 whose position is limited by cover stem 4 and the rim of the ball cup 3 is turned over so as to rivet
tight the cover stem and make it an indecomposable integral structure. To improve the reliability of the
joint between ball pin and steering knuckle, the connecting bolt locks the ball pin through the ring groove at
the end of the ball pin. The ball pin is lubricated by grease and is equipped with dustproof cap 2 on the
lateral oscillating arm so as to prevent the entrance of filth.
(2) Stablizer bar. In order to lessen the lateral inclination and lateral angle vibration of the body when
turning in high-speed driving, LIFAN sedans are added with stablizer bar in suspension.
The fitting of front suspension’s stablizer bar is shown in Fig. 3-5. The flat “U” shape stablizer bar made of
spring steel is installed in the front bottom of the car laterally. Two ends of the middle of bar 1 bear in two
rubber buffer covers 9 freely, while the buffer cover 9 is fixed on sway bar bracket 2 and 3 through the
sway bar retaining clip 10 and left beam 4 by bolt 12 and the stablizer bar bracket is connected to the body
through bolt. Ends of stablizer bar’s two sides’ vertical parts joint each other through rubber ring 8 and
corresponding holes on lateral oscillating arm 5, terminals of which are tightened by retaining ring 7 and
nut 6.
(3) Coil spring and shock damper. The structure of coil spring and shock damper is shown in Fig. 4-6. The
shock damper is the bi-directional hydraulic barrel type, the upper end of which is mounted on the body
through front suspension mount assembly 14 and connected with the body by bolts. The lower end of the
shock damper is jointed with lower mount of the shock damper 15 and connected with the steering knuckle
through the lower mount.
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The front suspension mount 14 is integrated by rubber mount 2, rubber mount cap 1 and rubber mount
lining 11. The rubber mount 2 with larger volume can effectively mitigate the impact so as to improve the
comfort. The rubber mount lining 11 is installed on the cylinder rod 4 with its terminal fixed by nut 13.
Equipped with bolt, the rubber mount cap 1 is connected with the body through the bolt and is fixed.
The coil spring 5 is equipped on the shock damper, the upper and lower ends of which are mounted on the
spring upper seat 3 and spring lower seat 6 respectively.
The spring upper seat is on the cylinder rod, while the lower seat is jointed with the shock damper. In order
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to ensure the convenience and agility of steering, the thrust bearing 10 lubricated with grease is installed
between front suspension mount 14 and spring upper seat 3. In order to prevent the entrance of dust from
upper part, the dustproof cap 12 is installed on the rubber mount lining.
When the coil spring is forced to be compressed and deformed, if the stae of deforming is excessive, the
cylinder rod will move downward longer than that of the shock damper cylinder so that the shock damper
will be damaged; therefore, the rubber buffer stopper 9 is installed on the bottom of spring upper seat to
lessen the impact and limit the position. Dustproof cap 9 and buffer stopper 9 are merged into a whole.
The axis line of McPherson suspension’s kingpin is the line between the centers of upper and lower hinges.
Because the lower mount of the shock damper sways with the lateral oscillating arm, the angle of the axis
line of its kingpin is changeable. Therefore, when this kind of suspension is deformed, the kingpin
orientation angle and the track will be altered to some extent. If the deployment of lever system is
appropriately designed, the orientation parameter of the wheel can be changed only a little. The outstanding
feature of this kind of suspension is that it can enlarge two front wheels’ inside flexible space so as to
facilitate the deployment of the engine and other parts; therefore, it is often applied to sedans.
2. Rear suspension
The rear suspension consists of lateral oscillating arm I of the rear suspension, lateral oscillating arm II of
the rear suspension, vertical tension rod, coil spring and shock damper with their structures shown as
follows:
(1) Lateral oscillating arm and vertical tension rod. The structure of the lateral oscillating arm and vertical
tension rod is shown as Fig. 3-8. The lateral oscillating arm of the rear suspension is made through the butt
weld to the armor plate with its cross section of box type. The outside of lateral oscillating arms I and II
hinges with bottom of the rear shaft head bracket 3 through bolt 8 and the rubber bush installed in
corresponding holes in the rear shaft head bracket. The inner end of the lateral oscillating arm, whose hole
is equipped with rubber bush, joints with the body through bolts.
The joint between inner end of oscillating arm II and the body is equipped with rear wheel toe-in adjusting
mechanism, which consists of adjusting cam for toe-in 5, toe-in adjusting plate 6 and bolt 7. Turning the
adjusting cam for toe-in can change the toe-in value of the rear wheel. The vertical tension rod 4 is made of
steel tube, which decreases the unsprung weight. The tension rod, whose front holes are installed with
rubber bushing and rear end is shaped to furcation, joints with the body through bolts, hinging with the rear
shaft head bracket through bolt 8 and the rubber bushing in corresponding holes of the rear shaft head
bracket 3.
Less longitudinal rigidity of rubber bushing at every joint between lateral oscillating arm of rear suspension
and the vertical tension bar may effectively ease the longitudinal impact from road surface; meanwhile,
larger lateral stiffness may change the wheel orientation angle less. There are grooves on the outer ring
surface of rubber bushes at two sides of the vertical tension bar, which can diminish the longitudinal
rigidity of the vertical tension bar so as to ease the vertical impact.
(2) Coil spring and shock damper. The structure of coil spring and shock damper of rear suspension is
shown as Fig. 3-9. The structure of shock damper of the rear suspension is the same as that of the front
suspension, with its supporting characters that the upper end of shock damper mounts on the body through
the rear suspension mount 1 and its lower end joints with the shock damper bracket and connects to the rear
shaft head bracket through a mount.
The structure of coil spring 5 is the same as that of the front suspension with its supporting feature of the
rubber pad 2 added between the coil spring and spring upper seat. The rear suspension mount 1, made of
rubber, is added back plate 10 during compression molding. Through this back plate, the rear suspension
mount connects with the upper end of cylinder rod of shock damper 9 with its end fixed by nut 11. The rear
suspension mount 1 is equipped between the body 12 and spring upper seat 3, connecting the spring upper
seat and the body with bolts.
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(3) Stablizer bar of rear suspension. LF7132 is equipped with the stablizer bar on its rear suspension with
its structure manifested in Fig. 3-10. The basic structure of the stablizer bar is the same as that of the front
suspension. Their key distinction lies in the connection of ends of the stablizer bar’s two sides and the
lateral oscillating arm. The stablizer bar 6, whose ends are shaped to be flat, is set on the stablizer bar
supporting rod 8, with its top and bottom installed with rubber pad 5 and gasket and nuts’ axial fastening.
Lower end of stablizer bar supporting rod 8 hinges with supporting rod mount 9 through bushes and bolts
with the supporting rod mount fixed by bolts on rear oscillating II 7.
(2) Replacement of button head pin dustproof cap. Dismantle the dustproof cap with a screwdriver, during
which, don’t damage the dustproof cap mount. Inject lubricant grease into the button head pin dustproof
cap then and finally press into the dustproof cap with special maintenance tool. Please don’t splash the
lubricant grease or oil on the dustproof cap mount.
(3) Replacement of front oscillating arm bush. Dismantle the lower lateral oscillating bush with special
tools and press into a new bush
3. Inspection to stablizer bar
As shown in Fig. 3-13, check the deformation or damage of the stablizer bar and its retaining clip as well as
deformation of the left and right brackets of the stablizer bar.
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(2) Turn the front and rear bumper with force to make them move upwards and downwards so as to check
whether the shock damper works within the scope of extending and compressing. If the vehicle body
vibrates upwards and downwards for two to three times with no abnormal sounds, it can be concluded that
the shock damper works well.
(3) After driving for a distance, stop the vehicle and feel the shock damper with hands. The shock damper
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LIFAN320 Service manual
without temperature difference has faults.
(4) Within mileage of 5mm-10mm, when the cylinder rod is moved upwards and downwards rapidly, the
force needed should not be changed.
(5) In the course of above inspection, if there are any abnormal states or sounds, the shock damper shall be
changed.
Note: Move the cylinder rod for three to four times upwards and downwards before implementing above
inspections. The oil leakage or damage inspection shall be carried on the shock damper of LIFAN sedans
every 40,000km. If the shock damper leaks oil or is damaged, please replace it.
LF7132 adopts front axle (front shaft) drive, and its rear axle (rear shaft) is a lateral oscillating dead axle.
The configuration of the tripod universal joint is shown as Figure 3-17. The universal joint bushing 5 is
framed with the internal half shaft with three axial raceways processed inside.
The tripod assembly 10 is connected to intermediate drive shaft 1 through spline with its end limited by
snap ring 3. Three shaft journals, with three ball type rollers 6 limited by the gasket and snap ring through
needle roller bearing 8, are processed on the tripod assembly. With the cooperation of the three rollers and
the three axial raceways in the universal joint bushing, the tripod assembly can not only conduct axial
movement relatively to the universal joint bushing to modify the length of the drive shaft, but also turn a
angle relatively to the axes of the universal joint bushing so as to transmit the force when there is a certain
angle between the internal half shaft and the intermediate drive shaft. This tripod universal joint with
simple structure saves the part of expansion bend, so the resistance is small, and the impact from the
ground to the body can be eased.
The configuration of the rzeppa universal joint is shown as Figure 3-18. The universal joint mainly consists
of internal ball seat, ball type housing, retainer and steel drive ball, etc. The internal ball seat 7 limited by
snap ring 9, with 6 grooves on the surface as the external raceway, is connected to the intermediate drive
shaft 1 through the internal spline. Six steel drive balls 6 are installed in every groove respectively with the
retainer 4 keeping them within the half facet. During the transmission, the drive force is delivered by the
intermediate drive shaft 1, internal ball seat 7, steel drive ball 6 and ball type housing 8 in turn. Both the
rzeppa universal joint and the tripod universal joint adopt the lubricant grease. The rzeppa universal joint
can deliver the drive force under maximum corner of 42 degree between 2 shafts, and in working, whatever
the drive force transmission direction, the six steel balls will participate in the transmission; this universal
joint with strong carrying capability, compact structure and easy dismantling process is widely used in the
steering drive axle. The relationship of the steering knuckle, front wheel hub, front drive shaft and relevant
parts of LIFAN sedans is shown in Figure 3-19.
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Figure 3-18 Rzeppa universal joint
1. Intermediate drive shaft 2. Clip 3. Dustproof cap 4. Retainer 5. Clip
6. Steel drive ball 7. Internal ball seat 8. Ball type housing 9. Snap ring 10. Steel ball
Figure 3-19 Relationship of steering knuckle, front wheel hub, front drive shaft and relevant parts
1. Brake disc 2. Caliper assembly 3. Wheel hub 4. Splash guard 5. Steering knuckle
6. Bolt 7. Nut 8. Shock damper 9. Half shaft 10. Cotter pin 11. Steering track rod
12. Nut 13. Front oscillating arm 14. Bolt 15. Snap ring 16. Nut
Fig. 3-24 Tire outside abrasion Fig. 3-25 Tire shoulders abrasion
5. The main cause of tire shoulders abrasion is the excessively low tire air pressure.
6. The main cause of tire center abrasion is the excessively high tire air pressure.
7. Main cause of tire jagged abrasion
② Take out the cotter pin, nuts of front wheel hub, and the brake disc. (Fig. 3-31)
③ Take apart the steering track rod and the front stabilizer, bulb cotter bolt of lower transverse arm of front
suspension and button head. (Fig. 3-32)
Fig. 3-33 Drawing out the steering knuckle from the drive shaft
⑤ Dismantle the front wheel bearing. Remove the oil seal of wheel hub bearing with screwdriver first and
dismantle the inside (outside) of the bearing from the wheel hub with special tools.
⑥ Take out the snap ring with needle nose pliers, and remove the bearing from the steering knuckle with
special maintenance tools.
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(2) Decomposition:
① Unscrew the strap on the front drive shaft with a screwdriver to take apart the dustproof cover.
② Take apart the inside universal joint. As shown in Fig. 3-34, make assembly mark inside the universal
joint bushing and on the surface of the bearing with oil paint to prevent washing out.
Fig. 3-34 Making assembly mark inside the universal joint bushing
③ Remove the snap ring with snap spring pliers.
④ Dismantle the inside universal joint tripod assembly, make the assembly mark at the end of the tripod
assembly and the axle with drift pin, as shown in Fig. 3-35, and knock down the tripod assembly from the
axle with a copper rod, as shown in Fig. 3-36. Make sure to put the copper rod at the protruding part of
tripod assembly and not at the roller.
Fig. 3-35 Making the assembly mark at the Fig. 3-36 Pushing the tripod assembly
end of the tripod assembly and the axle
2. Assembly
The assembly order of the front drive shaft is reverse to that of removal, and pay attention to items below:
(1) When assemble the inside universal joint tripod assembly to the universal joint, please make the
edentulous end of the tripod assembly face the axle and aim at the assembly mark made during the removal.
(2) During the tripod assembly installation, make sure to put the copper rod at the protruding part of tripod
and not at the roller.
(3) When assemble the inside universal joint bushing, fill the universal joint bushing with lubricant grease
and aim at the assembly mark made during the removal.
3. Inspection
As shown in Fig. 3-37, check the crack and damage of the front steering knuckle, damage of the front
wheel hub, damage or the abrasion of the brake disc surface, deformation of the dustproof cap of the brake,
etc. If there are any problems, please repair or renew in time.
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As shown in Fig. 3-38, check the wearing parts of the front drive shaft. Check the damage or abrasion of
the inside universal joint bushing, damage or abrasion of the universal joint tripod assembly, crack of the
dustproof rubber cover, abrasion or damage of the outside universal joint assembly end, etc. If seriously
worn or damaged parts are detected, they shall be repaired or changed.
(3) Remove the brake pipe from the slave cylinder with special tools, and dismantle the rear brake
assembly (Fig. 3-40).
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(4) Dismantle the rear shaft head sub-assembly. Remove the rear shaft head and connecting bolt and nut of
the vertical tension rod; remove the connecting bolt and nut of the rear shaft head and suspension
oscillating arm I; remove the connecting bolt and nut of the rear shift and suspension oscillating arm II;
remove the connecting bolt and nut of the rear shaft head and shock damper mount; dismantle the rear shaft
(Fig. 3-41).
IV. Tightening torque for main parts of front and rear shafts
As for tightening torque for main parts of front and rear shafts, please refer to Table 3-1
Table 3-1 Tightening torque for main parts of front and rear shafts
Name of parts to tighten Tightening torque/N∙m Name of parts to tighten Tightening torque/N∙m
Conneting bolt of 88.2~127 Connecting bolt of rear 73.5~102.9
steering knuckle and shaft head bracket and
shock damper oscillating arm II
Fixing bolt of steering 78.4~102.9 Connecting bolt of rear 73.5~102.9
knuckle and lower shaft head bracket and
oscillating bulb vertical tension rod
Connecting bolt of rear 88.2~117.6 Tightening nut of front 180~230
shaft head bracket and and rear shaft wheel
shock damper lower hub
mount
Connecting bolt of rear 73.5~102.9
shaft head bracket and
oscillating arm I
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The model of tire of LF7132 sedan is 165/70R14, which belongs to tubeless transverse-cord tire.
Front left wheel-rear left wheel-front right wheel-rear right wheel-front left wheel
(4) Make a mark at the tire center of rear end of every front wheel and measure the distance A between
measuring marks (Fig. 3-46).
(5) Push the vehicle forward slowly until the wheel turns over 180° (Fig. 3-47).
(6) Measure the distance B between marks made in step (4), as shown in (Fig. 3-48). Calculate the front
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wheel toe-in value, namely A-B value. The front wheel toe-in value is regulated as -1mm~3mm.
(7) Adjust the front wheel toe-in (Fig. 3-49). Relax the locknut of steering lateral rod joint; adjust the toe-in
through turning the steering lateral rod joint. Note: Don’t turn the dustproof cover during adjustment; the
turning amount of the left and right lateral rod shall be identical before the toe-in adjustment; the length of
C shown in Fig. 4-49 must be the same; otherwise, the turning angle of left and right angle will be different.
(8) Check whether the sideslip value accords with the regulated value of -3mm/m~3mm/m or not with
sideslip measuring apparatus.
② Insert the hexagon wrench into the hexagon hole on the back of the adjusting cam (Fig. 3-51) and turn
the hexagon wrench. When the left and right adjusting cam is turning, the rear wheel toe-in value will
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change about 5mm, with identical angular turning of the left and right adjusting cams. When the adjusting
cam turns in clockwise direction, the rear wheel toe-in will increase; in counter-clockwise direction,
decrease.
This power steering system consists of manual steering system and hydraulic power steering booster. Its
hydraulic power cylinder is fixed on the housing of steering gear, and the piston control lever of the
hydraulic power cylinder hinges on the steering rack, by which, the steering power is output.
The LIFAN sedan power steering system adopts the rotary type steering control valve with compact
structure as the control device, vane type power steering pump as the power source, piston control lever of
the hydraulic power cylinder and rack as the power delivery mechanism. When the vehicle needs steering,
the engine drives the power steering pump through the transmission belt and generates the hydraulic power.
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The flow of the steering fluid and pressure is adjusted by the adjuster in the pump. The hydraulic pressure
is delivered to the rotary type steering control valve of the steering gear mechanism by the steering pump.
The steering control valve will adjust the hydraulic pressure according to the turning state of the steering
wheel and change the flowing direction of the steering fluid, guide the pressure oil fluid into the hydraulic
power cylinder, boost the piston control lever and rack to do beeline movement to help the swerving wheel
to turn and realize the power steering so as to deliver the filtrated steering fluid in the fluid reservoir
returing from the low pressure side of the power cylinder to the steering pump to circulate.
3. Steering gear tube, steering axle and steering drive axle (Fig. 3-54)
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Fig. 3-54 Steering gear tube, steering axle and steering drive axle
1. Steering gear tube 2. Upper bracket 3. Lower bracket
4. Steering axle 5. Universal joint 6. Steering drive axle
7. Dustproof cover I 8. Dustproof setting bracket 9, 11, 13. Bolt
10. Dustproof cover II 12. Nut
The steering gear tube is fixed with bolts on the bottom of front dash panel and dash board in cab through
the lower flange and upper fixing panel.
The steering axle consists of axle and bushing connected by colophony pin. When the vehicle crash
happens, the excessively large impact can snip the colophony pin so that the steering axle and bushing can
move relatively so as to protect the driver from the stab of the steering axle. Considering the overall vehicle
disposal and safety as well as the malfunction of the steering gear due to the vehicle body transformation,
the steering drive axle is adopted between the steering axle and steering gear.
The round vehicle steering wheel is the two radial type wheel made of colophony materials
The brake system of LF 320 is composed of driving brake system and parking brake system. The driving
brake consists of brake pedal, brake master cylinder, vacuum booster, ABS mechanism, brake wheel
cylinder, brake and brake pipeline. See Figure 3-56. The parking brake system consists of control lever and
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parking brake cable, etc.
1. Brake
(1) The structure and the installation disposal of the front wheel brake are shown in Figure 3-57. The front
wheel brake is the floating pliers disc brake. Clearance self-adjusting device and brake pad wear limit
warning device are installed in the brake.
When braking, the brake fluid is pressed into the brake caliper oil tank. The piston is moved to the brake
disc under hydraulic pressure to make the brake pad pressed on the brake disc through the silent pad. At the
same time, the brake caliper is axially floating under the hydraulic pressure and press the outside brake pad
on the brake disc to actualize brake.
Brake pad wear limit warning device has been installed on brake pad of the disc brake for LIFAN sedan,
with structure shown in Fig. 3-58.
The master brake cylinder is made up of cylinder body, piston, spring, spring seat, oil seal and filter, and
connected with power-assistant front end with two bolts. There is a brake store fluid can on the master
cylinder, and two working cavities are connected in the master cylinder. When stepping on the brake pedal,
the push rod will move to the left to make the seal ring plug up the front oil hole, which produces fluid
pressure in the front cavity; then it will push the piston to the left to plug up the rear oil hole, which
produces fluid pressure in the rear cavity, and connects to the front and rear brake trough brake pipe and
brake hose.
For brake system common fault and fault elimination of LIFAN sedan, please refer to Table 3-3.
Table 3-3 Brake system common fault and fault elimination
Fault
Possible cause Elimination method
phenomena
(1) The clearance self-adjusting mechanism
(1) Repair or replace the parts of the
of the brake is ineffective, and the clearance
self-adjusting mechanism
Ineffective is too big.
brake, and too (2) The brake shoe of rear brake is excessive
(2) Replace the pad of brake shoe.
big clearance of wore.
brake pedal (3) Adjust the free play of the pedal.
(3) The free play of the pedal is too big.
(4) Bend and distortion of brake shoe (4) Replace the brake shoe
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Step on the
(2) Vent the air in this system
pedal with (2) There is air in hydraulic system
invariable
(3) Inject the specified brake fluid
power, with (3) Use the unspecified brake fluid
pedal touching
(4) The piston leather packing of master
floor (4) Replace the leather packing
brake cylinder is too wore or scraped.
(5) The body of master brake cylinder is too
(5) Replace the master brake cylinder
wore or eroded.
(1) The air pressure of left and right tires is (1) Adjust tire pressure
different.
(2) Replace hub bearing
(2) Hub bearing is wore or broken.
(3) The brake pad or shoe of one side is dirty. (3) Clean the brake pad or shoe
(4) Brake shoe of one side is bent or
(4) Replace the brake shoe
Braking distorted.
deviation (5) Brake bottom plate of one side is (5) Fasten or replace the brake bottom
distorted or loose. plate
(6) The fixed bolt of one-side brake caliper is
(6) Fasten the fixed bolt.
loose.
(7) The piston of one-side brake caliper is
(7) Repair or replace the brake caliper.
felted or locked.
(8) Installation of mounting bracket or the (8) Fasten the bolt or replace the parts
fixed bolt is loose of the mounting bracket
(3) Pull the piston with cross-recessed screwdriver, and dismantle the limiter bolt and seal pad.
(4) Pull the piston with cross-recessed screwdriver, and dismantle the flexible retaining ring with caliper.
(5) Remove the first and secondary piston from the master cylinder.
3. Check the brake master cylinder
After disassembling the brake master cylinder, please pay attention to the parts and contents as shown in
Fig. 3-68.
Fig. 3-69 Remove the vacuum booster from the vehicle body Fig. 3-70 Disassemble the vacuum booster
(2) Install the diaphragm, push rod and air valve assembly onto the piston and lock them with a retaining
ring (Fig. 3-73).
(3) Install reaction plate, reaction rubber block and reaction ring and lock them with a tooth ring (Fig. 3-74)
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(5) Install the control valve on the valve seat. Then install them together on the rear housing and install the
control valve spring, valve spring and spring seat (Fig. 3-76).
(6) Install the filter cartridge and washer and lock them with E retaining ring. Then install the dustproof cap
and assemble the front and rear housings of the booster. Screw down the nuts at left and right sides of the
special tool by even force. Please remind not to tighten the nuts too much and make sure that the diaphragm
is not pressed; counterclockwise rotate the screw of special tool to align the assembly marks on the front
and rear housings.
(7) Install the front housing air seal, output stem, nut and push rod fork.
(8) Adjust the clearance of booster output stem. Adjust the clearance of output stem by rotating nuts on the
top of the output stem to reach the regulated value.
Fig. 3-78 Remove the lining, sound-proof plate and guide vane
2. Check the front brake
Check the brake lining. Check the thickness of brake lining by the access hole on the clamp (Fig. 3-79).
The regulated thickness of brake lining is 10mm and limit thickness is 1mm.
(3) As shown in Fig. 3-83, firstly remove the fixed pin and tension spring of brake shoe, and dismantle the
parking brake cable from the parking brake rocker arm and remove the brake driven shoe of rear wheel.
(4) Remove the split retaining ring on the brake shoe, and also parts such as brake rocker arm, adjustment
plate and pawl.
(5) Remove oil pipe from the brake slave pump, then the fixed bolts of slave pump and also brake slave
pump of the rear wheel from the brake bottom plate.
2. Check the rear brake
Check the parts and contents of rear brake as shown in Fig. 3-84.
Fig. 3-87 Check and adjustment of the free play of brake pedal
(3) Screw in the brake lamp to make the thread end contact the buffer pad, and then lock it by lock nut 1 of
brake lamp switch.
(4) Connect the wire plug of brake lamp switch.
Note: After adjustment, please make sure that the free play is normal and the brake lamp works normally.
(2) Check the load air tightness. Start the engine and then step on the pedal after it operates for 1-2 min.
Stop the engine while keeping the pedal force unchanged. The pedal height should no change within 30s
(Fig. 3-90).
(2) Check the air tightness. Start the engine, and then stop it when the degree of vacuum is over 66.5 kPa,
and measure the degree of vacuum. It should not descend within 15s after stopping the engine.
(3) Check the load air tightness. Under condition that the engine works, step on the pedal by 196N force.
When degree of vacuum at 66.5 kPa, stop the engine and measure the degree of vacuum. It should not
descend for 3.325 kPa within 15s after stopping the engine.
(4) Check the working state under no power assisted. Make the degree of vacuum be zero when engine
does not work. Check the relation between the brake pedal force and the master cylinder output hydraulic
pressure. The regulated value as follows:
When pedal force is at 98N, the output hydraulic pressure is 637 kPa; when pedal force is at 294N, the
output hydraulic pressure is 3704.0kPa.
(5) Check the working state under power assisted. Make the engine operate. When the vacuum meter reads
4547.2 kPa, stop the engine and then step on the brake pedal and check the relation between brake pedal
force and pedal master cylinder output hydraulic pressure. The regulated value is as follows: when pedal
force is at 49N, the output hydraulic pressure is 1803 kPa; when pedal force is 98N, the output hydraulic
pressure is 4547.2 kPa; when pedal force is 147N, the output hydraulic pressure is 4588.0 kPa; when pedal
force is 196N, the output hydraulic pressure is 6262.2 kPa.
III. Inspection and replacement of brake fluid
1. Inspection of brake fluid liquid level
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It is recommended to check the liquid level of brake fluid in fluid reservoir after 10,000 km’s drive. The
proper fluid level should be between the upper limit marking (max) and lower limit marking (min) (Fig.
3-93).
If brake fluid level is out of the range, some brake fluid (Fig. 3-94) need to be injected into the fluid
reservoir, till the fluid level up to the upper limit marking.
(4) Make the maximum pedal travel heavily after trampling the brake pedal for several times, and keep
trampling.
(5) Loosen the air bleed screw by turning it for 1/3 to 1/2 turn each time, the brake fluid flows out of the
tube. And the air bleed screw must be then screwed up tightly before the fluid pressure inside the wheel
cylinder disappears.
(6) Repeat (4) and (5) for several times. Only when the brake fluid flows without bubbles from the tube,
can the operation be stopped.
(7) Fill brake fluid into the fluid reservoir.
(8) Trample the brake pedal and check each part of the brake tube. No fluid should leak.
VI. Adjustment of the clearance between the push rod and 1st piston of the brake master
cylinder
Proper clearance between master cylinder and piston should be ensured when connecting the brake master
cylinder and vacuum booster servo chamber. The clearance should be adjusted as below:
(1) Firstly correctly place the special maintenance tool to make the stew stem contact the brake master
cylinder piston, as shown in Fig. 3-96. Mounting pad of brake master cylinder should be installed during
adjustment.
(3) Place the special maintenance tool as shown in Fig. 3-97. Adjust the length of brake master cylinder
push rod 2 to make the clearance between it and the screw stem on special tool be zero.
(4) As shown in Fig. 3-98, adjust the clearance between the push rod and piston by rotating the nut on the
end of the push rod.
After adjustment, under full load, when pulling the parking brake knob by a force less than 400N, the
parking gradient should be more than 20% as required.
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The ABS of LF320 sedan is composed of electronic control unit, hydraulic control unit, sensor and motor.
III. Sensor
The sensor sends the signal from the gear rotation detection to ECU.
IV. Motor
The motor rotates according to the signal of ECU. And the bearing transfers the rotation into straight
reciprocating motion to cycle the brake fluid.
Solenoid Solenoid
Solenoid valve valve
valve Electricity condition Solenoid valve Electricity condition
Normally
opened Normally
valve On Off opened valve Off On
Normally Normally
closed valve Off Off closed valve Off Off
Table 3-6 ABS pressure decrease operation condition Table 3-7 ABS pressure decrease operation condition
4. Other notes
(1) Use diagnostic instrument to find out fault reason before repair.
(2) Wrap off spare part only before installation.
(3) Use original part only.
(4) Pay attention to cleanliness. Only use cloth except tweed.
(5) Clean the surface with cleanser without mineral oil before removal.
(6) Do not use compressed air or move the vehicle when system is opened.
(7) Block the hydraulic pressure outlets with plugs as soon as possible after removal of ABS assembly.
(8) Remove other parts hindering operation.
(9) Use DOT#4 brake fluid.
(10) Soak the seal component with brake fluid, not with engine oil or brake unguent.
(11) Check for leakage of connectors of all hydraulic pipes.
5. Replacement of HECU
(1) Remove connecting piece of pin 25 and wire harness of HECU in engine compartment when engine
stops. See Fig. 3-104.
(5) Remove the 6 bolts on wet HECU with 6mm hexagonal wrench in a counterclockwise direction, as in
Figure 3-106.
(6) Assemble the wet HECU and bracket with a 5mm tool (hexagonal wrench) by tightening the 3 inserted
nuts M6 in clockwise direction with tightening torque of 8~10N·m.
(7) To install spare HECU, reverse the removal procedures of item (1) ~ (3) above.
As ABS is controlled by the electronic hydraulic pressure, the phenomena in the following table are normal
under normal working condition of ABS, not faults.
In such a situation, faults can be simulated to check if the fault occurs again.
1. When vibration may be the main reason:
(1) Shake the connector lightly in all directions;
(2) Shake the harness lightly in all directions;
(3) Shake the sensor lightly in all directions;
(4) Shake the other moving parts (like wheel bearing) lightly.
Note: If the harness is twisted off or fractured for tight pull, it must be replaced with new parts. Especially
when vehicle is moving, the sensor will move up and down, which may cause instantaneous open/short
circuit. As a result, sensor signal check must be carried out when vehicle is moving.
3. When overlarge contact resistance of power supply circuit may be the main reason:
Open all electrical switches, including the headlight and rear defrosting lamp.
If fault does not show again, it can only be diagnosed and repaired when it comes out next time. Generally
the occasional dynamic fault will only get worse, not better.
Take the procedure illustrated in Figure 3-107 for example. In the display area of the first DTC, as warning
lamp blinks twice (each on and off is T3, 0.5 second) before T4 (1.5 seconds before warning lamp is turned
on), the first mark (ten’s place) of the 2 digital code is 2; as warning lamp blinks once after T4 (1.5 seconds
after warning lamp is turned off), the second mark of the 2 digital code (unit’s place) is 1; as then warning
lamp is turned off for 3 seconds (T2), the display of the first DTC is finished, and the DTC is 21. Detailed
description of the fault can be found in DTC Table. It is the same with DTC 22.
(3) Deletion of DTC without fault diagnostic instrument
After DTC read and fault elimination according to DTC Table, previous DTC should be deleted before next
DTC check. The terms of DTC deletion is the same with that of DTC read, as shown in Fig. 3-108.
After DTC deletion, restore ECU mode of ABS to normal mode. Operation process is the same with that of
DTC diagnosis. If no DTC is in ECU of ABS, ground wire L and turn the key to connect the circuit; the
ABS warning lamp will flash in a way illustrated in Figure 3-109, and meanings of symbols are the same
with that above.
C1 206 C1 209 confirmed, delete the DTC (that can be deleted), drive the vehicle
at a speed of over 40 km/h, confirm the fault corresponding to this
Sensor open/short circuit: fault due to
Cause
DTC again and refer to the recorded DTC (and confirm the same
sensor battery positive or negative
DTC).
pole short circuit or open circuit
No
harness and sensor; confirm installation
Whether within 700~1500Ω
condition and pin location
Yes
Restart check from item ①
connecting piece A is
connected with positive Yes Yes Whether with No
electricity
pole of battery Replace harness wire
③ Remove connecting
Replace sensor Restart check
piece B and C beside
Whether without electricity不 from item ②
sensor; check whether
Yes
Yes No
Replace harness wire Whether with
electricity
Replace sensor
Restart check
from item ③
Sensor
Harness Harness
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Table 3-14 DTC table 2
Note: ① Air gap is the gap between gear ring and sensor; ② If
DTC
again and refer to the recorded DTC (and confirm the same
(resistance is 0), or gear ring is not
DTC).
properly installed.
Whether within 0.4 ~ 1.2mm No Adjust the air gap to specified range
Yes
C1 201 C1 204 C1 207 C1 210 ① Foreign materials, like engine oil and scrap iron in gear
may cause asymmetrical sensor signal;
② Air gap means the gap between gear ring and sensor;
Gear ring or sensor disturbance: ③ If faults corresponding to more than 2 DTC can be confirmed,
Cause
delete the DTC (that can be deleted), drive the vehicle at a speed of
If nonstandard gear ring is installed over 40 km/h, confirm the fault corresponding to this DTC again and
refer to the recorded DTC (and confirm the same fault code).
No
Whether within 0.4 ~ 1.2mm Adjust air gap to specified range
Yes
Yes
No
Whether there is foreign material Replace HECU
Yes
Occur when voltage too high or too low the recorded DTC (and confirm the same fault code).
Yes 1Ω
No Adjust grounding
Whether condition is good
condition of
Yes grounding connectors
No
Restart check
Whether above 17V
from item ①
Yes
Replace alternator
Yes
No
Whether fuse is normal Check and replace valve fuse
Yes
No
Whether forcible driving is good Replace HECU
Yes
Yes
No
Whether fuse is normal Check and replace valve
Yes fuse
Yes correctly
No
Whether forcible driving is good Replace HECU
Yes
faults the recorded DTC (and confirm the same fault code).
Replace HECU
Yes
No
Whether socket is normal Repair fuse socket
Yes
No
Check and replace drive
Elimination procedure
Replace HECU
No
Yes
Replace sensor
No
Whether problem still exists Complete check
Yes
Elimination procedure
Yes
Yes
No Replace parking
Whether normal
brake adjustment
Yes equipment
Elimination procedure
Exhaust check
Yes
Replace HECU
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Table 3-24 No DTC fault table 5
Fault No fault code output (unable to communicate with fault diagnostic instrument)
① Fault diagnostic instrument is broken ② Fuse is blew out
Cause
③ Diagnosis wire is broken or connector is loose ④ ECU is broken
Yes
Yes
Elimination procedure
No
Whether fuse is normal Check and replace ECU fuse
Yes
No
Whether normal Check and replace diagnostic instrument
Yes
4. Case of replacement concerning that ABS works during low speed (below 40 km/h) brake
Case of HECU and sensor replacement concerning that ABS works during every low speed brake
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ABS may work during low speed braking according to road condition and brake pressure. If ABS works
every time, check whether the air gap of sensors of all wheels is too large, whether the ring gear is
disturbed and damaged.
Air gap adjustment method: After confirmation of part with abnormal air gap, replace or burnish the
mounting surface (contact area) of sensor and adjust to the specified air gap; when disturbance occurs, a
thin washer should be placed on the surface of sensor and then adjust to specified air gap.
5. Is it caused by ABS that the vehicle drifts to one side when running on a slippery road?
This is because the friction coefficients of the left and right wheels are different. ABS can stabilize the
vehicle in this situation, but the driver should also control the steering wheel to avoid accident.
6. The vehicle will drift before braking when turning on a slippery road. Does ABS work if to brake
now?
Definitely ABS will work effectively and may stabilize the vehicle according to the speed, but the position
of vehicle can only be adjusted slightly even ABS works because the outward force is too large for the
inertia. Usually there are two kinds of forces during turning: one is needed when running and braking; the
other is needed when turning and stabilizing. Actually running, braking and turning of the vehicle are
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coordinated by the two kinds of forces above; and they are in inverse proportion to each other. As a result,
the brake force will increase while the turning and stabilizing force will decrease if to brake when turning.
The two kinds of forces can be adjusted to the best on the vehicle with ABS; but they can not be adjusted
on the vehicle without ABS, which will weaken its steering performance and stability.
If the two kinds of forces are too small (For example, the vehicle will leave the running route as the speed
is too high when drifting), the force to adjust the vehicle is too small, the ABS effect is not obvious. In a
word, deceleration in advance and safe turning is the best solution.
Appendix III ABS Interior Hydraulic Pressure Flow Diagram
The electrical system of LIFAN sedan includes: power startup system, electronic injection system, ABS
system, electric rear view mirror system, wiper and washer system, audio system, illumination signal
system, instrument cluster system, A/C system, air bag system, keyless entry system, window regulator
system, and BCM system.
Section Ⅱ Battery
2. Basic components
The lead-acid battery used by LIFAN sedans is mainly composed of positive/negative plates and sulfuric
acid electrolyte; refer to Fig. 4-11. The storage, discharge, and recharge of the battery are realized by the
electrochemical reaction bwtween active material and electrolyte on the polar plate. The active material
which is brown on the positive plate of the battery is PbO2, while the active material on the negative plate
is Pb. The electrolyte of the battery is made up from a mixture of pure sulphuric acid and distilled water
proportionally. Both positive plate and negative plates are connected in parallel with multichips in order to
enlarge the capacity of the battery. Positive plate group is interdigitated with negative plate group, and an
insulating barrier is installed between the two groups so as to avoid shortcircuits. A pair of positive and
negative plates groups forms a cell, and its normal voltage is 2V. Therefore, a battery rated 12V requires 6
cells to be connected in series. The structure of common battery refers to Fig. 4-12.
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Pb2+, and then dissolve in electrolyte. Meanwhile, PbO2 on the positive plate keeps ionizing so as to add
the lost Pb4+. Pb on the negative plate provides electrons by continuous ionization. During the discharge
process, Pb2+ and SO42- in the electrolyte combine and release PbSO4, and they will then attach to the
surface of the positive and negative plates. The active material PbO2 and Pb on the plates will gradually be
converted into PbSO4. H2SO4 in the electrolyte decreases while H2O increases, as a result of this, the
density of electrolyte falls.
(3) Charge of battery
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When the battery stops discharging, a little PbSO4 on both positive and negative plates will inoize.When
the battery is charging, the charging supply will form electric field force, which can absorb electrons on the
positive plate and transform them to the negative plate, and then charge current will come into being. Pb2+
on the positive plate loses electrons and changes into Pb4+. By combining with water in the electrolyte,
Pb4+ is reduced to PbO2 and attaches to the positive plate. Pb2+ is reduced to Pb and attaches to the
negative plate after it gains electrons. During the charge process, PbSO4 on the positive and negative plates
is gradually reduced to PbO2 and Pb, H2O in the electrolyte decreases while H2SO4 increases, as a result
of this, the density of electrolyte rises.
4. Battery type & capacity
The battery capacity of LIFAN sedan increases in order to meet the increasing power consumption of
automotive electrical and electronic equipments. The Battery type& capacity: 12V60Ah 640CCA.
2. Self-discharge
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Self-discharge refers to that battery loses energy without any connection of the external circuit. Normally,
self-discharge is inevitable; however, self-discharge fault forms if the self-discharge capacity is over 2%
per day and night. Self-discharge fault can cause shortage of the stored charge only hours or days after the
battery is out of use for days.
(1) Fault causes
1) Creepage will occur if the battery cap is covered with oil stains, dust and electrolyte.
2) Too much sediment in the bottom of battery case result in short circuit of positive and negative plates.
3) Insulating barrier fracture result in short circuit of positive and negative plates.
4) Impure electrolyte with too much metal impurities.
(2) Fault elimination measures
Elimination method should be selected according to the fault causes
1) Check the surface of battery, clean it if necessary.
2) Check whether electrolyte is brown when charging, if yes, the battery is self-charge because of too much
sediment in the bottom of battery case. Pour out the electrolyte, use distilled water to wash the inside of the
battery case, infuse it with fresh electrolyte, and finally fully charge the battery.
3) If self-discharge fault still exists since all check results are normal or all faults have been excluded, it
might be caused by impure electrolyte, elimination method: fully or over discharge the battery so as to
transfer all the impurities into electrolyte, then pour out the electrolyte, use distilled water to wash the
inside of the battery case, infuse it with fresh electrolyte, and finally fully charge the battery.
Note: The same phenomenon with self-discharge fault can be caused when the current-using equipments
are not turned on or when short circuit and creepage occure, therefore, external circuit should be checked
firstly before checking or eliminating self-discharge fault.
Quartz digital clock, electronic tuning radio (with radio memory), and computer memory of electronic
injection engine are in power-up status even if the ignition switch is turned off, so when the ignition switch
and all current-using equipments switches are turned off, it’s normal to find the output current is not 0 or
the circuitous resistance is not open. But the electric current should be less than 1A, and the electric
resistance should be less than 100Ω, otherwise, circuit or switch has short circuit or creepage fault.
r25℃=rt+0.00075(T-25)
I. Overview
BCM controller is a body integrated controller. It controls various functions of the body by a modern
embedded microcomputer, such as central control of door lock; automatic control of power windows and
user-friendly intelligent control; anti-theft control, engine and alarm are unavailable without lawful
authority; remote control, the remote is easy to use for it sends and receives non-directionally with wireless
technique. When the remote controller is fully charged, the remote control distance is required ≥20m. BCM
main functions:
Standard: remote control for central lock, window regulator control, and anti-theft system.
Simple: central lock (no remote controller) and window regulator control.
(Note: burglar alarm is selective with an interface reserved. Alarm is assumed in the following
descriptions.)
2. Standby state
(1) Press the locking key, controller will enter anti-theft state when it gets the signal.
(2) Open the door or turn on ignition switch, controller will enter normal state. Central control lock switch
and window regulator are available.
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3. Anti-theft state
(1) Normal state is available when the unlock key is pressed to disarm alert state. The anti-theft indicator
will flash rapidly. Open the door or the ignition switch and the anti-theft indicator will go out. Small lamps
flash for once, the siren sounds for once. Door is unlocked at the same time when it is locked.
(2) Press lock keying to lock doors under anti-theft state, small lamps flash for twice and siren sounds for
twice.
(3) If anti-theft state is unreleased, open the door or turn on ignition switch, the alarm will sound (small
lamps flash at the same time). Press any key on the remote controller, alarm will rering 3 seconds later.
Only system intrusion stops 30 seconds later can the alarm stop, otherwise, the alarm will keep ringing.
(4) If the door is not opened or the ignition switch is not turned on within 30 seconds after the alert has
been disarmed, the control system will return to anti-theft state.
(5) Anti-theft indicator LED flashes slowly at anti-theft state.
3. Model
(1) Speedometer with a stepper motor;
(2) Tachometer with a stepper motor;
(3) Fuel gauge with a stepper motor;
(4) Odometer with LCD;
(5) Instruments are connected with sockets.
(6) Speedometer
1) Odometer
Show mileage through speed sensor and instruments board circuit. Odometer consists of subtotal odometer
and accumulated odometer. As for short mileage count, subtotal odometer can be reset by pressing the reset
button.
2) Speedometer
Instrument gets the signal from speed sensor, the signal will then be sent to instrument cluster after treated
by ECU; then the instrument cluster will drive the stepper motor to make the pointer swing and indicate the
driving speed of he vechicle.
3) Tachometer
Engine rotation speed signal is generated by engine rotation speed sensor; the signal will then be sent to
instrument cluster after treated by ECU; then the instrument cluster will drive the stepper motor to make the
pointer swing and indicate the rotation speed of engine.
4) Fuel gauge
Fuel gauge is used to indicate the fuel in the tank. The lowest fuel level warning lamp will flash when the
fuel gauge indicates “0” level; there are about 8L fuel left, fuel is advised to be filled immediately in nearby
gasoline station. Fuel gauge gets fuel tank level signal through the fuel level sensor. The fuel level sensor is
asliding resistance potentiometer. Float rod changes with the fuel level, driving the the movement of
gleithretter and change the resistance of circuit in the fuel gauge. Test this resistance, and make the electric
motor to turn to the right position (Fig. 4-17).
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5) Oil pressure warning lamp is used to monitor engine oil pressure. When the oil pressure is lower than the
set one during the engine operation process, the warning lamp will then flash. Stop the vehicle and check
the oil level. If the oil level is normal while the warning lamp keeps flashing, check the engine lubrication
system. Oil pressure warning lamp is controlled by oil pressure sensor on the main oil passage of the engine
lubricating system. When the engine operates, normal oil pressure will disconnect the sensor contact, and
the warning lamp goes put. If the pressure is lower than the set one, the switch will close and the alarm
lamp will then be lit.
6) Brake fluid level warning lamp is used to warn the too low brake fluid level.
7) If engine fault warning lamp flashes or shines when the engine is under operation, engine injection or
ignition system has faults. Stop the vehicle and check it.
8) Charging indicator monitors charging system fault. If the indicator lights under normal engine operation,
charging system fault exists.
The whole air bag system is mainly composed of driver air bag module (DAB), front passenger air bag
module (PAB), air bag clock spring (SRS CS), air bag electronic control unit (SRS ECU), safety belt
pre-tensioners for driver side and front passenger side (deluxe scheme), air bag harness, warning label, and
so on.
Fig. 4-18 Air bag ECU Fig. 4-19 Driver air bag module
1. Hexagon head bolt, spring washer, and flat washer assemblies
2. Air bag ECU
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Driver air bag module, whose communication with ECU is carried out through air bag clock spring, is
installed on the steering wheel and turns simultaneously with the steering wheel. The clock spring,
comprising swirly calbe, turnplate, housing, harness, auxiliary components, etc, is installed on the
combination switch, as shown in Fig. 4-20.
The working principle of air bag clock spring: the installation housing of the clock spring is fixed on the
steering column, the upper part of the clock spring turn plate is inserted into the steering wheel, and the
swirly cable is installed between the turnplate and installation housing. When the steering wheel turns left
or right, the clock spring turnplate will turns simultaneously with the steering wheel, turning the output end
of the cable and stretching or tightening the swirly cable. For this reason, the harness is prevented from
being wound upon the steering column. Beyond that, the continuity of the harness and the connection of the
electronic signal is assured. Thus, the harness of the clock spring is also the bridge for supplying electricity
from the vehicle body to the related functional components of steering wheel.
When frontal collision accident occurs, the collision sensor shall produce signal for the collision, and the
air bag ECU shall detect and analyze the collision signal to determine the necessity for ignition requirement.
If necessary, the ignition impulse shall be sent out immediately, the ignition pipe in each air bag module be
ignited, and then the gas generating material in each of the air bag module shall be ignited by the ignition
pipe. Therefore, abundant gas generated in extremely short time shall inflate the air bag suddenly, forcedly
open the ornamental cap, and the fully inflated air bag be formed. By this way, the impact upon the driver
and passenger arising from the collision accident shall be absorbed, and the injury of the driver and
passenger shall be avoided or lessened. Working principle of the air bag is shown in Fig. 4-23.
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If the air bag is not repaired according to the right operation instructions, it may be deployed by accident
and lead to serious accident! Besides, if the air bag is repaired in a wrong operation, it may not be deployed
when it is needed! Before repair, read the following instructions and follow the right operational procedure!
2. Use special voltmeter and ohmmeter (minimum 10/V) to test the voltage and the resistance instead of
detector lamp, general voltmeter and ohmmeter.
3. When eliminating the air bag system fault, fault codes must be read first before disassembling the earth
wire of the battery.
4. Before specific repair operation, disassemble the earth wire on the negative pole of the battery, and carry
out repair work after at least 3 minutes later. If not, the air bag may be deployed by accident. Besides,
cover the disassembled negative pole with insulating tape for insulation.
Notes: Operations must be performed more than 3 minutes after the power is shut. If not, serious accident
could happen.
5. After slight collision, the driver air bag module and air bag ECU assembly should be checked even
though the air bag is not deployed.
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6. If the repair work may cause the sensor to vibrate, disassemble the air bag ECU assembly before
repairing.
7. Do not use air bag system components from other vehicles. Replace the components with new ones.
8. Do not disassemble or repair the driver and front passenger air bag modules or the air bag ECU assembly
for reusage or other purpose.
9. If the driver and front passenger air bag modules and the air bag ECU assembly drop and vibrate, or
there are crack, indentation or other damages on the shells, support saddles, or interfaces, replace them
with new ones.
10. Do not place the driver and front passenger air bag modules and the air bag ECU assembly in hot air
or fire.
11. Disassemble and put away the air bag ECU, air bag module and clock spring if there are affections
caused by over heat (more than 93℃) during the operation.
12. Interfaces of air bag ECU assembly, between air bag ECU assembly and clock spring, between clock
spring and driver air bag module, between front passenger air bag module and air bag ECU are
equipped with protection mechanism to avoid the air bag to be deployed by accident. Follow the
instructions when operating the air bag system, otherwise the air bag may unfold by accident or
damages will be caused to components.
13. Follow the instructions on the components of the air bag system and the relevant positions inside the
vehicle while operating.
14. When the air bag system is under operation, put the air bag modules into the vehicle immediately when
they are taken out from the conveyer. If the operation is stopped, put the modules back to the conveyer;
do not place them into an overlooked place. Unfold the air bag and face it up when putting away the air
bag modules.
15. After operation, check the electricity and confirms there is no mistake first, and then connect the air bag
module with the circuit.
16. No one should be inside the vehicle when connecting the air bag system to the power supply. When the
air bag ECU is not fixed, do not connect it to the power supply.
18. For the service life of the air bag is limited (see the operating instructions), replace the air bag and
labels when the air bag reaches its service life time.
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LF7132 air bag system can carry out self-diagnosis, and the basic diagnostic procedure is as follows:
(1) Connect the negative ground wire on the battery, turn on the ignition switch at the position of ON.
(2) Measure the PW voltage at the end of the air bag harness.
(3) Normal voltage: 10-14V.
(5) Turn the ignition switch to the position of ACC or ON and wait for at least 20s.
(6) Eliminate the flash DTC by the diagnostic instrument and read out the flash DTC.
II. Notes for removal, installation and maintenance of driver air bag module (DAB)
1. Removal process and notes
(1) Locate the ignition switch in position LOCK.
(2) Disconnect the battery negative cable for more than 3 min.
(3) Remove the two hexagon flange bolts at the left and right sides of steering wheel hub.
(4) Pull the driver air bag module from the steering wheel, and disconnect the interface of clock spring with
the terminal of gas generator
(5) Disconnect the interface of horn wire, and take out the air bag module. Removal is finished.
Note: Take care not to haul the air bag harness when removing the driver air bag module and keep the
ornamental cap upwards when storing the mould. Disassembling the driver air bag module is not allowed.
Do not knock the air bag module. If knocked, install a new one. Forbid exposing the mould under the
temperature over 90°C, and contact with lubricants, lubricant grease as well as water. Seal the old mould
removed in a sealing bag, and return it to Lifan Passenger Car Co., Ltd.
(7) Remove the clock spring from the steering column, and pay attention to the two buckles fastening
the clock spring on the steering column. Seal the old clock spring removed in a sealing bag, and
LIFAN sedan air conditioning system provides an air condition system with all the functions including
refrigeration, heating and ventilation service. In summer, air conditioner works to cool down the
temperature in the vehicle; while in winter, heating device works to keep warm and defrost the glasses.
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Table 4-8 Functions of vehicle air conditioning system
Purpose Functions devices
Maintain favorable temperature Heating and cooling device
Maintaining favorable humidity Humidifying and dehumidifying
Maintain a comfortable
device
environment for passengers
Maintaining favorable air flow Air supply device
Maintaining clean air Ventilation device and air purifier
Remove the frost and mist from Defroster or demist equipment
Maintain a clear field of vision
front and rare window glasses
The principle of LIFAN sedan cooling system is shown as Fig. 4-28. Refrigerant fluid takes away the heat
in the vehicle from vaporizer. Then it is changed into low-pressure and low-temperature steam. At last it
was pumped in compressor. Compressor compresses the steam into high-temperature and high-pressure gas,
and then emits it into condenser. The gas cools down with the effect of the air in condenser and becomes
fluid after giving out heat. Water could be filtered when the fluid goes through reservoir. Before it goes into
vaporizer, both the pressure and temperature of refrigerant would decrease with choking effect of
expansion valve. The refrigerant fluid with low temperature and low pressure would change into gas again
by absorbing the heat in the vehicle. Then the gas would be absorbed in compressor. Air conditioning
system works in a cycle to cool down the temperature.
I. Cooling system
LIFAN sedan cooling system is mainly formed by compressor, Vaporizer, condenser, drying chamber,
expansion valve, air-blower, control structure and so on, as shown in Fig. 4-29. Vaporizer is the core of the
cooling system with the temperature lower than dew point of air. So the cooling system also can provide
dehumidifying service and pure air.
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Adjustment measures of temperature Temperature controller
Nominal cooling capacity 3,800W(3,267kcal/h)
Compressor WXH‐086 WXH‐086
86 86
Lubricant/mL PAG56 120ml
Magnetic clutch power consumption/W 44W
Air-blower Maximum quantity of wind(m/h) 380m3/h
Air regulation stick shift Gear III
Motor power consumption/W 230
Condenser Size (thickness×width×height)/mm 143×478×410
Heat exchange/W ≥10,200W(8,770kcal/h)
Air resistance/Pa ≤145pa
Fan motor current/A 5.6
Fan motor speed/(r/min) 2,700
Vaporizer Size (thick×width×height)/mm 351×280×366
Cooling capacity/W ≥3,800W(3267kcal/h)
Expansion valve External blance model
Drive belt 4PK815
Refrigerant fill amount/g 480g
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1. Compressor
(1) Compressor function
Compressor is the corn instrument of cooling system, which is to pump, compress refrigerant and recycle
the process.
○1 Suction function. Compressor reduces the pressure of refrigerant in evaporation hose through suction
(work with expansion valve choking effect), to achieve the conversation process from fluid to gas and take
away heat in the vehicle through absorption of heat.
○2 Compression function. Compressor compresses the low-pressure refrigerant gas to increase its pressure
and temperature. This could change the refrigerant from gas to fluid and take heat out of the vehicle
through condenser.
○3 Circulating pump function of compressor. The circulation of refrigerant could be achieved through
ceaselessly suction and compression, so compressor is regard as the power source of refrigerant circulation.
(2) The structure of compressor:
As shown in Fig. 4-30, LIFAN sedan air conditioner adopts scroll air conditioner compressor for vehicle.
2. Condenser
(1) Condenser function
Condenser is to take out the heat of high-temperature and high pressure refrigerant gas from compressor so
as to transform refrigerant into fluid.
(2) The structure of condenser:
Condenser introduces the parallel flow structure. It is installed in the front of engine radiator. It works
forcibly throught radiator fan and the wind blew into the vehicle. Its structure is similar with engine
radiator. Cooling plates are added to condenser wall to increase radiating area. Refer to Fig. 4-31.
3. Vaporizer
(1) The function of vaporizer:
Vaporizer could make the low pressure fluid state refrigerant change into steam by reducing pressure
process in expansion valve, and to cool down the temperature and achieve dehumidification effect in the
vehicle.
(2) The structure of vaporizer:
As shown in Fig. 4-32, vaporizer core of LIFAN sedan is installed inside the housing.
4. Expansion valve
Expansion valve function:
Expansion valve could lower the pressure of high pressure refrigerant fluid by the choking effect. It can
automaticly adjust the refrigerant flow according to the temperature change of refrigerant flowed into
compressor. This could guarantee the refrigerant is gas before it flows into compressor.
5. Drying chamber
Drying chamber is used to absorb moisture, filter impurities and store refrigerant to make up the system
normal leakage.
Drying chamber is 1/3 of cooling system working medium volume. Silica gel desiccant is filled between
the two filters, and it could change color when it absorbs water.
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II. Heating system
LIFAN sedan heating system supplies heat by water. Housings of fan heater and vaporizer are connected
together. And it shares air-blower and air duct with cooling system. Its structure is shown in Fig. 4-33.
Warm air-blower draws engine cooling water into radiator inside the heater. Then air-blower would blow
the heat into the vehicle or window glass to improve the temperature inside the vehicle and defrost. Heat
exchanger is the main component in heating system.
Heat exchanger is installed inside the heating system housing. High temperature cooling water flows into
heat exchanger from inlet, then flows out to pump connected with engine. The high heat cooling water
flows in circulation in heat exchanger. The heat emitted by it is sent into the vehicle or windowpane
through air duct with the effect of air-blower. The flow of heat exchanger cooling water is adjusted by
thermostat next to engine outlet, while the supply air temperature is controlled by fan speed controller and
output temperature adjustment switch.
2. Pressure switch
Air conditioning system has a two-state pressure switch.
(1) When the refrigerant pressure is low (OFF). When the refrigerant pressure is lower than spring pressure,
the mental plate will bounce under the force of spring, and then disconnect the up and low contacts (OFF).
(2) Normal working (ON). When the refrigerant pressure is higher than spring pressure, mental plate would
move down to press the up contact, and then connect the tow contacts (ON).
(3) Refrigerant pressure too high (OFF). When the refrigerant pressure continues to increase and the up
contact is already in the limit position, the slipper block moves and then the metal plate moves, which will
disconnect the up and low contacts (OFF).
3. Magnetic clutch
Air conditioning system compressor works with engine main shaft through magnetic clutch. Magnetic
clutch determines the start and close of compressor. Therefore, magnetic clutch is the implementation
component in air conditioner automatic system, and is controlled by temperature switch, pressure switch,
speed relay, power switch and so on.
2. Pressure control
Pressure control protects system working normally by pressure switch. Functions are shown below:
(1) Low pressure protection. When pressure <0.2MPa, disconnect the compressor.
(2) Over pressure protection. When pressure >3.14MPa, disconnect the compressor.
(3) Normal pressure. When pressure is 0.2MP-3.14MP, air conditioning system work normally.
(4) High pressure control. When pressure >0.17MPa, control fan rotating in high speed.
1. Check by hand
You can check by your hands to touch the components and make diagnosis according to the temperature.
When you touch the high voltage loop (compressor outlet→condenser→reservoir→expansion valve inlet),
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the temperature should be a little hot. If one part is especially hot or temperature at inlet and outlet are
different, it indicates the part is blocked. When you touch low voltage loop (expansion valve
outlet→evaporator→compressor inlet), the temperature should be a little cold. If the compressor high and
low voltage sides have no temperature difference, this indicates no refrigerant in system.
2. Appearance inspection
Check whether oil stain exists in pipe joints, compressor oil seal, condenser and evaporator surface. The oil
stained indicates leakage existed in system.
Refrigerant
volume Insufficient Appropriate Excessive
No refrigerant
Item refrigerant refrigerant refrigerant
High pressure side High pressure side
High and low High and low
temperature is temperature is little
pressure side pressure side High pressure
little higher than higher than low
pipeline temperature are side is over hot.
low pressure side pressure side
temperature the same
temperature temperature
Almost transparent.
Continuous Bubbles could be seen
bubbles are when engine speeds
No bubble.
generated. When up or down and air
Refrigerant is
Observe the refrigerant run Bubbles could be conditioning is
transparent and
condition inside out, bubbles seen every 1‐2 turn‐off. Then the
no bubble when
the window would disappear seconds bubbles would
air conditioner
but something gradually disappear.
is turned off.
like moist There is no distinction
bubbles flow. between the two
conditions.
High pressure Pressures in
Cooling system Pressures in both Pressures in both
side pressure is both sides are
pressure sides are low sides are normal
too low high
Put out
Check, repair,
Check and add excrescent
Solution vacuumize, add
refrigerant refrigerant from
refrigerant
low pressure
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repair valve.
1. Install headlights into the proper position first when fixing the headlight assembly, and then fix the lights
with 3 sets of bolt group components.
2. Both high beam and low beam bulbs adopt model H1 (12V 55W). When installing, you must align the
heave part and the sunken part of bulbs, and then fix with spring steer wire.
3. The light beam of low beam and high beam can be adjusted by the two knobs on the group light
assembly.
4. Position indicator bulbs (12V 5W) adopt interface model, while steering lights bulbs is 12V 21W.
5. Rear group light assembly includes rear position light, steering light, and the combination of brake lamps.
Rear position light and brake lamp adopts combination bulbs of 12V 5W/21W. When install, you should
fix the lamps to the rear body with the cross recessed screw, gasket combinations and a buckle.
6. Reversing light, rear position light, steering light and brake lamp adopt bulbs of 12V, 21W.
7. Roof lamp is fixed in the middle of the cab with 2 taps, and the bulb is vasiform with 12V, 10W.
8. Front fog lights are fixed on the front bumper with 2 Q32006nuts separately, adopting H3 bulbs (12V,
55W).
9. Rear fog light and reversing light assembly is the combination of rear fog light and reversing light, with
bulbs of 12V, 21W. When installing, fix them to the rear bumper with 2 hexagon flange face nuts.
10. High-mounted brake lamp and spoiler assembly are fixed on the rear luggage boot cap with 4 hexagon
flange face nuts. High-mounted brake lamp adopts LED.
Fig. 4-35 Luggage boot light Fig. 4-36 License plate lamp assembly
1-Bulb 2-Lamp holder 1-Bulb 2-Lampshade
3-Cross recessed screw and gasket combination
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Fig. 4-37 Left front group lamps assembly Fig. 4-38 Left rear group lamps
1- Hexagon bolt, spring gasket and gasket combination 1-Cross recessed screw and gasket combination
2-Left front group lamps 3-Bulbs 4-Bulbs 5-Bulbs 2-Left and right group lamps 3-Bulbs
Fig. 4-39 Front roof light Fig. 4-40 Rear fog light and reversing light assembly
1-Bulbs 2-Front roof light 1-Lampshade 2- Hexagon flange face nuts 3-Bulbs
3-Hexagon flange face nuts
Fig. 4-41 Left front fog light Fig. 4-42 High-mounted brake lamp and spoiler assembly
1-Lampshad e 2-Bulbs 1- High-mounted brake 2- Spoiler
1. Generator composing
The generators of LIFAN sedans are adjuster inner installed silicon rectifier generators, mainly including
rotor (pole), stator (armature), rectifier, adjuster, brush and brush carrier. The generator composing is
shown in Fig. 4-43.
(1) Rotor: Rotor is the pole of generator, with the effect that it can bring current through brush and slip
ring and create a revolving magnetic field. Rotor is made up of unguiform iron core and exciting winding
and the two slip rings on the axis of the rotor are connected with two ends of exciting winding.
(2) Stator: Stator is the armature of the generator, with the effect of producing faradism electromotive
force in the revolving magnetic field. The stator is also made of iron core and winding, with 3 windings
symmetrically installed, and connecting as a triangle.
(3) Silicon rectifier: The effect of silicon rectifier is to commute the three-phase alternating current made
by generator armature winding into direct current. The generator silicon rectifier of LIFAN sedans has 9
diodes, including 6 high-power diodes to form the three-phase bridge rectification circuit offering
rectification to generator, and 3 low-power diodes to form bridge rectification circuit offering magnetizing
current to exciting winding
(4) Adjuster: The effect of adjuster is to stabilize the pressure of the generator through adjusting
magnetizing current when the engine rev changed. The purpose is to ensure electro-equipments can work
Ver:LF-20121225
LIFAN320 Service manual
normally. The adjuster is made up of molectron and a high-power audion.
(5) Brush and brush carrier: The functions of brush and brush carrier are to bring direct current in to
rotational exciting winding. Depended on the spring of the brush fame, the brush is contacted with the slip
ring on the rotor well.
(1) Power generation principle: The exciting winding of the generator brings direct current through brush
and slip ring. When the generator is running, there will be a revolving magnetic field within the generator.
And the stator winding installed symmetrically incises the magnetic line of force to create an, which is
shown in Fig. 4-45 (a).
(2) Commutating principle of rectifier: The three-phase bridge rectification circuit made up of VD1,
VD3, VD5, VD2, VD4 and VD6 commutes the three-phase alternating electromotive force created by
armature winding to be direct current to export to electro-equipments and accumulator (Fig. 4-45b). While
the three-phase bridge rectification circuit made up of VD7, VD8, VD9, VD2, VD4 and VD6 is mainly
used to offer magnetizing current to the exciting winding of the generator.
(3) Magnetizing mode of the generator: Before the generator builds the pressure, the accumulator will
offer magnetizing current (separate excitation) to the exciting winding through ignition switches, brush, slip
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LIFAN320 Service manual
ring and adjuster (switch audion); when the generator achieves certain rotation speed, and the direct current
pressure accumulated by the generator is higher than the accumulator pressure, the three-phase bridge
rectification circuit made up of VD7, VD8, VD9, VD2, VD4 and VD6 offers magnetizing current
(self-excitation).
(2) The stabilized voltage principle of the adjuster:The import of the adjuster brings to the pressure of the
generator, and the high-power audion of the adjuster is in series in the energizing loop of the generator (Fig.
4-44). Only if the audion is connected, the energizing loop would be connected. The adjusting process of
the adjuster as follows:
1) When the rotation speed is low and the pressure is lower than the designed pressure, the electron circuit
of the adjuster makes the high-power audion saturate and connect, and the exciting winding is connected to
offer magnetizing current by accumulator or the rectification circuit of the generator.
2) When the generator achieves certain rotation speed and the pressure of the generator achieves the
working pressure of the adjuster, the electron circuit makes the high-power audion stop and change
alternately all the time, and the pressure of the generator waves in a certain extension of up limited and
down limited (Fig. 4-46) to keep its average pressure in the design level.
3) when the rotation speed of the engine is up,the pressure of the engine is ascended fast and descended
slowly, which makes the connected time of the high-power audion of the adjuster reduced, and the stop
time is increased. It makes the average magnetizing current of the engine descended and the intensity of
magnetic field weaken, which makes the pressure of the engine keep stable. The rotation speed changing
condition of the pressure and magnetizing current with adjuster is shown in Fig. 4-47.
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LIFAN320 Service manual
Fig. 4-46 Engine pressure wave in a certain rotation speed with adjuster
U1-Up-limited voltage which makes the switch audion of the adjuster connected
U2-Down-limited voltage which makes the switch audion of the adjuster stopped
(2) Decomposition: The disassembly figure is Fig. 4-50, and the disassembly methods are as follows:
1) Disassemble the connecting bolt of the front and rear end closures, and dispart the front and rear end
closures and the pontes.
2) Tear down the end line joint of stator winding, and take out it from the rear end closure.
3) Tear down the binding nuts and bolts of the brush, and then take off the adjuster and the brush brackets
discreteness.
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LIFAN320 Service manual
2. Rotor overhauling
(1) Common rotor fault:
1) The surface of slip ring smudged and ablated makes bad connection between brush and slip ring, also
cutout or decrease of magnetizing current, which leads to no generation or bad generation.
2) Short, open or ground circuit of magnetic field winding make the rotor can’t produce electromagnetic
field or a decrease of magnetic field, which leads to no or bad power generation.
2) Measure the resistance between the line end of the stator winding and the iron core with the ohms range
of multimeter to check whether there is ground circuit in stator winding (Fig. 4-54). The normal condition
should be unconnected. If the closed circuit or the resistance is less than 50MΩ, it means that there is a
ground circuit fault or bad insulation, and you should change the stator.
5. Rectifier overhauling
(1) Common fault: short and turnoff of commutation diode leads to bad generation or no generation.
(2) Check and repair: measure the forward and reverse resistance of each commutation diode with the
resistance range of multimeter. The normal condition is that the difference is very big. If the forward and
reverse resistance of some commutation diode is ∞, it means that there is a turnoff in the diode; if the
forward and reverse resistance is 0, it means there is a short in the diode. You should change the rectifier in
both conditions.
4) When the engine is in a normal work temperature, make the rotation speed of the engine stable in
2,000r/min, 3,000r/min, and 4,000r/min. Adjust the resistor in the stable-rotation speed condition to make
the terminal voltage is 13.5V, and then check the output current. The output current in stable-rotation speed
condition is shown in Table 4-15.
If it can’t achieve the value listed in the Table 4-15, please check and repair the generator.
I gear 35:11=3.181
II gear 35:19=1.842
IV gear 33:36=0.917
V gear 29:41=0.707
Rated power 63 KW
Central distance 63 mm
Gear number 20
Modulus 1
Major diameter
φ 21(-0.01/-0.3)
9. Input shaft
10. Clutch
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LIFAN320 Service manual
11. Crankshaft
12. Engine
14. Idler
1. Clutch housing
2. Input shaft
3. I gear
4. Reverse gear
5. II gear
6. III gear
7. IV gear
8. V gear
9. Rear cover
11. Differential
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20121225
LIFAN320 Service manual
12. Output
O shaft
V. Transmis
T ssion structure anaalysis illusstration:
1. Transmissio
T on housing assembly
7. Constant mesh gear of input shaft 9. Constant mesh gear of input shaft
8. Input shaft
II gear III gear
14. 3rd & 4th gear synchronizer 15. 3rd & 4th gear synchronizer lock
13. 3rd & 4th gear synchronizer hub
spring ring loop
16. Constant mesh gear of 17. Constant mesh gear bush 18. Deep groove ball bearing
input shaft IV gear of input shaft IV gear of input shaft
22. 5th gear synchronizer joint sleeve 23. Synchronizer spring ring 24. 5th gear synchronizer slides
25. 5th gear synchronizer hub 26. Synchronizer spring ring 27. Synchronizer thrust washer
28. Taper spring gasket 29. Lock nut of input shaft 30. Oil guide cover of input shaft
31. Output shaft cylindrical roller bearing 32. Bearing lock of output shaft 33. Bolt
34. Main drive gear of main reducer 35. Output shaft 36. Needle roller bearing
41. Constant mesh gear of 42. 1st & 2nd gear synchronizer
40. Taper spring gasket
output shaft I gear lock loop
44. 1st & 2nd gear synchronizer 45. 1st & 2nd gear
43. 1st & 2nd gear joint sleeve
spring ring synchronizer slides
47. 1st & 2nd gear synchronizer 48. Constant mesh gear bush
46. 1st & 2nd gear synchronizer hub
spring ring of output shaft II gear
52. Constant mesh gear damping plates 54. Constant mesh gear of
53. Elastic retaining ring for shaft
of output shaft II gear output shaft III gear
55. Odometer transmission 56. Constant mesh gear bush 57. Deep groove ball bearing
drive gear of output shaft IV gear of output shaft
61. Lock nut 62. 5th speed shift fork 63. Elastic cylinder lock
3. Shifting components
1. Shifting shaft
5. Washer
6. Lock nuts
7. Bolt
8. Torsion spring
17. Washer
19. Bolt
33. Bolt
4. Differential assembly
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LIFAN320 Service manual
3. Planet gear
4. Planet gear
9. Bolt
1. Put the transmission on the table; unscrew drain screw plug and circumrotate the work bench to
dump all the fuel. Then take off the odometer from driven gear and reverse gear lamp switch.
2. Take off the reverse gear lamp switch attached on wire harness clip by hand. Open the rear cover by
using a special tool to unscrew rear cover bolt. At the same time, you should unscrew the Self-locking ball
clamp bolt and take out three self-locking ball springs and three balls.
3. Remove the nylon lubricant path, and then apply V gear. Put the thin copper stick between the 5th gear
drive and driven gear. Unscrew the 5th gear drive gear lock nuts by spanner.
4. Take out lock nut of input shaft, taper spring gasket, and then remove the spring pin of 5th speed
5. Remove 5th gear synchronizer assembly, 5th gear synchronizer ring, 5th drive gear and 5th speed
fork.
6. Remove the bolt connected transmission and clutch by a special tool. Take out bracket-cable-support
7. Use snap ring pliers to unscrew the input shaft elastic retaining ring, and take out transmission
housing by using special tools to separate transmission housing and clutch housing.
8. Fix three shift lever by using special tools, then knock in the rocker dies, which could fix 1st/2nd
speed fork, 3rd/4th speed fork and 1st/2nd speed shift fork, and the spring pin of reverse speed fork.
9. Draw 1st/2nd, 3rd/4th and 5th gear reverse speed fork-axle, remove 3rd/4th, 1st/2nd speed shift
forks rocker dies and reverse speed shift rocker die. At the same time, draw the reverse idler shaft; remove
10. Remove the retaining bolt of shifting swing link bracket assembly by special tools, then take out
the shifting swing link bracket assembly. Pull out the speed shift fork-axle lock and 1st/2nd speed shift
fork.
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LIFAN320 Service manual
11. Remove the input shaft bearing clamp by using special tools to unscrew the retaining bolt on it.
12. Take out input and output shaft assemblies by two hands. And remove the differential assembly.
Installation:
Differential installation is in reverse order of its disassembly. Please pay attention to following items:
1. Make sure all the components are clear before installation. Guarantee clean environment to
2. Be carefully for installation to avoid oil leakage caused by oil seal scratch. Special protection sleeve
can be applied.
3. Make sure the joint surfaces are clear before coating with sealant to avoid oil leakage.
4. All the bolts tightening torques should be operated according to the data showed in appendix.
5. Coating with lubricant grease at nozzle of oil seal when installing the input shaft oil seal and
differential oil seal. Then completely press the oil seal into the transmission housing by special tools.
Appendix I
1. For clutch shift up and down, press down clutch pedal completely when shifting. Immediately
operate shifting lever to shift gear after making transmission separate from engine torque.
3. Random gear selection should not be applied when shifting from low gear to high gear. Otherwise,
4. Starting engine with forcing synchronizer work is forbidden on the neutral flameout condition.
6. Don’t put hands on the shifting switch when driving. Otherwise abrasion can be caused to shifting
7. For discovery of abnormal voice or obvious abnormal operations like heavy operation, stop vehicle
to check for fault immediately. Continue driving only after eliminating faults.
noise or Improper gear axial position and clearance Check and adjust
abnormal
Add oil to the
noise Too low oil level, insufficient lubrication
prescribed position
Check and
Foreign material exists in assembly
remove
range
Transmission shifting rockers become flexible Repair
bearing
Unqualified bearing Replace
down when
Gear abrasion Replace
reverse gear
16 O-ring seal 1
1. Rust prevention measure should be applied for transmission to guarantee transmission in normal
2. Encasement and transport frame should be applied before transmission transportation to guarantee
Part VI
Vehicle Body Service
Integral body structure is adopted in LIFAN sedan. And the body of hatchback model LF7132 is steel with
5 doors. As a combination of practicality and elegance, the modern beauty originates from the elegant body
framework and streamline shape with decoration of large angle window. Impact effect is considered during
the front engine bay and hatchback door designs, and the strength and rigidity of the passenger
compartment can guarantee the safety of the passengers in the vehicle.
I. Body structure
The body of LIFAN sedan is composed of body framework, exterior assembly parts and interior assembly
parts. (This chapter is mainly to focus on the body framework.)
As the basic part of the vehicle, the body framework (body-in-white assembly) carries the whole weight of
the vehicle. The performance, quality and reliability of the vehicle are closely related to the body
framework, and its quality plays an important role in the modern manufacturing.
(1) Strict and advanced processing technology before painting is adopted. For example, 11 working
procedures of parkerizing are carried out before painting so that a thin zinc phosphate film is coated, which
is useful for the adherence of next dope and can protect the surface of the vehicle body.
(2) The vehicle body is immediately painted with priming after cathodic electrophoretic coating processing,
which can greatly improve its antisepsis ability.
(3) Anti-stone-bumping PVC is coated on the underbody and wheel shield to effectively prevent corrosion
in the surface of the vehicle body caused by sandrock damage and road surface scuffing.
(4) Sealant is coated in the weld seam of vehicle body metal sheets to improve its antisepsis ability.
5. Reliable seal
As the seal is crucial for dust prevention, water prevention, antisepsis, heat prevention, heat preservation,
noise reduction and other performances, the seal of vehicle body of LIFAN sedan is carefully considered.
Various effective seal measures are adopted to guarantee its sealing performance. The main measures are as
following:
(1) Electric seal gum is coated on the overlap edge when the metal parts are welded.
(2) All the overlap edges of vehicle body are coated with seal gum after the assembly welding is finished.
(3) Polystyrene foam is sprayed in the closed cavity of the body framework to seal, prevent dust, preserve
heat and insulate heat.
(4) Thick anti-stone-bumping dope with excellent sealing performance is sprayed on the underbody.
(5) Traditional sealing measures are adopted for the assembly parts on the vehicle body, such as rubber seal
ring, cover stem, rubber strip and dustproof cover.
I. Hand tool
1. The regular hand tools for vehicle body repair are shown in Fig. 6-3. Choose the appropriate type of
tool during repair according to the shape of curved surface and other conditions of the steel plate to be
repaired.
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LIFAN320 Service manual
A) Standard special vehicle body tool suit B) Rivet holder C) Metal plate working hammer
1 - Hammer rivet holder 2 - Beat rivet holder 3 - Regular rivet holder
4 - Plane rivet holder 5 - Weld dregs shovel 6 - Vehicle body trimming knife
7 - Long hammer 8 - Flanging tool 9 - Rubber hammer
10 - Long crane beak bar 11 - Bulletheaded shaping hammer 12 - Flatheaded shaping hammer
13 - Body file 14 - Crane beak hammer 15 - Beat hammer
16 – Flat trimming knife 17 - Long arm rivet holder 18 - Plane rivet holder
19 – Regular rivet holder 20 - Long rivet holder 21 - Beating rivet holder
22 - Hammer rivet holder 23 - Long head hammer 24 - Rubber or wood hammer
25 - Metal plate hammer 26 - Crane beak hammer
2. Power tool
(1) Body and frame straightener As show in Fig. 6-4, the body and frame straightener is mainly composed
of plummer, stretcher, measurement system, clamping and positioning device and lifting device. Before
poling or stretching rectification to one or above places on the distorted vehicle body, this machine fastens
the vehicle body on the plummer, lift the vehicle to the appropriate position and then diagnose and examine
the vehicle (Fig. 6-5). The universal vehicle body and frame straightener can rectify the shapes of various
vehicles. Different from the traditional rectification method, its application can lower the labor intensity,
improve the vehicle body repair efficiency and guarantee the repair quality. As a result, this kind of
universal vehicle body and frame straightener is highly praised and widely accepted in the international
vehicle repair industry.
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LIFAN320 Service manual
(2) Roll flattening machine As a popular flattening machine among the numerous leveling equipments, roll
flattening machine (Fig. 6-6) is used to flatten the surface of metal plate so as to improve its surface
precision. When working the metal plate is clamped between the two rollers which are to drive the metal
plate to repeat parallel movement continuously for flattening purpose. The repeated back and forth rolling
of the rollers is driven by the piston rod spline and gear system. In order to guarantee the flattening quality
of the metal plate surface, the surface of the roller should be highly precisely smooth.
Fig. 6-6 Roll flattening machine Fig. 6-7 Polishing method of polisher
Ver:LF-20121225
LIFAN320 Service manual
Apart from its stability and much higher efficiency, the roll flattening machine is also featured with more
reasonable machinery processing technic, higher precision, better quality, lower labor intensity and lower
noise than the manual beating with hammer. However, it still can not completely replace the manual
hammer beating.
(3) Disk polisher. There are electric and pneumatic disk polishers which are to polish the metal plate of the
vehicle body after repair with higher efficiency and easier operation than the manual polishing. The contact
angle between the polishing disk and polishing surface affects greatly the polishing quality of the metal
plate. As a result, 1/3 of the disk surface should contact with the polishing surface (Fig. 6-7) to get the best
polishing quality. If the contact angle is too large, only an extremely small part of the disk can rub with the
polishing surface, which will cause rough processed surface; and if the disk contacts with the surface
parallelly, scraggly processed surface will be produced as the movement will not be stable for too large
rotation resistance.
Fig. 6-8 Metal plate breakdown drawing of the front part of vehicle body
1 - Engine hood assembly 2 - Front anti-collision beam assembly 3 - Water tank upper beam assembly
4 - Front headlight right mounting beam 5 - Front headlight left mounting beam 6 - Water tank lower beam assembly
7 - Front anti-collision beam left mounting plate
8 - Left front girder baffle 9 - Left front wheel cover connection plate assembly 10 - Left bracket of mudguard
mounting support
11 - Front tow hook assembly 12 - Left front girder wheel cover assembly 13 - Outer panel
of left front fender 14 - Upper beam assembly of front baffle
15 - Front baffle assembly 16 - Outer panel of upper beam of front baffle 17 - Right bracket of mudguard mounting
support 18 - Right front wheel cover connection plate assembly
19 - Right front girder baffle 20 - Front anti-collision beam right mounting plate 21 - Right front girder wheel cover
Ver:LF-20121225
LIFAN320 Service manual
assembly 22 - Outer panel of right front fender
Fig. 6-9 Metal plate breakdown drawing of the middle part of vehicle body
1 - Roof panel assembly 2 - Rear beam assembly of roof panel 3 - Right clapboard assembly 4 - Upper curb girder
assembly of right B-pillar 5 - Inner plate assembly of right A-pillar
6 - Close board of right side wall 7 - Inner plate assembly of right B-pillar 8 - Right rear wheel cover assembly 9-
Left rear wheel cover assembly 10 - Inner plate assembly of left A-pillar
11 - Close board of left side wall 12 - Inner plate assembly of left B-pillar 13 - Left clapboard assembly 14 - Upper
curb girder assembly of left B-pillar 15 - Cover plate assembly of parking brake
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LIFAN320 Service manual
16 - Front floor weld assembly 17 - Right girder assembly of front floor 18 - Left girder assembly of front floor
Fig. 6-10 Metal plate breakdown drawing of rear part of vehicle body
1 - Weld assembly of rear floor 2 - Front beam assembly of rear floor 3 - Right rear girder assembly
4 - Left rear girder assembly 5 - Rear beam assembly of rear floor
6 - Inner plate assembly of apron board of rear wall 8 - Anti-collision beam of rear wall
9 - Inner plate assembly of rear door 10 - Outer plate assembly of rear door
The touch-up paint procedures for LIFAN sedans are mainly as follows:
(1) Remove the wax and oil
(2) Phosphatization
(3) Soak cleaning
(4) Wash to get rid of hydronium
(5) Paint primer
(6) Drying
(7) Coat some parts with lacquer putty
(8) Drying
(9) Polish the lacquer putty
(10) Clean
(11) First finish paint
(12) Leave it for volatilization
(13) Drying
(14) Second finish paint
(15) Leave it for volatilization
(16) Drying
11 I-i 1070.47
B1,b1 Mounting hole for fender T, t Mounting hole for rear tail lamp
B2,b2 Mounting hole for fender U, u Mounting hole for engine radiator
Mounting hole for front shock damper Positioning hole for welding of front
C, c V, v
assembly floor
Positioning hole for welding of front
F Mounting hole for five-way valve W, w
floor
K Mounting hole for front door limiter X, x Mounting hole for rubber cover stem
Mounting hole for rear shock damper
L, l Mounting hole for fender itself Y. y
assembly
N Mounting hole for rear door limiter
RE R1
LH L1 L2 L3 L4 L5 L6
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G01 G02 G21 G23 G25
I16 I16 I39
I14 I14
G21
IA1 IA1 IK IK IF
ID1 IK
EA1 EA1 FK FK SF
F2 BD1 FK
IA1 IA1
I10 F2 FK
EA1 EA1
IK
E23 E25 F1 S1 F4 F5 B4 B1
E1 E1
I10
G21 G22
I21
I21
I13
I28
I21
I21
IB
I13
UB I29 I28
I28 I28 I28 I29 I28
ID2
BD2
I8
I35
BH
I28 I28 I28 I28 I29 I29 I29
LH
L2
I34 I34 I36 I36 I36
I35
UC UC IA1 IA1 UC UB UC UB t
EC EC EA1 EA1 EC IB EC IB I31 I31
I36
I1 I3 L6
E24 I33
I34
I31
LH
E1 E1 E1 E1 E1 BH
I1 I3
I33