BYD AUTO BYD NEW F3 Maintenance & Repair Manual

www.bydauto.com.cn

BYD New F3 Auto Maintenance & Repair

Manual

1
BYD AUTO BYD NEW F3 Maintenance & Repair Manual

Foreword
This Repair and Maintenance Manual, which is intended for maintenance technicians,
provides information on diagnosis and maintenance procedures as well as the adjustment
and specifications of the BYD New F3 Auto. If necessary, please use this manual together
with the structural drawings.
You are recommended to contact BYD Auto Co., Ltd. in order to obtain information on the
product brands, part no. or special purpose tools that are mentioned in this manual. All
information, illustrations and product descriptions that are included in this manual are
valid as of this manual’s release date. However, BYD Auto reserves the right to amend this
manual entirely within our discretion without prior notice.
No part of this manual, including but not limited to the characters, charts and tables, may
be reproduced, stored in a retrieval system, or transmitted, in any form or by any means
(including but not limited to electronically, mechanically, by photocopy, recording or
otherwise), without the prior permission of BYD Auto Co., Ltd.

BYD Auto Co., Ltd.

May 2012

All Rights Reserved.

2
BYD AUTO BYD NEW F3 Maintenance & Repair Manual

Caution

Warning: In order to reduce the risk of injury and/or property damage, please strictly follow
these instructions below:

1. This manual, which is supplied by BYD Auto Co., Ltd., is intended for qualified professional
technicians. Repair or maintenance work that is carried out without the proper training and proper
tools and equipment may cause injury to the maintenance staff or others. In addition, it may cause
damage or improper operation to the vehicle.
2. Correct vehicle repair and maintenance is very important for both the personal safety of the
maintenance staff and the safe, reliable operation of the vehicle. To replace a certain component,
please use the same component or the component that is specified by BYD Auto Co., Ltd.
(hereafter BYD Auto). Do not use any replacement components deemed unacceptable by BYD
Auto.
3. Maintenance procedures recommended and introduced in this manual are effective methods for
repair and maintenance. Some procedures require special tools.
Therefore, before using the replacement components, maintenance procedures, or tools that are
not recommended or accepted by BYD Auto, first ensure that no danger will be caused to the
personal safety or the safe operation of the vehicle.
4. Please strictly follow the various ―Warning‖, ―Caution‖ and ―Notice‖ guidance included in this
manual so as to reduce the risk of human injury in repair or maintenance. Improper repair or
maintenance will cause damage or potential safety hazard to the vehicle. ―Warning‖, ―Caution‖ and
―Notice‖ guidance in this manual does not contain the full details. BYD Auto cannot give warning or
offer compensations for all potential risks resulting from incompliance with these instructions.
5. This manual includes the maintenance procedures for vehicles equipped with the SRS System
(―airbag‖ below). Please refer to ―Warning‖, ―Caution‖, ―Notice‖, and ―Warning‖ guidance in the
section ―Protective Devices‖. Before carrying out repairs on or near the airbag components and
wires, please refer to the layout drawings of the airbag components and wires in ―Protective
Devices‖. Disobeying these ―Warnings‖ may lead to airbag deployment, injury, or unnecessary
repair to the airbag.
If repair is required for both the airbag and other vehicle systems, it is recommended to repair the
airbag first so as to avoid any unexpected airbag deployment or personal injury.

Send Your Fault Reports or Suggestions

You are welcome to report mistakes in this manual and send your suggestions to BYD Auto by
mail or fax. Our contact details are:
Technique Service Division of BYD Auto Sales Co., Ltd.
Add: No. 2, Yadi Road, New Industrial Park, High-tech District, Xi‘an, Shaanxi, P.R.C.
Zip code: 710119
Fax: (029) 85692841
Please get the following information on hand for filling quality report when contacting us:
◇ Your name
◇ Name of your Sales & Service Store
◇ Phone and fax number of your Sales & Service Store
◇ Your topic of concern and its description
◇ Required information (such as sample or page number)
◇ Any applicable electronics information (such as Part No.)
BYD Auto will reply your questions in the following procedure:
◇ Forward your question to associated maintenance engineers
◇ Consult associated maintenance engineers for proper answer

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BYD AUTO BYD NEW F3 Maintenance & Repair Manual

◇ Reply your question within 10 business days upon reception

Quality Report for Repair and Maintenance Manual

To Manager of Technical Service Division

Manual Name Release Date

Distributor
Reporter Name
Name

Topic

Description of Issue

473QE Engine Service Manual

4
 Engine&Transmission 1
Contents

Chapter 1 Foreword .................................................................................................................... 1

Section 1 Technical Specifications and Parameters of the Finished Vehicle ......................... 3
Section 2 Vehicle Identification ............................................................................................ 6
Section 3 Service Rules ....................................................................................................... 7
Section 4 Inspection Rules ................................................................................................ 22
Section 5 Abbreviations and Wire Color Marks .................................................................. 30
Chapter 2 473QA/QB Engine .................................................................................................... 32
Part1 Gasoline Engine ....................................................................................................... 34
Part 2 Lubricating System .................................................................................................. 88
Part 3 Air Manifold and Exhaust System ............................................................................ 93
Part 4 Engine Cooling System ........................................................................................... 95
Part 5 Fuel and Exhaust System ........................................................................................ 98
Chapter 3 473QE Engine Service Manual ............................................................................... 106
Part 1 Engine ................................................................................................................... 108
Part 2 Lubricating System ................................................................................................ 161
Part 3 Air Intake and Exhaust System .............................................................................. 167
Part 4 Engine Cooling System ......................................................................................... 172
Part 5 Fuel and Exhaust System ...................................................................................... 175
Chapter 4 483QA/QB Engine .................................................................................................. 183
Part 1 Gasoline Engine .................................................................................................... 184
Part 2 Lubrication System ................................................................................................ 198
Part 3 Cooling System ..................................................................................................... 204
Part 4 Flywheel ................................................................................................................ 206
Part 5 Engine Fuel System .............................................................................................. 207
Chapter 5 5T-14 Transmission................................................................................................. 210
Section 1 Structural Parameter .........................................................................................211
Section 2 Service Regulations ......................................................................................... 212
Section 3 Service Transmission ....................................................................................... 213
Section 4 Differential ........................................................................................................ 240
Chapter 6 CVT Transmission .................................................................................................. 244
Section1 General Introduction .......................................................................................... 245
Section2 Service Information ........................................................................................... 261
Section3 Service Instructions ........................................................................................... 270
Section4 Trouble Shooting Guide .................................................................................. 322
Chapter 7 CVT Management System...................................................................................... 336
Section 1 Component Layout ........................................................................................... 337
Section 2 CVT Overview .................................................................................................. 337
Section 3 Diagnostic Procedure ....................................................................................... 338
Section 4 Terminal Detection ........................................................................................... 339
Section 5 Overall Diagnostic Flow .................................................................................... 341
Section 6 Preparing Tools ................................................................................................ 385
Section 7 Disassembly and Assembly .............................................................................. 385

I
 Chapter 1 Foreword

Contents

Section 1 Technical Specifications and Parameters of the Finished Vehicle ................................ 3

1.1 Main Technical Parameters of the Finished Vehicle................................................... 3
1.2 Engine Specifications................................................................................................ 4
1.3 Main Assembly Types and Parameters of Engine Accessories, Chassis and Body .... 4
Section 2 Vehicle Identification ................................................................................................... 6
2.1 Vehicle Identification Number (VIN) .......................................................................... 6
2.2 Engine No ................................................................................................................ 6
2.3 Vehicle Nameplate .................................................................................................... 6
Section 3 Service Rules .............................................................................................................. 7
3.1 Warning and Caution ................................................................................................ 7
3.2 Notice ....................................................................................................................... 7
Section 4 Inspection Rules ....................................................................................................... 22
4.1 Troubleshooting ...................................................................................................... 22
4.2 Electronic Control System....................................................................................... 22
4.3 Troubleshooting Flowchart ...................................................................................... 29
Section 5 Abbreviations and Wire Color Marks ......................................................................... 30
5.1 Wire Color Marks .................................................................................................... 31

1
Introduction to This Manual boldface in this manual where necessary.
(1) This manual is compiled in accordance with 4. Definitions of Terms
applicable national standard and BYD Auto‘s Warning - serious personal injury may be
technical standard. caused to maintenance staff Cautions -
(2) Maintenance operation is divided into the damage may be caused to the components of
following major procedures: the vehicle Notice - useful information to help
① Diagnosis you finish the maintenance more effectively
② Dismantling/installing, replacing, 5. National Standard Metric Units
disassembling/assembling, inspecting, and National standard metric units are adopted in
adjusting this manual.
③ Final inspection
(3) This manual introduces the first two major
procedures of the maintenance operation
while leaving out ―Final Inspection‖.
(4) The following basic operations must be
strictly executed in actual practice, though they
are not introduced in this manual:
① Use jack or lifting jack
② Clean the disassembled components if
necessary
③ Make visual inspection
1. Preparations
Sometimes special tools and special servicing
materials may be required for maintenance,
which shall be used strictly in accordance with
the proper steps. Please refer to associated
sections for instructions.
2. Maintenance Steps
(1) As required, each chapter contains
component drawings.
(2) Detailed descriptions for the non-reusable
components, lubricating fittings, pre-coated
parts, and torque requirements are given in the
components drawings.
(3) Fastening torque, lubricating fittings, and
non-reusable components are introduced as
key points in maintenance steps.
(4) Assembling procedure is generally
opposite to disassembling procedure, so only
extra steps in assembling are described in
details.
(5) Only key points are specified in text.
Specific steps and other details are illustrated
graphically.
(6) The steps are given one by one in this
manual.
① The illustrations indicate what to do and
where to do it.
② The titles indicate the item to be done.
③ The explanatory words tell how to finish the
work, and provide other information such as
specifications description, warnings, etc.
3. Maintenance Norm
―Specifications Description‖ is given in

2
Section 1 Technical Specifications and Parameters of the Finished
Vehicle
1.1 Main Technical Parameters of the Finished Vehicle
No. Item Unit Parameters
Length 4568
Overall Width 1716
dimensions Height
1480
(no-load)
Wheel base 2615
Front 1486
Track mm
Dimensions Rear 1466
1
Front overhang 943
Rear overhang 1010
Inner length 1925
Passenger
Inner width 1430
compartment
Inner height 1230
Trunk capacity Volume L 430

2 Seating capacity Persons 5

QCJ7153A QCJ7183A3
QCJ7153A3 QCJ7183A4
kg
Curb weight 1180 (473QB) 1205
Mass
Laden weight 1580/1555 1580
3 Parameters
Front axle 717/688 753
No Load
Weight Rear axle 488/492 452
kg
Distribution Full Front axle 860/830 885
Load Rear axle 720/725 695
Height of the center of mass
4 mm 564/539 -
(no-load/full-load)
Minimum turning diameter m 10.2
Trafficability Minimum ground clearance mm 170 (no load)/145 (full load)
5
Parameters Approach angle (full load) 17.6°
Departure angle (full load) 18.6°
Wheel
6 Alignment Front wheel camber -0°17′±45′
Parameters
Front wheel toe-in -0.5~3mm
Kingpin inclination 12°45′±45′
Kingpin caster 2°36′±45′
Rear wheel camber -1°28′±30′
Rear wheel toe-in mm (1.1±2.5) mm
Front Wheel
7 Inner m/km (-3~+3) m/km
Sideslip
Outer (-3~+3) m/km
8 Steering Outer angle 33°04′±3°
Inner angle 39°12′±3°
9 Fuel grade >93#
10 Fuel tank capacity L 50 (gasoline)
Note: a quality parameter tolerance is ±3%; the dimension parameter tolerance is ±1%.

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1.2 Engine Specifications

Item Unit Type and Parameter

Model 473QB BYD483QA
In-line 4-cylinder, 16 valves,
In-line 4-cylinder, water-cooled,
Type water-cooled, natural
double overhead camshaft
aspiration
Electronic Injection
Electronic fuel injection
System type
Cylinder bore mm 76 83
Travel stroke mm 82 85
Displacement L 1.488 1.839
Compression ratio 10 9.3
Rated Power kW 78kw /6000 r/min 90kw /6000r/min
Maximum Torque N·m 134/4500 160/(3700~4200)
Minimum Fuel
g/kW·h 260 275
Consumption
Fuel Supply Mode Multi-point Electronic Fuel Injection
Ignition Type Distributorless dual coil igniter

1.3 Main Assembly Types and Parameters of Engine Accessories, Chassis and Body

Assembly Structural Parameters

Exhaust system Two grade muffler with three-way catalytic converter

Air intake
Air intake pipeline, air filter
system

Fuel supply Including fuel pump, fuel filter, accelerator pedal, 50L oil
system tank, etc.

Cooling system Water-cooled, electronic engine fan

Clutch Dry type, single-disk, diaphragm spring, hydraulic control

Type 5-gear manual Continuously variable transmission

1st gear 3.583 2.30

2nd gear 1.947 1.63

Gear box
Gear
3rd gear 1.343 1.11
ratio
4th gear 0.976 0.84

5th gear 0.804 0.67

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 6th gear 0.56

Reverse 3.416 2.68

Final drive Gear ratio 4.052 5.76

Driving shaft Type Constant velocity universal joint

Suspension Front suspension Independent MacPherson Suspension

Semi-independent Suspension, Trailing Arm with Torsion

Rear Suspension
Bar
Tire type Radial ply tire
Tires
Tire size 195/ 60R15

Steering gear type Rack-and-pinion steering, hydraulic power steering

Steering
4-spoke steering wheel with a 380mm external
Steering apparatus
diameter, steering column angle adjustable

Front wheel
-0°17′±45′
camber
Front wheel toe-in (-0.5~3) mm
Kingpin inclination 12°±45′
Wheel
alignment Kingpin caster 2°36′±45′

Rear wheel
-1°28′±30′
camber
Rear wheel toe-in (1.1±2.5) mm

Structural type Dual hydraulic circuit, vacuum booster, ABS (optional)

Brake System Service brake Disc brake for front/rear wheels

Parking brake Mechanical cable brake, with rear wheel drum brake

Structural type Vapor-compression refrigeration, water heating

Knob control, controllable airflow direction, with selection

Air Conditioning Manipulation and adjustment of wind speed, temperature and air
System circulation available

Refrigerant R134a, filling weight: 580g

Specification Refrigeration capacity: 4.5kw, heating capacity: 4.5kw

5
Section 2 Vehicle Identification

2.1 Vehicle Identification Number (VIN)

VIN Description:

L G X C 1 6 D
1 2 3 4 5 6 7
Vehicle Transmission Type Body Type Safety System
Manufactory
brand and Drive Mode

G 0 8 0 0 0 0 0 0 1
8 9 10 11 12 13 14 15 16 17
Engine Check Model Factory serial Production Serial No.
Type Digit Year number

2.2 Engine No
The engine No. is marked on the cylinder block of engine, as shown in the figure.

2.3 Vehicle Nameplate

The vehicle nameplate is located on the dash panel in the engine compartment, as shown
in the right figure.

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Section 3 Service Rules forbidden measures you shall pay close
attention to. Ignoring ―Caution‖ may lead to the
3.1 Warning and Caution following consequences:
1. Definitions of ―Warning‖, ―Caution‖ and 1) Damage to vehicle
―Notice‖ 2) Unnecessary vehicle maintenance
In this manual, the diagnosis and maintenance 3) Unnecessary component replacement
procedures involve two categories of 4) Abnormal operation or performance of the
Warnings, Cautions and Notices: general and repaired system or component
specific. 5) Damage to any system or component
which depends on the normal operation of the
To ensure normal running of the auto, BYD repaired system or component
Auto will provide as much maintenance 6) Abnormal operation or performance of any
information as possible to help the system or component which depends on
maintenance staff diagnose and maintain the normal operation of the repaired system or
systems. However, for some procedures, component
operations not in accordance with the 7) Damage to the fasteners, basic tools, or
recommended methods may cause danger to special tools
the maintenance staff. Warnings, Cautions, 8) Leakage of coolant, lubricant, or other
and Notices compiled with the purpose of common fluid
avoiding the above danger, but not all dangers 4. Definition of Notice
are predictable.
―Notice‖ declares and emphasizes the
Such information is given at the conspicuous necessity of a certain diagnosis or
position in this manual. Such information is maintenance procedure. ―Notice‖ is declared
intended to prevent the following cases: for the following purposes:
1) Serious personal injury to the 1) Clarify a procedure
maintenance staff 2) Provide additional information to finish a
2) Damage to vehicle procedure
3) Unnecessary vehicle maintenance 3) Clarify reasons for operating in
4) Unnecessary component replacement accordance with the recommended procedure
5) Improper maintenance or replacement of 4) Provide information to help finish the
vehicle components. Any warning or caution procedure in more effective ways
provided in general information is quoted from Provide the previous experience information to
the related maintenance procedure. the maintenance staff so as to finish the
procedure more easily.

2. Definition of Warning 3.2 Notice

Warning is a description of mandatory 1. Basic maintenance tips

measures you shall take or forbidden (1) Operational Requirements
measures you shall not take. Ignoring 1) Dressing: keep high-standard cleanliness
―Warning‖ may lead to the following
consequences:
1) Serious personal injury to the ▲ Pay special attention to maintenance
maintenance staff staff‘s:
2) Serious personal injury to other personnel ◇ Work clothes ◇ shoes ◇ hands
in the working area
3) Serious personal injury to the vehicle
driver and/or passengers in case of improper
repair

3. Definition of Caution
―Caution‖ is a description of necessary or

7
 ▲ Do not lean your body on the vehicle; do not
put your foot on the bumper.
2) Vehicle protection
▲ Before operation, get the following items
ready:
◇ Floor mat ◇ steering wheel cover ◇ seat
cover
◇ Fender cover ◇ radiator grid cover
◇ Door edge protector

Seat cover

▲ Sufficient distance should be kept between

two vehicles.
▲ Do not put paper on the surface of the
vehicle for writing; do not use vehicle
accessories like cigarette lighter in
maintenance.
Fender cover

▲ Do not put tools or parts on the car roof,

engine hood, or trunk lid.

▲ Sufficient space shall be kept for doors so

that they will not knock into
◇Wall ◇toolbox ◇ table

▲ Avoid exposing metal or hard objects inside

or outside work clothes. For example:
◇ Belt buckle ◇key chain ◇ button
◇Tools placed in pocket (such as spanner) ◇
watch

8
3) Operation safety disassembled, please recoat them with the
specified lockup sealant after refastening
▲ When two or more persons work together, them.
please take care of each other‘s safety. ③To reuse a precoated part, please remove
▲ When the engine is running, make sure the the old sealant first, then blow it dry with
working place is well-ventilated. compressed air, and coat it with the lockup
▲ To repair components working in conditions sealant.
of high temperature, high pressure, rotating, Caution: Fastening should not exceed the
moving or vibrating, please use proper upper limit of the torque tolerance.
protective apparatus. Take extreme care to For certain lockup sealants which get cured
prevent personal injury to yourself or others. slowly, please wait a moment until they are
▲ To lift the vehicle, please use safety cured.
equipment.
▲ To jack-up the vehicle, please use safety
jack to support it at specified positions.
4) Prepare Repair Tools and Measuring
Instruments
Before operation, you should get ready the
tool rack, special electric diagnosis tester,
gauge, related tools and instruments, engine
oil, rag, and parts for replacement. Lock-up sealant
5) Disassembly/Assembly Operation
▲ Make a thorough diagnostic analysis to the
fault before you take repair operations.
▲ Before dismantling any part, check (4) Gaskets
deformation or damage in the appearance and If necessary, coat the gasket with sealant to
the assembly installation conditions. avoid leakage.
▲ For complicated assembly involving a great (5) Bolts, Nuts and Screws
many of electrical connectors, bolts or ▲ Please strictly abide by instructions
pipelines, make necessary marks for regarding the fastening torque.
convenience in reassembly. If necessary, ▲ Torque wrench must be used.
make temporary marks on the pipelines and (6) Fuses
related interfaces. To replace a fuse, please only use one of the
▲ If necessary, please clean and thoroughly same rated amperage.
inspect the disassembled parts before (7) Clips
reinstallation. The method to dismantle and install the clips
6) Disassembled Parts used for body trim is shown as follows:
▲ Disassembled parts should be placed in Caution: any clip damaged in the process of
order to avoid mess or contaminating new dismantling shall be replaced with a new one.
parts.
▲ Replace non-reusable parts, such as
gasket, O-ring, self-locking nut, etc. according
to descriptions in the manual.
▲ Please keep the disassembled parts if so
requested by the owner.

(2) Jack-up and Support Vehicle

Take extreme care to jack up and support the

vehicle. Make sure the vehicle is jacked-up
and supported at the right position.
(3) Precoated Parts
①Precoated parts refer to the bolts and nuts
coated with lockup sealant in production.
②When the precoated parts get loose or

9
Shape (example) Disassemble/Assemble

Vice

Clip remover

Protection tape

Screwdriver

Protection tape

Scraper

10
 Shape (example) Disassemble/Assemble
Disassemble Assemble
Screwdriver
Press

Clip remover

Push out the main pin and remove it,

then unclench off the pin bushing

Disassemble Assemble
Screwdriver

Clip remover

Unscrew the main pin and

unclench the pin bushing

Disassemble Assemble

Press

Screwdriver

Clip remover

Small clip remover

Unclench the main pin, remove the clinch
and then unclench the pin bushing

11
(8) Disassembly and Assembly of Hoses ②Before conducting specific maintenance
▲ To disconnect a hose, please hold its end operations, please turn the ignition to ―LOCK‖,
and rotate to pull it off. Do not hold the middle dismantle the negative ground cable of the
part of the hose or pull it down forcibly, battery and wait for 3 minutes. Otherwise, the
otherwise the hose may be damaged. airbag may unfold unexpectedly. In addition,
please use insulating tape to wrap the
dismantled negative pole, as shown in the
figure below.
Wrong- Correct

Negative
terminal (-)

▲ For convenience in reassembling the hose,

please apply labels for easy identification
when disconnecting it.
▲ After reassembling the hose, please check The contents stored in the clock and sound
the hose carefully to make sure it is connected system will be deleted when the battery
properly. connecting wire is disconnected. Therefore,
▲ While using measuring instrument, do not before servicing, please record the storage
connect the hose to oversized connector contents in each memory so that you can
forcibly. The connector size should be restore the clock and sound system to their
adjusted gradually. Notice: once the hose is original status when the maintenance is
straightened, air leakage may occur. finished.
2. Vehicles equipped with SRS and seatbelt ③After a slight impact, please inspect the SRS
pretensioner system even if the airbag has not unfolded.
BYD New F3 is equipped with Supplemental ④It is prohibited to use any SRS component
Restraint System (SRS) and seatbelt disassembled from other vehicles. If
pretensioner. replacement is required, please only use new
During maintenance of airbag system, if the components.
operating process isn‘t executed properly, the ⑤If servicing other systems or components of
airbag may expand unexpectedly, resulting in the vehicle may cause vehicle vibration,
serious accidents. please disassemble the SRS ECU before
Misoperation during repair of the airbag servicing.
system may cause airbag‘s failure to unfold ⑥It is prohibited to dismantle or repair
normally. Therefore, before servicing components such as DAB, PAB, SAB, SRS
(including disassembling and assembling parts, ECU for the purpose of reuse or other
doing inspection or replacement), please read reasons.
the following precautionary information ⑦If such component as DAB, PAB, and SRS
carefully and comply with the correct operation ECU fall to the ground, suffer vibration or
procedures: knock, or have crack, dents or other damage
(1) General Cautions on the shell, bracket or connector, please
①As it is difficult to identify fault symptoms of replace it with a new one.
the SRS system, DTCs serve as the essential ⑧It is prohibited to directly expose such
basis for servicing. DTCs for other systems component as DAB, PAB, SAB and SRS ECU
may get lost when negative ground cable of to hot air or flame.
the battery is removed. As a result, please In case of paint spraying, overheating (>93℃)
record the system status before you remove may cause negative effect, please remove and
the negative ground cable of the battery during well keep such components as SRS ECU,
maintenance to the SRS system. DAB, PAB, SAB, and clock spring, etc.

12
Detecting light, normal voltmeter and handling the disassembled airbag module to
ohmmeter shall not be used in testing, please prevent collision and vibration. Before
only use voltmeter and ohmmeter with high switching on the system power:
impedance (minimum 10kΩ/V). Do not use ◇ Clear away dust and lubricating grease from
ohmmeter on DAB, PAB, SAB or pretensioner. the installation surface.
Unless otherwise described in this manual, it is ◇ Put the airbag module on the installation
not allowed to test any circuit of the airbag surface horizontally.
system with electric testing equipment. ◇ Adjust the direction of the airbag module so
⑩There warning labels on the SRS that the arrow mark on it point to the vehicle
components and at related positions inside the front.
vehicle. Please follow the instructions on the ◇Fasten all the fasteners, bracket fasteners of
labels while operating. airbag module to the specified torque value.

Correct

Wrong

Do not use ohmmeter on the

airbag or pretensioner.

⑾ Before and after replacing any component,

please conduct system self diagnosis Correct
operation to thoroughly check whether the Wrong
system functions normally.
Warnings for SRS Special Tools
To avoid accidental airbag deployment in the
event of SRS fault, please use the tools and
devices specified in this manual and follow the
instructions in this manual to conduct
maintenance. Failure to use the tools and ②Do not measure the resistance of the airbag
devices according to the associated module igniter. Otherwise the airbag may
instructions may result in airbag deployment, deploy inadvertently and cause severe
personal injury, and unnecessary SRS personal injury.
servicing. ③Do not apply any kind of grease on the
● The normal service life of the airbag is ten steering wheel, nor use any kind of detergent
years; upon expiry, the airbag and label shall to clean the liner.
be replaced. ④Airbag inflator contains toxic and flammable
(2) Clock Spring sodium azide and potassium nitrate, which
The steering wheel must be properly installed may generate harmful irritant gas (sodium
on the steering column to ensure that the clock hydroxide is produced easily in moist places)
spring cable is located in the center. Otherwise, or flammable compound when they encounter
there could be cable disconnection or other with acid, water, or heavy metal. As airbag
faults. system contains compressed argon gas, do
(3) Driver Airbag (DAB), Passenger Airbag not try to disassemble the airbag system or
(PAB) and Side Airbag (SAB) damage the airbag inflator; do not pierce or
①During SRS servicing, the airbag module burn the airbag; do not connect SRS system to
must be equipped into the vehicle immediately electricity or keep it in the environment above
after it is removed from the shipping container; 93°C.
if operation suspension is necessary, the ⑤When conducting electric welding any part
airbag shall be put back into the shipping of the vehicle, please disconnect the SRS
container. It is forbidden to put the airbag at an system before operation to prevent accidental
unattended place. Take extreme care when airbag deployment.

13
⑥To prevent personal injury due to accidental ①Do not measure resistance of the seatbelt
airbag deployment and the resulting, do not pretensioner. Or the pretensioner may be
dispose of the airbag module as general waste. activated accidentally, causing severe
If the airtight container is damaged during personal injury.
disposal process, some substances contained ②Never disassemble seatbelt pretensioner.
in the undeployed airbag module may cause ③Do not install a used seatbelt pretensioner
serious illnesses or personal injury. Please onto any other vehicle.
dispose of the airbag module safely in
accordance with the explosion procedure in After an impact, to avoid personal injury due to
the associated sections in this manual. Failure unrepaired damage in the airbag system, each
to comply with the disposal procedures may seatbelt system shall be inspected thoroughly.
violate the applicable laws and regulations and If there is sign of damage on any component
result in personal injury. of the seatbelt system, the system must be
⑦After airbag inflation, please replace the replaced.
damaged instrument panel if any. ④Seatbelt pretensioner shall be stored in a
⑧Seat with side airbag bears a label ―SRS place with temperature below 80¡ãC (176¡ãF)
SIDE AIRBAG‖ on the seatback. As a seat with away from high humidity and electrical noise.
airbag differs from a seat without airbag in To hold an unfolded seatbelt pretensioner:
structure (such as seatback cover, seat body), ◇ Do not hold the pretensioner by wire or
make sure correct parts are used if connector.
replacement is required. ◇ Hold the pretensioner by piston tube, and
keep your hand and fingers away from wires.
◇ Make sure the open end of seatbelt
pretensioner‘s piston tube points away from
any person.
◇ Do not cover your hand on the opening of
Side airbag label

seatbelt pretensioner‘s piston tube.

⑤When conducting electric welding any part
of the vehicle, please disconnect the SRS
system before operation to prevent accidental
airbag deployment.
⑥Before disposing of the vehicle or seatbelt
pretensioner, please activate the seatbelt
pretensioner. The operation shall be made in a
safe place away from electrical noise.
⑦Seatbelt pretensioner will heat up after
activation, so it must be cooled down before
disposal. Never cool it with water!
⑧Do not spill water or oil on outer seatbelt of
front seats; do not clean outer seatbelt of front
When cleaning the seat, do not dip it in liquid seats with any detergent.
or spray vapor on it. Do not repair or replace (5) SRS Electronic Control Unit (ECU)
the seatback cover when it is damaged or ①It is prohibited to reuse an ECU
worn-out. Inflated side airbag after an impact disassembled from another vehicle.
must be replaced. If seat back cushion is ②Before conducting specific maintenance
broken, it must be replaced. If seat back operations, please turn the ignition to ―LOCK‖,
structure is deformed, it must be replaced. Do dismantle the negative ground cable of the
not install unauthorized seat accessories, such battery and wait for 90 seconds. Otherwise,
as covers, cushions, seat heater and the airbag may unfold unexpectedly.
indicators, on the vehicle. ③The SRS ECU connector, clock spring
⑨After SRS maintenance, do not rush to connector, DAB connector, PAB connector,
connect the airbag module to the circuit. SAB connector and pretensioner connector
Please inspect the electric circuit conditions are all equipped with protection mechanism to
first. prevent the airbag from accidental
(4) Seatback Pretensioner deployment.

14
(6) Wire Harness and Connectors together with some other data are cleared.
All wire harness and connectors in this system Please save the necessary data before
are in standard yellow. If wire harness is removing the battery cable.
disconnected or the connector is broken in the ⑤The battery contains corrosive acid, which
system due to an accident or other causes, may produce explosive gas. Current
replacement is required. generated by the battery is intensive enough
3. Electric control to cause burns. Therefore, to reduce the risk of
(1) Disassembly/Assembly of Battery personal injury during operations nearby the
battery, please follow the guidance below:
◇ Please do wear the safety glasses.
◇ Avoid bending your body over the battery.
◇ Never keep the battery near open flame or
spark.
◇ Do not get battery acid into your eyes or on
your skin. In case that it happens,
- Use running water to flush the affected parts
immediately.
- Go and see the doctor ASAP.
(2) Disassembly/Assembly of Electronic
Components
① Before servicing any electrical component, Cautions for handling ESD sensitive
please disconnect the battery cathode cable to components
prevent the tools or devices from touching the A lot of solid-state electrical components are
exposed charged terminals, which causes vulnerable to Electro-Static Discharge (ESD).
short circuit and may result in severe personal Not all ESD sensitive components are marked
injury and/or damage to the vehicle control with an ESD label. Deal with all electrical
system or other electrical components. components carefully. Pleas follow the safety
② To connect or disconnect the battery cable, instructions below so as to avoid ESD
battery charger, or jumper cable, the ignition damage:
key and all electrical loads must be turned off ◇ Before servicing any electronic component,
unless otherwise specified in the operation especially after sliding your body on the
procedures. vehicle seat, please touch the metallic ground
point first to discharge the static in your body.
◇ Do not touch any bare terminal, as it may be
connected to an ESD sensitive circuit.
◇While servicing a connector, do not let the
tool touch any bare terminal.
◇ It is prohibited to remove a component from
its protective shell, unless it is expressly
required.
◇ Do avoid the following operations, unless
otherwise required by the diagnostic
procedure:
- Get a component or connector bridged or
③ To connect or disconnect the battery cable, grounded.
battery charger, or jumper cable, first turn off - Connect the testing equipment probe to a
the ignition key, unscrew the nut of the cable component or connector. To use a test probe,
terminal, then remove the cathode cable from please connect the ground lead first.
the battery terminal post, and finally ◇ Before opening the protective shell of a
disconnect the anode cable; for reconnection, component, please ground it first. Do not place
the anode cable shall be connected first, any solid-state component on a metal
followed by the cathode cable. It is prohibited workbench or on the top of an electrical device,
to twist or pry the cable terminal. such as a TV set, radio.
④When the battery cable is removed, all the
data in clock device and sound system

15
 system in a place free of ignition sources such
as electric welder, grinder, electric drill, electric
motor, and stove. Please prepare a dry
chemical fire extinguisher (grade B) on hand.
②Do not work in a concave pit or nearby
where fuel vapor may accumulate.
(2) Assembly/Disassembly of Fuel System
Components
①Before servicing the fuel system, please first
relieve fuel system pressure as follows to
reduce the risk of personal injury - power off
the fuel pump and start the engine until it stalls,
or disconnect the fuel pipe connector. After the
②To disconnect the connector of an electronic fuel system pressure is relieved, a little fuel will
component, please unplug the connector itself. still spill out when servicing fuel pipeline,
It is prohibited to pull off the cable. injection pump, or connector. To reduce the
③Take care not to drop, knock, or vibrate any risk of personal injury, before disconnecting
electronic component, such as a sensor or the pipeline or connector, please cover the fuel
relay. In case of any of the above occurs, system components with cotton rag to absorb
please replace the component with a new one. the leaked fuel. After disconnecting the fuel
④To clean the engine with a liquid such as system, put the cotton rag into a permitted
water or steam, please protect the electronic container.
components, air filter, and exhaust elements ②To service the fuel system, please o wear
against water. the safety glasses to prevent the fuel from
⑤Do not use the impact method to assemble getting into your eyes.
or disassemble any electronic component. ③Fuel pressure in the fuel system should not
exceed the limit value; or the fuel pressure
regulator or gauge may be damaged.
④To reduce the danger of the fire and
personal injury, please comply with the
following cautions during servicing the fuel
system evaporative emission tube:
◇ During assembly, please replace all fuel
pipes with crack, scratch, or other damage
rather than try to repair them.
◇To assemble a new fuel pipe, do not use the
hammer to directly knock on the fuel pipe clip.
Any damage to the fuel pipe may lead to fuel
leakage.
◇When servicing near the evaporative
emission tube needs heating, please cover the
tube with a wet towel. Do not expose the
⑥When checking the conductivity of an vehicle to the environment with temperature of
electronic connector, please handle the probe over 85°C over 1 hour or to the environment
with care to avoid bending the terminals. with temperature of over 60°C for long time.
4. Assembly/disassembly of fuel system ◇ Before connecting the fuel pipe connector,
components please do keep it clean to ensure proper
(1) Work Place for Assembly and Disassembly connection, thus eliminating any possibility of
of Fuel System Components fuel leakage.
①Gasoline and gasoline vapor are highly ⑤Be careful not to inhale the air from the
flammable and may easily cause fire if there is evaporative emission tube or hose. The fuel
any source of ignition. To avoid the danger of vapor from the evaporative emission system
fire or explosion, it is prohibited to use any may cause personal injury.
open container to collect or store gasoline or ⑥While servicing the fuel tank, please tighten
diesel oil. Please conduct maintenance to fuel the fasteners of retaining band gradually and

16
alternately until the specified torque value is may start up and lead to personal injury.
reached. Failure to tighten the fasteners in Please keep your hands, clothes, and tools
strict accordance with the specification may away from the electronic fan inside the engine
result in upward bending of fuel tank bottom. In compartment.
which case, the fuel gauge will still indicate (5) While servicing the engine cooling system,
fuel level when the fuel tank is empty. to avoid scald, it is prohibited to disassemble
⑦Do not use fuel containing methanol, which the radiator cap, fluid reservoir cap, or pipe
may lead to damage or corrosion to the fuel connector before the engine cools down. If you
system. open the radiator cap, fluid reservoir cap, or
⑧Do not try to straighten any twisted nylon pipe connector when the engine and radiator
fuel pipe. Instead, please replace all twisted are still hot, the cooling system will release
nylon fuel pipes to avoid damage to the liquid and vapor with high temperature and
vehicle. pressure.
⑨To avoid static damage, please get the fuel (6) Air Intake System Parts
pump, fuel tank, and the vehicle grounded. Do ①While servicing the air intake system, please
not get the floor wet to prevent slipping. Do not use clean rag, tape, or other appropriate
use water to wash the spillage or gasoline, or materials to cover the opening of the air intake
the resulting pervasion may lead to fire. system and engine to avoid foreign objects
Meanwhile, please keep the oily rag inside a entering the system.
fireproof container. ②When it is necessary to disassemble the air
⑩It is prohibited to use hammer or electrical filter assembly, please do cover the inlet of
equipment, such as electric motor and work throttle body to avoid foreign objects entering
light, to avoid spark or high temperature. the engine.
5. Disassembly/assembly of engine parts ③The compressed valve spring will exert a
(1) Cautions for Engine Lifting very high tension on the valve spring
To lift or support the engine for whatever compressor. If the valve spring is compressed
reason, do not locate the jack under the oil pan, or released improperly on the valve spring
metal plates, or crankshaft belt pulley. Lifting compressor, the valve spring will bounce off
the engine in a wrong way may cause the compressor violently. Therefore, be very
damage. careful when disassembling/assembling the
(2) Cautions for Engine Bearer valve stem key or using the valve spring
If the engine bearer is broken, certain parts of compressor to compress or release the valve
the transmission system may be dislocated. spring. Careless operation may result in
Dislocated parts of transmission system may personal injury.
lead to unrepairable damage. (7) Check Transmission Oil
Caution: when one engine bearer is broken, To disassemble the transmission oil fill plug,
the stress imposed on other engine bearers please keep the vehicle in stationary and level
will increase, which may result in breaking of state, otherwise excessive amount of oil may
such other engine bearers. run away. Be careful not to be scalded as the
(3) Cautions for Malfunctions of Electric transmission oil might be very hot and injected
Diagnosis Tester from the fill plug. Please keep your body away
Please only use BYD Auto‘s special purpose while disassembling the oil fill plug as the
electric diagnosis tester and you are welcome actual fluid level is unknown. Get a container
to send us feedback on the faults occurring in ready to collect the oil outflows.
using the electric diagnosis tester. Using a
(8) Clutch
malfunctioning electric diagnosis tester may
lead to misdiagnosis and unnecessary part (1) While servicing the clutch parts, please do
replacement. not grind or polish the clutch plate, nor use dry
(4) Cooling Fan brush or compressed air to clean the parts, as
①To avoid personal injury and vehicle such operations may generate dust. Please
damage, in case of any bending, crack, or use a wet rag (not soaked) to do cleaning. The
damage to the fan blade or fan cover, please clutch plate contains asbestos fiber, which
make replacement. may get into the air if dust is generated in the
②Even if the engine is not running, the process of servicing. Inhaling the dust with
electronic fan inside the engine compartment asbestos fiber will cause serious harm to the

17
health. the engine for a long time; if it is necessary,
(2) It is prohibited to use the mineral oil or please finish the measurement within the
paraffin oil in the clutch hydraulic system. shortest time possible.
Such oil will damage the rubber parts inside ◇When the fuel tank runs low, you shall stop
the oil cylinder. the engine. Otherwise, the engine may misfire
(9) Exhaust System and thus exert extra burden on the catalytic
①Do not repair the exhaust system until it converter.
cools down as maintenance under hot status
may cause scald.
② Any modification to the engine or its
components may affect the vehicle‘s emission
control, in which case the fault indicator may
turn on. The modified vehicle may also fail to
pass emission examinations or maintenance
tests.
Any modification to the following systems may
affect the emission control system of the
vehicle and turn on the fault indicator:
◇ Engine ◇ transmission ◇ exhaust system ◇
fuel system (12) Heated Oxygen Sensor and Oxygen
In case of tire replacement, if the specification Sensor
of the new tire differs from the original one, the ①Handle the oxygen sensor with care to avoid
emission control of vehicle may be also damage to the parts. Do not drop or mishandle
affected. the oxygen sensor.
Faults resulting from modification to the ②Make sure the electrical connector and
systems above or installation of an improper exhaust inlet end are not stained with any
tire may not be covered under the warranty. At pollutant. Do not use any detergent for the
the same time, the vehicle may fail to pass sensor.
emission examinations or maintenance tests. ③Do not repair the lead wire, connector, or
(10) Knock Sensor terminal. In case of damaged lead wire,
Hot engine coolant may lead to serious scald. connector or terminal, please replace the
Even when the cooling system drained, there oxygen sensor.
is still coolant residue left in the engine water ④While servicing the oxygen sensor, please
jacket. When disassembling the knock sensor, abide by the following instructions:
such coolant residue will flow out. ◇ Do not disassemble or disable the ground
(11) Catalytic Converter wire of the oxygen sensor (if any). Vehicles
①To avoid damage to the connector or equipped with ground sensor may rely solely
internal parts of the converter assembly, on this ground wire as the only ground contact
please apply support to the converter. While point for the sensor. Disassembling the ground
moving the catalytic converter assembly, wire may also lead to poor engine
please avoid crash or knock on the outer shell. performance.
②Large quantity of unburned fuel entering the ◇ Make sure that the peripheral sealing of the
catalytic converter may lead to overheating vehicle‘s wire harness connector is in good
and fire of the catalytic converter. To prevent conditions so as to avoid damage caused by
these phenomena, please do abide by the water penetration.
following precautionary information: ◇ It is strictly prohibited to adopt welding for
◇ Only the recommended oil can be used. servicing, or damage will be caused to the
◇ Avoid idle running for more than 20 minutes. part.
◇ Avoid spark-over test: 6. Assembly/disassembly of brake system
- The spark-over test can be conducted only parts
when it is absolutely necessary, and it shall be (1) Only use BYD DOT3, DOT4 or equivalent
finished within the shortest time. brake fluid stored in a clean sealed container.
- The engine shall not run at high speed during Do not use any brake fluid in an open
the spark-over test. container, as moisture may have get into the
◇ Avoid performing pressure measurement on fluid.

18
Use of polluted brake fluid or brake fluid rather Otherwise, the clock spring inside the steering
than the recommended types may cause column may deviate from the central position
failure or damage to the hydraulic brake and get damaged.
system, which may result in accident and (2) Before disconnecting the following parts,
personal injury. the steering column must be in LOCK position:
Brake fluid is irritant to eyes and skin. In case ◇ Steering column ◇ countershaft ◇lower
of any contact with the eyes or skin, please steering shaft
immediately take the following measures: After disconnecting the parts above, don‘t
◇ Eye contact - flush eyes thoroughly with move the front wheels and tires. Failure to
running water. follow these procedures may cause improper
◇ Skin contact - wash skin with soap water. positioning of some parts during installation.
◇ Swallow - go and see the doctor (3) Do not keep the steering wheel staying in
immediately. the extreme positions over 3 seconds, or the
(2) Do not use petroleum-bases brake fluid, steering pump may be damaged.
which may cause inflation or aging of rubber (4) After servicing the power steering system,
parts in the hydraulic brake system, and brake the air inside it should be discharged
fluid mixed with water has a lower boiling point. completely so as to get the accurate reading of
Brake fluid containers should be sealed firmly steering fluid level. The air in the steering fluid
to prevent pollution. may cause cavity noise in the steering pump
(3) While servicing brake parts on a wheel, and even damage the steering bump as time
please avoid the following operations: goes by.
◇ Do not grind the brake lining. (5) Do not start up the vehicle when any inlet
◇ Do not use sandpaper to polish the brake or outlet hose of the power steering gear is
lining. disconnected. Please plug up or cover all the
◇ Do not use dry brush or compressed air to openings when any hose is disconnected.
clean wheel brake parts. Otherwise, the power steering fluid may be
(4) To service the brake caliper, please use a polluted or lost, leading to the damage to the
steel wire to support it to avoid damage to the system.
brake pipe. (6) To add or replace the steering fluid, please
(5) Avoid the brake fluid splashing onto the only use a product which meets the DEXRON
paint surfaces, electrical connectors, lead III specifications or other equivalents.
wires, or cabled. The brake fluid may lead to Improper steering fluid may cause damage to
damage to paint surfaces and corrosion of the power steering hose and sealing, leakage
electrical components. In case that the brake of steering fluid and faults of steering fluid
fluid contacts the paint surface, please flush pump.
the contact part with water immediately. In 8. Air conditioning system
case that the brake fluid contacts the electrical (1) Avoid inhaling 134a (R134a) refrigerant,
connectors, lead wires, or cables, please use lubricant steam or oil mist in the air
rag, proper container, or fender cover to conditioning system. These liquids are
prevent the brake fluid contacting the surface. irritating to your eyes, nose, and pharynx.
Reseal and wipe clean the brake fluid Maintenance shall be made in a well-ventilated
container to avoid further overflow. place. To remove R134a from the air
(6) Certain parts in the Antilock Brake System conditioning system, please use SAE
(ABS) can not be repaired separately. Any J2210-certified servicing equipment (R134a
attempt to disassemble or disconnect such regeneration equipment). In case of accidental
parts may lead to personal injury and/or leakage, please get the workspace well
abnormal system operation. You can only ventilated before further servicing. You can
repair the parts which are allowed to be obtain further information on health and safety
disassembled and reinstalled. from the manufacturer of the refrigerant and
7. Assembly/disassembly of steering system lubricant.
parts (2) If shattered glass gets into the air outlet of
(1) Before disconnecting the steering column defroster, it may be blown into the passenger
or countershaft from the steering gear, make compartment and thus cause personal injury.
sure the wheels are oriented right ahead and 9. Disassembly/assembly of body &
the steering column is in LOCK position. accessories

19
(1) To disassemble or connect the brace rod of surfaces to avoid personal injury.
engine hood, the force can be only exerted on (4) Complete curing of servicing materials
its ends. It is prohibited to exert force in the takes at least 24 hours. Do not touch the
middle of the brace rod, or it may be damaged repaired part until complete adhesive curing,
or bent. or it may lead to personal injury.
(2) To disassemble or assemble the brace rod (5) Use appropriate fasteners at different
of engine hood, please apply support to the positions. The new fastener used to replace
engine hood to prevent personal injury or the old one shall be applicable to the specific
damage to the vehicle. applications and have the correct parts no.
(3) If window glass or windscreen has cracks Parts that require using of thread sealant,
but is still held together, please use protective lubricant, preservative agent or sealant will be
tape to bind the window glass or windscreen in expressly indicated in maintenance
cross form to prevent further damage and the procedures. Unless otherwise specified, do
risk of personal injury. not use paint, lubricant or preservative agent
(4) Do not use gaskets while assembling the on fasteners or fastener mating faces. These
front windscreen, as the stress from the gasket materials affect the fastener torque and
may lead to damage. connector clamping force, and may lead to
(5) To avoid personal injury and vehicle damage to fasteners. Install the fasteners in
damage when replacing the carpet, please use proper tightening sequence, so as to prevent
a carpet with the same thickness and size as damage to parts and systems.
the original one. The new carpet shall be (6) When moving a flexible separating
installed in the exact same position as the connector from its normal installation position,
original one. do not over bend or damage it. The maximum
(6) When using cotton cloth, shaver blade or allowable curvature of the flexible separating
other stuck to the vehicle body, please take connector is 6°, which equals to 1 inch
care to prevent damage to the paint surface. movement of 1 foot pipe section. A 3 feet
10. Vehicles equipped with mobile pipe‘s maximum movement can not exceed 3
communication system inches.
(1) Antenna shall be installed away from the (7) Do not twist the hose during assembling.
ECU and sensors of the vehicle‘s electronic Do not make the hose bent or deformed for
system. sake of convenience, or it may lead to damage
(2) Antenna feeder shall be kept at least 20cm to parts.
away from the ECU and sensors. (8) To prevent personal injury and/or damage
(3) Keep the antenna and feeder away from to parts, proper tools are required to
other electric wires. In this way, interference disassemble the damper coil spring. If spring
between communication equipment and other tension is not released when springs are
equipments on the vehicle can be avoided. separated from the damper, the coil spring will
(4) Check whether the antenna and antenna be subject to extreme pressure and may eject
feeder are commissioned properly. accidentally.
(5) Do not install any high-power mobile (9) When the maintenance staff inspects the
communication system. claimed trouble location, the vehicle should be
11. Others driven by qualified professional personnel.
(1) For this servicing procedure, please do Otherwise, an accident may occur and lead to
wear safety glasses and gloves to reduce the personal injury.
risk of personal injury. (10) When executing specific tests as required
(2) When polishing/cutting any kind of metal or in the workshop, the following guides shall be
compound die part, to avoid harms to the observed if applicable:
health due to exposure to welding ray or toxic ◇When any test requires lifting the vehicle
smoke from metal plating, the workplace shall with a jack and rotating the driving wheel,
be well-ventilated and labor protection please abide by these safety instructions:
appliances shall be worn, such as gas mask, - When rotating one driving wheel rotating
safety glasses, earplug, welding gloves and with the other one staying still, the speed can
protective clothing. not exceed 56 km/h.
(3) When working around running engines, - In such case, tachometer reading is only
avoid contacting moving parts and hot half of the actual speed, thus this limitation is

20
very important. Excessive wheel rotation (3) Cautions on using jack and safety stand:
speed may cause personal injury. ◇ During maintenance, always place a chock
If both driving wheels rotate synchronously, block at a level position.
the speed can not exceed 112 km/h. ◇ Use a safety stand with rubber accessories.
Excessive wheel rotation speed may cause
personal injury. Rubber accessory
All staff shall stay away from rotating parts and
counter weights in order to prevent personal
injury.
- When the engine runs for a long time, do not
get the engine and transmission overheated.
◇When any test requires running the vehicle
after lifting the vehicle and dismantling the
wheels and brake discs, please abide by these
safety instructions:

- Support the suspension at the normal ride

◇When using a jack and rigid support, only
height.
support the vehicle at specified positions.
- Do not apply the brake after the brake disc is
◇ Before lifting the front wheels, release the
dismantled. parking brake and put chock blocks behind the
- Turn off the ignition switch in order to stop
rear wheels; while lifting the rear wheels, put
rotation of the power train.
chock blocks in front of the front wheels.
(11) To make a road test, you shall ensure ◇The jack can only be used together with a
good safety conditions and observe the traffic
rigid support.
regulations. Do not try any operation which
◇When lowering a vehicle that has its front
may endanger the vehicle control. Violating wheels jacked up, release the parking brake
the above safety instructions may lead to
and put chock blocks in front of the rear
personal injury and damage to the vehicle.
wheels.
12. Vehicle lifting
(1) To lift the vehicle, pay attention to these
Wheel center
guides:
◇The weight class of the lifting or hoisting
equipment shall meet or exceed the vehicle
weight.
◇The lifting or hoisting equipment must be
operated according to the operation
instructions from the manufacturer. Jack position
◇ Lift or hoist the vehicle on clean, solid, dry, Auto‘s center of gravity (no-load)
and horizontal ground. Support position for jack

◇ Lift or hoist the vehicle only through the

appointed hoisting or lifting points. It is (4) Cautions on using the four-post car lift
prohibited to use the lifting or hoisting ◇ Follow the safety guides listed in this
equipment at any other position of the vehicle. manual.
(2) To lift the vehicle, pay attention to the ◇ Use supporting arms with rubber
vehicle conditions: accessories.
◇ Make sure the car is not loaded; take out or Make the car lift‘s center close to the vehicle‘s
fasten all articles in the vehicle to prevent center of gravity by keeping length ―L‖ as short
motion during lifting or hoisting. as possible.
◇Disassembling a major part while supporting ◇ Keep the vehicle on the lift in horizontal
the vehicle with a lifting device may cause shift position, and align the lift‘s groove with the
of vehicle‘s center of gravity. In order to hold supporting position of rigid support.
the vehicle in place, apply counterweights to ◇ Before and during the lifting, the supporting
prevent it from swinging or shifting, and arm must be locked up.
support it with a jack at the side opposite to the ◇When lifting the vehicle off the ground,
part that need to be disassembled. shake the vehicle to check the stability from a

21
safe distance. ◇ Replacement of any part shall only be made
◇Take preventive measures to prevent the on the basis of tangible evidence.
supporting arm from damaging the tires, (4) Case application method
wheels and body. ◇This method applies the result of typical
cases to search for solutions directly, reducing
Lifter center line unnecessary inspections.
◇This method is only applicable to failures
with the same symptoms on vehicles of the
same model or failures in similar systems.
◇This method is not applicable to common
faults, as the same symptom can be attributed
to a variety of causes.
Rubber (5) Empirical method
Auto‘s center of ◇ Apply the experience learned in previous
accessor
gravity (no-load) troubleshooting practices to improve the
y
troubleshooting effectiveness.
Failure to follow the guides above may cause ◇ You can apply your experience to analyze
damage to the vehicle or lifting equipment. the similarities and differences in troubles and
make your judgment flexibly.
Section 4 Inspection Rules ◇ As for special, typical troubleshooting, you
should make summary and record the gains
4.1 Troubleshooting and losses in order to optimize the experience.
(6) Logic inference method
(1) Enquiry diagnosis
◇ Make an analysis of the failure and deduce
◇ During an inquiry, you should be kind,
the fault point according to the test data and
earnest, responsible, and listen carefully.
system operating principle.
◇The inquiry shall be made with a
◇ It is required to understand the operating
comprehensive perspective in mind, focusing
principle and function of the engine, electronic
on key points and getting a deep
fuel injection system and relevant parts.
understanding of the history and frequency of
◇ Logical inference and analysis is
the fault.
indispensable for the troubleshooting of some
◇ Make your analysis, judgment, and
faults.
preliminary fault identification through the
(7) Backward chaining method
description of failure phenomenon that is
◇ If a part is assumed to have failed, the
provided by the vehicle owner.
symptoms of the resulting fault can be inferred
(2) Observation diagnosis
backwards.
◇ Make a visual observation in good order
◇ Summarizing the symptom corresponding to
while taking the fault phenomenon into full
a certain failed part can facilitate the
consideration. The observation shall both
identification of the fault point.
cover the whole system and focus on
(8) Flowchart analysis method
suspicious parts.
◇This method is used for the troubleshooting
◇ Make an external visual inspection,
of complex failures.
especially of the water, gas, oil and electricity
◇ Operate according to the given flowchart in
circuits.
order to find out the fault point.
◇ Inspect the relevant instruments and
◇ Other methods can also be used to help
apparatuses on the vehicle to determine the
your analysis and judgment.
failure cause.
◇ Carefully observe the phenomenon, DTC, 4.2 Electronic Control System
sound, etc. in the case of failure and make a
judgment. A variety of ECU control systems are
integrated in the BYD New F3 Auto. ECU is
(3) Part substitution method generally supposed to be complicated and
◇ Replace the suspicious part with a new one. require high level of knowledge and skills in its
◇ Make a further confirmation by using the troubleshooting. However, if you have
suspicious part on another vehicle. reasonable knowledge on the ECU system
and electrical engineering, you can make an

22
accurate judgment and carry out the
necessary maintenance in ECU Knock slightly
troubleshooting. Please refer to the related
sections for details on BYD New F3 ECU
systems.
(1) Using inspection instruments
①Before using an inspection instrument, you
shall read its instrument or operation manual
carefully.
②After connecting an inspection instrument to
the ECU control system, turn on the ignition
switch and start the inspection instrument. If
the instrument cannot communicate with the
ECU system, the vehicle or instrument has
failed.
◇ If the communication is normal between the
instrument and other vehicles, check the data
cable or the vehicle‘s ECU circuit.
◇ If the communication is abnormal between Shake slightly
the instrument and other vehicles, the
instrument may have faults. Please read the
instrument‘s manual or contact the
manufacturer.
(2) How to carry out troubleshooting
You shall determine the troubleshooting
procedure before specific troubleshooting
operations. Swing slightly
(3) Fault simulation
During troubleshooting, the most difficult
situation is that no fault symptom is identified. This method can be used in cases where
Under this circumstance, make a vibration is believed to be the main cause for
comprehensive analysis of the fault, and the fault.
simulate the same or similar situations in A. Part and sensor: hit on the suspicious parts
which the vehicle goes wrong. If the with your hand gently to see whether the fault
technicians, no matter how experienced or appears. A relay may get open if it undergoes
highly skilled they are, ignore the analysis and forcible vibration.
identification of fault symptoms, then delays, B. Connector: shale the connector up and
omissions, or wrong operation will be caused. down gently.
The fault simulation is intended to determine C. Wire harness: swing the wire harness up
the fault symptom, and identify the faulty and down gently. Take note that the contacting
position or part. Firstly, narrow down the positions and swinging pivots are the focal
suspicious scope, then connect the electric points for inspection.
diagnosis tester to perform a symptom ②Heating method
simulation test, which is intended to judge This method can be used in cases where
whether the inspected system has a fault and, faults are probably caused by increasing the
if any, confirm the fault symptom, and finally temperature of some parts.
identify the cause of the fault by reference to
the DTC table.

① Vibration Method

23
 (4) Circuit Inspection
Fault ①Basic Inspection
□ Measurement conditions for resistance of
electronic components
Unless otherwise specified, all resistance tests
shall be measured at 20°C indoor temperature.
If you make a measurement when the vehicle
is started, the result will go beyond the
specified value due to increased temperature.
Therefore, the measurement of resistance
should be carried out when the engine has
Use a hair dryer or equivalent to heat the cooled down.
suspicious components and see whether the □ Disassembly/Assembly of Connectors
fault appears. ◇To disconnect a connector, first press on
Notice: both ends of the connector to release the
A. The heating temperature can not exceed shackle, and then press the retaining jaws.
60°C. ◇It is prohibited to pull the wire harness to
B. Do not directly heat any ECU component. disconnect the connector. Please hold the
③Spraying method hard ends directly in order to disconnect it.
This method can be used in the cases where ◇ Before reconnecting the connector, please
faults probably caused by the rainy day or high check whether is deformed or damage and
humidity whether any port is missing.
◇While connecting the connector, a click
sound indicates successful engagement.
◇When it is required to test a connector from
the rear end (wire harness end) with a probe,
please note that the rear end of a waterproof
connector cannot be utilized for testing; you
may connect a sub wire harness for inspection;
while handling the inserted probe, be careful
not to damage the terminal.
□ Connector inspection
◇While connecting a connector, please press
both ends until it is inserted and locked up
securely.
While spraying water onto the vehicle, please ◇While the connector is disconnected, you
note these guides: can check for unengaged, dropped or loose
A. Do not spray water onto the engine directly, terminals, or damaged wires by gently pulling
but you can spray water onto the front end of the wire harness from the rear end of the
radiator in order to change the temperature connector.
and humidity indirectly. In addition, please visually check whether
B. It is strictly prohibited to spray water onto there is any corrosion, metal debris, foreign
any electronic component directly. object or water, and whether the terminal is
C. Rain leakage into the vehicle may cause bent, rusty, overheated, polluted or deformed.
damage to the ECU electronic components or
connectors. Please pay special attention
during the test.
④High-voltage load method
This method can be used in cases where a
fault is probably caused by over load of
electronic components.
Turn on the fan heater, headlight, rear
windscreen defroster, and all other electrical
equipment to see if the fault appears.

24
 Wrong Wrong

Wrong
Socket-like terminal

□ Check a Terminal‘s Contact Pressure ◇ It is prohibited to loosen the wire harness by

Prepare a plug matching the connector and twisting or stretching.
insert it into the socket until complete ◇The wiring harness shall not come into
engagement, and check whether there is good contact with anything hot, rotating, moving,
tension. vibrating, or pointed. Please also prevent it
□ Repair of Connector Terminals from contacting the panel edge, screw tip, or
other similar objects.

Wrong
Correct

◇ If there is dust on the terminal, please use

an air blower or rag to clean the contact point.
Do not use sandpaper to do the cleaning, or
the protective coating may be damaged. ◇While assembling parts, it is prohibited to
◇ If the contact pressure is abnormal, please mix them with the wiring harness.
replace the socket with one with the same ◇It is prohibited to cut or teat the wire harness
specifications. sleeve. When it is necessary to cut or tear the
◇ All damaged, deformed, or corroded sleeve during maintenance, please replace
terminal should be replaced. If the terminal is with a new sleeve or use polythene tape or
not locked in the shell, please replace the shell similar materials to repair it.
as well. ②Open Circuit Inspection
Disassembly/Assembly of a Wiring Harness □ To perform open circuit inspection for the
◇ Before disassembling or assembling the wire harness in the figure, please check the
wiring harness, please check the wiring conductivity and voltage in order to locate the
harness connection and fastening status in open circuit position.
order to make the correct reassembly. □ Resistance inspection

25
 Tested Terminals Specified
Condition

Connector A Terminal <1Ώ

Sensor 1 - Connector B1
Terminal 1

Connector B2 10kΏ or
Terminal 1 - higher
Connector C Terminal
1
◇ Disconnect and measure the resistance
between connector A and C, as shown in the
figure, and the value shall be lower than 1
Ohm. Notice: please shake the wire harness
gently during inspection. Sensor

Tested Terminals Specified Condition

Connector A Terminal 10kΏ or higher

1 - Connector C
Terminal 1
If the result conforms to the conditions in the
Connector A Terminal <1Ώ table above, it is in open circuit between
2 - Connector C connector C terminal 1 and connector B2
Terminal 2 terminal 1.
□ Voltage inspection
If the result conforms to the conditions in the ◇When the circuit is electrified (ECU
table above, it is in open circuit between connector terminal powered up), you can
connector A terminal 1 and connector C check whether the circuit is open by a voltage
terminal 1. inspection.
As shown in the figure, when all connectors
are connected, measure the voltage between
the ECU 5V output terminals, that is,
Open circuit connector A terminal 1, connector B terminal 1,
Sensor
and connector C‘s terminal, and the body
ground respectively.

Short circuit

◇ Example of Results:

Tested Terminals Specified

Condition

Disconnect connector B and measure the Connector A Terminal 5V

resistance between the connectors. 1 - Body Ground

26
 connector B2 and the body ground
Connector B Terminal 5V
respectively.
1 - Body Ground

Connector C Terminal 5V Tested Terminals Specified

1 - Body Ground Condition

Connector A Terminal 10kΏ or higher

If the result conforms to the conditions in the
1 - Body Ground
table above, it is in open circuit between
connector B terminal 1 and connector C
Connector B2 <1Ώ
terminal 1.
Terminal 1 - Body
③Short Circuit Inspection
Ground
□ If any wire harness is in short circuit to the
ground, a resistance inspection of the body
ground can find out the position where short If the result conforms to the conditions in the
circuit occurs. table above, it is in open circuit between
□ Inspect the body ground conductivity connector B2 terminal 1 and connector C
terminal 1.
④ECU Inspection and Replacement
□ Notice:
◇ Connect the connector to ECU, and inspect
the connector from its rear end on the wiring
harness side.
Sensor ◇ If no special inspection requirements
specified, please turn off the engine and turn
the ignition switch to ON before inspection.
◇ Check whether the connectors are
connected well and whether the wire harness
is loose, corroded, or damaged.
◇ Disconnect connector A and C, and
measure the resistance between connector A
terminal 1, 2 and the body ground respectively:
10kΏ or higher. Notice: please shake the wire
harness gently during inspection.
Sensor
Tested Terminals Specified
Condition

Connector A <1Ώ
Terminal 1 - Body
Ground
□ ECU Grounding Wire Inspection
Connector A 10kΏ or Example
Terminal 2 - higher
Connector C
Terminal 2 Grounding

If the result conforms to the conditions in the

table above, it is in open circuit between
connector A terminal 1 and connector C
terminal 1.
◇ Disconnect connector B, and measure the
resistance between connector A terminal 1,

27
 connector in the faulty circuit, and make sure
ECU side
the contact pressure is sufficient. If the contact
is loose, you can adjust the terminal post or
replace it in order to increase the contact
pressure.
Grounding □ Poor contact between the terminal post and
wire
W/H side Use your hands to shake the wire harness
gently to check for poor contact in the faulty
circuit. In case of any abnormal phenomenon,
Grounding please do repair or replacement immediately.
□ Intermittent short circuit may be caused by
abrasion of the wire insulating layer when the
exposed conductor contacts other electrical
Repair the circuit if it has fault; if the circuit is wires or other parts.
normal, the ECU may have a fault. Replace □
the ECU with a new one and check whether
the symptom remains.
◇ Measure the resistance between the ECU
grounding terminal and body ground: < 1 ohm.
◇ Disconnect the ECU connector, and check
whether the grounding terminals are bent,
corroded, or stained with foreign matter.
Finally, inspect the contact pressure of the
socket.
⑤Intermittent Contact and Poor Contact
Intermittent contact is caused by the abnormal
connection between an electric component
and an electrical wire, although sometimes a
magnetic breaker or solenoid may function
□ The wire core inside the insulating layer is
abnormally. While inspecting for poor contact,
broken. In this case, you had better make a
please carefully check the suspicious circuit.
conductivity inspection. However, maybe only
one or two cores in a multi-core wire are in
good condition, and the resistance will be
higher. In case of any abnormal phenomenon,
please do repair or replacement immediately.

□ The connector and plug are not matching, or

the terminal post is not completely situated
inside the socket connector.
□ The terminal post is dirty or eroded. Please
keep the terminal post clean and free of any
other foreign matters. However, it is prohibited
to use the sandpaper or similar materials to
clean the terminal post.
□ Socket connector damage. The connector
may be damaged due to exposure to moist
and dirty environment, or wrong position
between the terminal post and the matching
socket connector or other components.
□ Incorrect or damaged terminal post.
Check the terminal post of each socket

28
4.3 Troubleshooting Flowchart

Vehicle enters the garage

Fault Diagnosis - inquiring of customer about

the vehicle condition and environment when
the fault occurs

Fault confirmation and test data:

(1) Check the battery voltage;
(2) Visually check the wire harness, connector,
and fuse for short circuit or open circuit;
(3) Warm up engine to normal work temperature;
and
(4) Confirm fault and condition, and compare the
measured date with the standard value.
Normal

Abnormal

Data check: determine

the system and parts that
shall be checked and the
procedure

Continued in the next page

29
 Continued

Circuit or Part Inspection: confirm

the system, circuit or part that shall
be inspected according to the DTC
code or check data

Repair: repair the faulty

system or part according to
the check result

Quality Check: After repair, double

check if all troubles are cleared; if any
trouble remains, repeat the repair
procedure until all troubles are solved.

End

Section 5 Abbreviations and Wire Color Marks

Abbreviation Meaning Abbreviation Meaning
ABS Anti-lock Brake System LH Left
(ABS)
A/C Air conditioner LO Bottom, little, lower
AC Alternating current MAP Intake manifold absolute
pressure

30
 ACC Accessories MAT Intake manifold absolute
temperature
ALT Alternator MAX Maximum
AM1 Ignition switch 1# MAIL Malfunction indicator
AM2 Ignition switch 2# MIN Minimum
AMP Amplifier MPI Multi-point injection
ANT Antenna N N gear
AUTO Automatic OSP+ Heated oxygen sensor
B+ Battery voltage PROM Programmable read only
memory
BAT Battery PTC Positive temperature
coefficient
CD CD Disk P/W Power window
CDC CD changer RAM Random access memory
CPU Central processing unit RH Right
DC Direct current RLY Relay
DEF Defroster ROM Read only memory
DLC Data link connector R Rear
DTC Diagnostic trouble code SD Map card
EBD Electronic brake force SEN Sensor
distribution
ECU Electronic control unit SRS Supplementary restraint
system
EEPROM Electrically erasable PROM SST Special service tool
ELR Emergency locking retractor STD Standard
ENG Engine SW Switch
EVP Evaporator SYS System
GND Grounding TB Throttle body
GPS Global positioning system TEMP Temperature
HCU Hydraulic control unit VCD Video compact disc
HI High VIN Vehicle identification number
IC Integrated circuit VSS Vehicle speed sensor
IG Ignition WOT Wide open throttle
INT Interval
ISC Idling speed control
LAN Local area network
LCD Liquid crystal display
LED Luminescent diode
5.1 Wire Color Marks
Mark Color Mark Color
B BLK Black O ORN Orange
L BLU Blue R RED Red
Br BRN Brown W WHT White
G GRN Green Y YEL Yellow
Gr GRY Gray P PNK Pink
V PPL Purple

Wires on the vehicle include single-color wire and dual-color stripped wire. Single-color wire is
indicated by one mark, such as G; dual-color wire is indicated by a pair of marks, such as G/Y, in
which the former indicates base color and the second indicates strip color.

31
BYD AUTO BYD NEW F3 Maintenance & Repair Manual

Chapter 2 473QA/QB Engine

Contents

Part1 Gasoline Engine .............................................................................................................. 34

Section 1 Overview ............................................................................................................ 34
1.1 Major Technical Parameters.................................................................................... 34
1.2 Technical Parameters for Maintenance ................................................................... 35
1.3 BYD473QA/QB Gasoline Engine Tightening Torque Table ...................................... 37
1.4 BYD473Q Engine Special-purpose Part List ........................................................... 39
Section 2 Cylinder Head .................................................................................................... 40
2.1 Adjust Valve Clearance ........................................................................................... 40
2.2 Remove/Install Crankshaft Pulley ........................................................................... 40
2.3 Remove/Install Silent Timing Chain ......................................................................... 41
2.4 Install Crankshaft Front Oil Seal.............................................................................. 45
2.5 Remove Cylinder Head Cover ................................................................................ 45
2.6 Remove Cylinder Head ........................................................................................... 45
2.7 Remove/Install Camshaft Sprocket ......................................................................... 49
2.8 Replace Camshaft Phase Sensor Signal Plate ....................................................... 51
2.9 Check Cylinder Head Warping ................................................................................ 52
2.10 Remove Rocker Arm Assembly ............................................................................. 53
2.11 Disassemble/Reassemble Rocker Arm and Rocker Arm Shaft .............................. 54
2.12 Check Rocker Arm and Rocker Arm Shaft............................................................. 54
2.13 Remove Camshaft ................................................................................................ 55
2.14 Check Camshaft ................................................................................................... 55
2.15 Remove Valve, Valve Spring and Valve Oil Seal.................................................... 56
2.16 Check Valve ......................................................................................................... 56
2.17 Check Valve Tappet-Valve Guide Clearance ......................................................... 56
2.18 Replace Valve Guide ............................................................................................ 57
2.19 Check Valve Seat ................................................................................................. 59
2.20 Install Valve, Valve Spring and Valve Oil Seal ....................................................... 60
2.21 Install Camshaft .................................................................................................... 61
2.22 Install Rocker Arm Assembly................................................................................. 61
2.23 Install Cylinder Head ............................................................................................. 61
2.24 Install Cylinder Head Cover .................................................................................. 65
Section 3 Cylinder Block .................................................................................................... 66
3.1 Check Connecting Rod-Crankshaft Axial Clearance ............................................... 68
3.2 Replace Crankshaft Main Bearing Bush .................................................................. 68
3.3 Replace Connecting Rod Bearing Shell .................................................................. 72
3.4 Remove Oil Pan ..................................................................................................... 74
3.5 Remove Crankshaft and Piston .............................................................................. 75
3.6 Check Crankshaft ................................................................................................... 77
3.7 Check Cylinder Body and Piston ............................................................................. 78

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BYD AUTO BYD NEW F3 Maintenance & Repair Manual

3.8 Replace Piston, Piston Pin and Connecting Rod ..................................................... 80

3.9 Check Connecting Rod Bolt .................................................................................... 84
3.10 Install Crankshaft .................................................................................................. 84
3.11 Install Oil Pan........................................................................................................ 86
Part 2 Lubricating System ......................................................................................................... 88
Section1 Check Oil Pressure Warner ................................................................................. 89
Section2 Inspect Oil Pressure ............................................................................................ 89
Section3 Change Engine Oil .............................................................................................. 89
Section4 Replace Engine Oil Filter ..................................................................................... 90
Section5 Replace Oil Filter Thread Pipe............................................................................. 90
Section6 Overhaul Oil Pump .............................................................................................. 91
Section7 Install Breather Cover Plate................................................................................. 93
Section8 Replace Oil Pressure Warner .............................................................................. 93
Part 3 Air Manifold and Exhaust System ................................................................................... 93
Section1 Remove/Install Intake Manifold ............................................................................ 93
Section2 Remove/Install Exhaust Manifold ........................................................................ 94
Part 4 Engine Cooling System .................................................................................................. 95
Section1 Check Thermostat ............................................................................................... 96
Section2 Check Water Pump ............................................................................................. 96
Section3 Replace Water Pump .......................................................................................... 96
Section4 Replace Thermostat ............................................................................................ 97
Section5 Replace Water Temperature Sensor .................................................................... 97
Part 5 Fuel and Exhaust System ............................................................................................... 98
Section1 Fuel Tank .......................................................................................................... 102
Section2 Power Fuel Pump.............................................................................................. 104

33
BYD AUTO BYD NEW F3 Maintenance & Repair Manual

Part1 Gasoline Engine

Section 1 Overview

BYD473QA/QB gasoline engine adopts electronically controlled fuel injection system, which is
developed by BYD and featured by sequential multi-point fuel-injection and advanced
self-diagnosis function. The engine has high power per liter, low fuel consumption, low noise, low
pollution and compact profile. BYD473QA/QB engine can optimize running under all working
conditions, allowing good performance of the BYD F3 AUTO in the aspects of safety, drivability,
economic and environmental performance.

1.1 Major Technical Parameters

The major technical parameters of BYD473QA/QB are shown below:

Model BYD473QA BYD473QB

Configuration In-line, water-cooled, SOHC, EFI, 4-stroke engine
Number of Cylinders 4
Cylinder bore (mm) 73
Piston stroke (mm) 80 88.9
Compression ratio 10.2
Ignition sequence 1-3-4-2
67 75
Declared power (kw)
(5800r/min) (5800r/min)
Maximum torque (N.m) 120 (4700 r/min) 135(4800r/min)
Declared speed (r/min) 5800
Minimum fuel consumption
275
(g/kW·h)
Oil pressure (kPa) 300～350(3000r/min±50r/min)
Minimum stable idle speed
780±50
(r/min)
Total displacement (L) 1.339 1.488
Oil/fuel consumption ratio
0.26
(%)
Overall dimensions
587×543×682 587×543×700
(L×W×H) (mm)
Net weight (kg) 87.5 92
CO≤0.15% HC≤40ppm (780±50r/min)
Idle exhaust emission
CO≤0.15% HC≤40ppm(2000±50r/min) GB18285-2005
Fuel unleaded gasoline
SG grade 10W/30 (year around in the south and spring, summer
Lubricating oil and autumn in the north)
SG grade 5W/30 (winter in the north)
Coolant Ethylene glycol based coolant
Dry-type, single-disk, diaphragm spring clutch, with constant
Configuration
pressure
Clutch Overall Clutch driven disk assembly φ200×8.9mm (free state)
dimensions (mm) Clutch cover assembly φ255×40.4mm
Weight 4.314kg
Gearbox Configuration Synchromesh transmission, 5 forward gears, 1 reverse gear

34
BYD AUTO BYD NEW F3 Maintenance & Repair Manual

1st gear 3.308

2nd gear 1.826
3rd gear 1.207
Gear ratio
4th gear 0.939
5th gear 0.730
Reverse 3.231
Final drive ratio 4.471
Overall (L×W×H) 504×382×363mm
dimensions (mm)
Lubricating oil Gear oil for medium duty vehicle (GL-4 SAE 80W/90)

1.2 Technical Parameters for Maintenance

Cylinder Head

Measuring Service
Part Name Measured Item Standard Value
Condition limit
Cylinder Warping 0.08mm
head Height 119.9～120.1mm
Camshaft axial clearance 0.05～0.25mm 0.5mm
Camshaft-bracket oil film
0.045～0.084mm 0.1mm
clearance
Camshaft Maximum
Total runout 0.04mm
0.03mm
Intake 35.38mm
Cam lobe lift
Exhaust 35.377mm
Intake 0.15～0.18mm
Clearance (cold)
Exhaust 0.23～0.28mm
Intake 5.470～5.485mm 5.45mm
Valve Tappet outer diameter
Exhaust 5.455～5.470mm 5.42mm
Intake 0.025～0.060mm 0.08mm
Tappet-guide clearance
Exhaust 0.04～0.075mm 0.11mm
Intake 0.85～1.15mm 1.60mm
Width
Exhaust 1.25～1.55mm 2.00mm
Valve seat
Intake 46.1～46.5mm 46.8mm
Tappet installation height
Exhaust 46.2～46.6mm 46.9mm
Intake 50.5mm
Valve spring Free length
Exhaust 57.2mm
Intake 5.51～5.53mm 5.55mm
Inner diameter
Exhaust 5.51～5.53mm 5.55mm
Valve guide
Intake 15.85～16.35mm
Installation height
Exhaust 15.85～16.35mm
Rocker arm-rocker arm shaft Intake 0.02～0.054mm 0.08mm
Rocker arm
clearance Exhaust 0.02～0.054mm 0.08mm

Cylinder Block

Measuring
Part Name Measured Item Standard Value Service limit
Condition
Cylinder Surface warping Maximum 0.07mm 0.10mm

35
BYD AUTO BYD NEW F3 Maintenance & Repair Manual

block 73～73.019mm
Cylinder bore 73.07mm
_
Cylinder bore conicity ---- 0.05mm
Cylinder reboring limit ---- 0.25mm
Outer diameter at 13mm
from the piston skirt 72.955～72.975mm 72.945mm
bottom
Piston Clearance to cylinder 0.035～0.054mm 0.06mm
Air-tight ring 1.02～1.04mm 1.07mm
Piston ring groove Air-tight ring 1.21～1.23mm 1.25mm
Oil-control ring 2.01～2.03mm 2.05mm
Piston ring-groove Air-tight ring 0.03～0.07mm 0.15mm
clearance Air-tight ring 0.02～0.06mm 0.13mm
Piston ring Air-tight ring 0.15～0.3mm 0.6mm
Piston ring gap Air-tight ring 0.35～0.5mm 0.65mm
Oil-control ring 0.2～0.7mm 0.8mm
Outer diameter 17.996～18mm
Piston pin Piston pin to piston-pin
0.005～0.015mm
boss clearance
Pin-connecting rod small
0.015～0.037mm
end bore clearance
Connecting rod small end
17.963～17.981mm
Connecting bore
rod Connecting rod big end
Normal 43～43.015 mm
bore
End play when installed
0.15～0.3mm 0.4mm
to crankshaft
Main journal diameter 49.937～49.955mm
Connecting rod journal
39.940～39.955mm
diameter
Connecting rod/main
0.005mm 0.01mm
Crankshaft journal conicity
Connecting rod/main
0.005mm 0.01mm
journal out-of-roundness
End play 0.1～0.35mm 0.45mm
Runout Maximum 0.03mm 0.04mm
Mainshaft bearing-journal
0.028～0.049mm 0.055mm
Crankshaft oil film clearance
bearing Connecting rod bearing
0.022～0.050mm 0.055mm
clearance

Engine Lubrication

Part Name Measured Item Measuring Condition Standard Value Service limit
Engine overhaul 4.0L
Replace oil (including
3.3L
Engine oil Oil capacity oil filter)
Replace oil (excluding
2.9L
oil filter)
Inner rotor-outer
Oil pump 0.075mm～0.15mm 0.18mm
rotor clearance

36
BYD AUTO BYD NEW F3 Maintenance & Repair Manual

Pump
housing-outer 0.06mm～0.136mm 0.18mm
rotor clearance
Pump
housing-outer
0.028mm～0.065mm 0.085mm
rotor shaft
clearance
Oil pressure Idle Minimum 30KPa
Pressure
under 80°C oil Engine speed at
relief valve Minimum 300KPa
temperature 3000rpm/min

Engine Coolant

Measuring
Part Name Measured Item Standard Value Service limit
Condition
Coolant capacity Engine
4.7L
(including engine, Overhaul
Radiator
heater, hose and water Coolant
3.6L
tank) replacement
Overflow
Coolant capacity 0.6L
kettle
Radiator Opening pressure 80kPa～110kPa
Starting to
76℃～80℃
Opening temperature open
Thermostat Fully open 90℃
Valve stroke when fully
Above 8mm
open
To ON 91～95℃
Thermoswitch Switching temperature 3～8℃ lower than the actual
To OFF
temperature switching to ON

1.3 BYD473QA/QB Gasoline Engine Tightening Torque Table

Tightening
SN Part /Location To Tighten Bolt Description torque:
(N.m)
Cylinder head bolt with 29 plus 130°
1 Cylinder head
washer rotation
Main bearing cap bolt with 25 plus 40°
2 Main bearing cap
washer rotation
9.8 plus 90°
3 Connecting rod cover Connecting rod bolt
rotation
4 Flywheel Flywheel bolt 95
5 Spark plug M14×1.25 20
6 Breather cover plate Bolt M6×12 12
7 Knock sensor Bolt M8×30 25
8 Oil pressure alarm device ---- 15
9 Cylinder head plug Bolt M10×1.25×12 30
10 Tensioner assembly Tensioner pivot bolt 22
Camshaft sprocket bolt
11 Camshaft sprocket 56
assembly
12 Guide assembly Bolt M6×16 12
13 Tensioner seat Bolt M6×30 12

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BYD AUTO BYD NEW F3 Maintenance & Repair Manual

Bolt M6×25 10
14 Oil pump assembly
Bolt M6×35 10
15 Water pump Bolt M6×35 12
Bolt M6×12 10
16 Oil collector
Bolt M6 10
Bolt M6×30 12
17 Oil pan Bolt M8×35 25
Bolt M6×50 12
Oil filter 12
18 Oil filter
Corrugated pipe 50
19 Dipstick tube welded assembly Bolt M6×12 10
20 Water outlet pipe part Bolt M6×12 10
Bolt M8×35 25
21 Intake manifold
Nut M8 25
22 Oil rail Bolt M6×12 10
Cross recessed pan head
23 Air intake temperature/pressure sensor 5
screw
Bolt M6×30 12
24 Intake valve assembly
Bolt M6×35 12
25 Accelerator cable bracket Bolt M6×12 12
Bolt M10×1.25×20 44
26 Exhaust manifold
Nut M10 44
27 Exhaust manifold heat shield Bolt M6×12 10
Bolt M8×16 25
28 Exhaust manifold bracket
Nut M8 25
29 Front oxygen Sensor ---- 45
30 Thermostat cover Bolt M6×20 10
31 Camshaft phase sensor Bolt M6×16 10
32 Water temperature sensor 20
Cylinder-head cover bolt
33 Cylinder head cover 12
assembly
34 Ignition coil Bolt M6×25 10
35 Carbon canister control valve bracket Bolt M6×12 10
37 plus 90°
36 Crankshaft pulley Pulley bolt with washer
rotation
37 Water pump pulley Bolt M6×12 14
Bolt M8×70 25
38 Generator
Bolt M8×25 25
Hexagon socket head cap
39 Clutch cover assembly 25
screw
Bolt M12×1.25×60 65
40 Gearbox Bolt M12×1.25×65 65
Bolt M12×1.25×95 65
41 Starter Bolt M10×1.25×45 44
Bolt M10×1.25×20 44
Bolt M6×16 12
42 Intake manifold bracket
Intake manifold bracket
12
washer bolt M6×30
Hexagon head bolt for
25
reamed hole
43 Timing cover Bolt M8×50 25
Bolt M8×70 25
Bolt M6×30 10

38
BYD AUTO BYD NEW F3 Maintenance & Repair Manual

Bolt M12×1.25×12 20
44 Clutch back plate Bolt M6×12 10
Cylinder identification signal (CID
45 Bolt M6×20 10
signal) cover
46 Camshaft phase sensor signal plate Hexagon socket screw 34

1.4 BYD473Q Engine Special-purpose Part List

Model
Part No.
BYD473QA BYD473QB
Part Name

Cylinder block assembly BYD473QA-1002100 BYD473QB-1002100

Main bearing cap assembly BYD473QA-1002300 BYD473QB-1002300
Timing cover BYD473QA-1002031 BYD473QB-1002031
Fractured connecting rods N/A BYD473QB-1004030
Machined connecting rod
BYD473QA-1004030 N/A
part
Crankshaft BYD473QA-1005021 BYD473QB-1005021
Exhaust manifold bracket BYD473QA-1008032 BYD473QB-1008032
Guide assembly BYD473QA-1021020 BYD473QB-1021020
Tensioner assembly BYD473QA-1021030 BYD473QB-1021030
Silent timing chain assembly BYD473QA-1021040 BYD473QB-1021040
Tensioner seat BYD473QA-1021061 BYD473QB-1021061

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Section 2 Cylinder Head

Regulating screw
2.1 Adjust Valve Clearance
Notice: valve can not be adjusted when the
cylinder head temperature is over 38°C.
1. Remove the cylinder head cover.
2. Rotate the crankshaft until the number one
piston is at TDC. ―UP‖ mark on the camshaft
sprocket shall be on the top, and TDC groove
on the camshaft sprocket shall be aligned with
the cylinder head‘s upper edge.

UP mark
Lock nut

6. Tighten the lock regulating screw and

recheck the valve clearance; repeat the
process above until the clearance is
appropriate.
7. Rotate the crankshaft clockwise. Repeat the
procedure for valve clearance adjustment to
adjust cylinder 3, 4, 2 in strict order.
8. Install the cylinder head cover.
DTC groove 2.2 Remove/Install Crankshaft
Pulley
3. Choose a proper feeler gauge for the valve
you will check. Removal Procedure
Remove the pulley bolt with a ratchet wrench,
extension rod and 19mm sleeve.
Intake valve clearance: 0.15mm～0.18mm
Installation Procedure
Exhaust valve clearance: 0.23mm～0.28mm 1. Clean the crankshaft pulley A, crankshaft B,
4. Insert the feeler gauge between the bolt C and washer D, and conduct lubrication
regulating screw and valve stem end, and process as shown in the figure below:
slide the gauge back and forth; a slight
resistance shall be felt.
Cleaning
5. If the resistance is too large or small, loosen
Lubricating
the lock regulating screw, and rotate the
regulating screw with a screwdriver until you
can fill appropriate resistance when sliding the
feeler gauge.

2. Install the crankshaft pulley and pulley bolt,

and tighten it to 37N.m with a torque wrench
and 19mm sleeve. Do not use an impact
wrench. For a new pulley bolt or new
crankshaft, tighten the bolt first to 177N.m,
loosen it and then tighten it to 37N.m.
3. Tighten the pulley bolt for additional 90°.

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2.3 Remove/Install Silent Timing

Chain Arrow

Notice: keep the silent timing chain away from

any magnetic field.
Removal Procedure
1. Remove the belt.
2. Remove the mounting bolt 1 from the
generator adjusting arm, and then loosen the
generator mounting bolt 2.

Mounting bolt 1 DTC mark

5. Remove the water pump pulley.

6. Remove the cylinder head cover.
7. Remove the crankshaft pulley.
8. Remove the oil pan.
9. Place a jack and wooden block under the
Mounting bolt 2 cylinder block to support the engine.
10. Keep the engine away from the timing
cover and then remove the timing cover.
3. Remove the idler pulley assembly.

Timing cover

4. Rotate the crankshaft pulley until its TDC

mark is aligned with the arrow.
11. Apply engine oil to the support surface of
the silent timing chain tensioner. Pry open the
hole on the support of the silent timing chain
tensioner with a screwdriver, and then remove
bolt 1 and loosen bolt 2.

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Tensioner support

Tensioner assembly

Guide assembly

14. Remove the silent timing chain.

Installation Procedure
Bolt 1 Bolt 2 Notice: keep the silent timing chain away from
any magnetic field.
1. Set the crankshaft to the TDC position.
12. Remove the support of the silent timing Align the TDC mark on the crankshaft sprocket
chain tensioner. with the arrow on the oil pump.

Arrow TDC mark

2. Set the number one piston to the TDC

position. ―UP‖ mark on the camshaft sprocket
shall be on the top, and TDC groove on the
camshaft sprocket shall be aligned with the
cylinder head‘s upper edge.

13. Remove the tensioner assembly and guide

assembly.

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DTC groove
2 color marks

UP mark

3. Install the silent timing chain to the

crankshaft sprocket, with the color mark Arrow
aligned with the TDC mark on the crankshaft
sprocket. 6. Apply engine oil to the threads of the
tensioner pivot bolt, and then install the
DTC mark tensioner assembly and guide assembly.

Tensioner assembly

Color mark Tensioner

pivot bolt Guide assembly
4. Install the silent timing chain to the camshaft
sprocket, with the arrow aligned with the color
7. Install the tensioner support and tighten the
marks.
bolt slightly.
3 color marks

Arrow

4. As for 473QA engine, when installing the

silent timing chain to the camshaft sprocket,
the arrow shall point to the center of the color
marks.

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and dry it.

13. Evenly apply sealant to the matching
surface between the timing cover and cylinder
block and on the female threads in the bolt
holes.
Notice:
 The sealant shall be 2-3mm wide along the
dash line.
 Apply 3-4mm wide sealant to the cylinder
block upper surface of the timing cover.
 The assembling shall be conducted within 4
minutes of applying the sealant. If not, the
sealant applied in the previous step shall be
cleared away and new sealant shall be applied
again.

Cylinder block
upper surface
contact

8. Apply engine oil to the sliding surface of the

tensioner support.

Tensioner
support
Dash line

14. Install the timing cover.

Timing cover

9. Rotate the tensioner support clockwise to

press tight the tensioner assembly, and then
install the other bolts to fix it.
10. Check whether the crankshaft front oil seal
on the timing cover is damaged. Replace the
crankshaft front oil seal if it is damaged.
11. Clear away the old sealant on the timing
cover matching surface, bolt and bolt hole.
12. Clean the timing cover matching surface 15. Install the oil pan.
16. Install the crankshaft pulley with washer.

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17. Install the cylinder head cover.

18. Install the water pump pulley.
19. Install the idler pulley assembly.
20. Install the mounting bolt for the generator
adjusting arm.

2.5 Remove Cylinder Head Cover

21. Install and adjust the belt.
1. Remove the intake manifold.
2. Remove 4 coils of the ignition device.
2.4 Install Crankshaft Front Oil Seal 3. Remove the cylinder head cover.
The SST assembling tool for front crankshaft
oil seal is required.
1. Use the SST to push in a new oil seal
straightly into the timing cover at the specified
installation height.
2. Measure the distance between the timing
cover surface (matching surface with the
cylinder block) and the oil seal.
Oil seal installation height: 34.5mm～35.2mm

2.6 Remove Cylinder Head

Notice:
 Use a fender cover to prevent damage to
the paint surface.
 To prevent damage, hold the connector by
the hard part and pull out the wire harness
connector carefully.
 To prevent damage to the cylinder head, do
not loosen the bolts until the engine coolant
temperature is lower than 38℃ (100℉).
 Make proper marks on all cables and hoses
to prevent wrong connection. Make sure the

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cables and hoses are not contacting each 9. Remove the engine wire harness connector
other or interfering with other parts. and wire clip from the cylinder head.
 Keep the silent timing chain away from any  4 fuel injector connectors
magnetic field.  Engine coolant temperature sensor
1. Drain the engine coolant. connector
2. Remove the air filter housing.  Camshaft phase sensor connector
3. Remove the water inlet/outlet hose from the  Oil pressure alarm device connector
throttle body.  Knock sensor
10. Remove the bolt for connecting wire
harnesses and wiring harness bracket.
11. Remove the connecting pipe for the water
outlet pipe, and positive crankcase
ventilation (PCV) hose.

Connecting pipe

4. Remove the water inlet/outlet hose from the

radiator.

PCV hose

12. Remove the cylinder head cover.

13. Remove the generator bracket mounting
bolts, and then loosen the generator mounting
bolts.
14. Remove the idler pulley assembly.
15. Rotate the crankshaft pulley until its TDC
mark is aligned with the arrow.
16. Remove the water pump pulley.
17. Remove the crankshaft pulley.
18. Place a 300×300×25mm wooden block
and a jack under the oil pan to support the
5. Remove the hose from the fan heater.
engine.
Notice: do not locate the jack in the middle of
the oil pan to prevent damage to it.
19. Remove the grounding cable and then
remove the front engine bracket.
20. Keep the engine away from the timing
cover and then remove the timing cover.

6. Remove the belt.

7. Remove the intake manifold.
8. Remove the exhaust manifold.

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24. Fix the crankshaft pulley, and fit the sleeve

wrench to the camshaft sprocket bolt.

Socket wrench

Bolt hole
Tensioner
assembly

21. Make a reference mark on the camshaft

Bolt
sprocket and silent timing chain.

Reference mark 25. Rotate the camshaft clockwise to

compress the silent timing chain‘s tensioner
assembly, insert a 6×1.0mm bolt into the bolt
hole on the cylinder block through the
tensioner assembly, and then tighten the bolt.
26. Hold the camshaft with an open-end
wrench, and then remove the camshaft
sprocket.

22. Loosely install the crankshaft pulley.

23. Apply engine oil to the sliding surface of
the silent timing chain tensioner support
through the oil return hole on the cylinder
head.

27. Remove the bolt fixing the silent timing

chain‘s guide assembly.

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28. Remove the cylinder head bolts. To prevent warping or deformation, loosen the bolts in an
alternating pattern, 1/3 round at a time, in the order shown in the figure below, and repeat this
process until all bolts are loosened completely.

Loosen the bolts in the order

shown in this figure

29. Remove the cylinder head.

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2.7 Remove/Install Camshaft Sprocket

Removal Procedure
Notice: keep the silent timing chain away from
any magnetic field.
1. Remove the cylinder head cover.
2. Make a reference mark on the camshaft
sprocket and silent timing chain.

Reference mark

5. Remove the M12×1.25×12 bolt and washer

on the timing cover, hold the crankshaft pulley,
and then attach a sleeve wrench to the
camshaft sprocket bolt.

Socket
wrench

Bolt hole
Tensioner
3. Apply engine oil to the sliding surface of the assembly
silent timing chain tensioner support through
the oil return hole on the cylinder head.

Bolt

6. Rotate the camshaft clockwise to compress

the silent timing chain‘s tensioner assembly,
insert a 6×1.0mm bolt into the bolt hole on the
cylinder block through the tensioner assembly,
and then tighten the bolt.
7. Hold the camshaft with an open-end wrench,
and then remove the camshaft sprocket.

Notice: hang the silent timing chain with an

iron wire.

4. Remove the sight port cover.

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Installation Procedure 3. Apply engine oil to the sliding surface of

Notice: keep the silent timing chain away from the silent timing chain tensioner support
any magnetic field. through the oil return hole on the cylinder
1. Install the timing chain onto the camshaft head.
sprocket after aligning the reference mark, and
then install the camshaft sprocket onto the
camshaft.

Reference mark

2. Hold the camshaft with an open-end wrench,

and then tighten the bolt.
Specified torque: 56N.m

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4. Fix the crankshaft pulley, and fit the sleeve

wrench to the camshaft sprocket bolt.

Socket wrench

5. Hold the camshaft with an open-end

Bolt M6X1.0
Washer wrench, and then loosen the hexagon socket
Bolt M10X1.25X12 screw.

5. Rotate the camshaft clockwise to compress

tight the silent timing chain's tensioner
assembly, and then remove the 6×1.0mm bolt.
6. Install the M12×1.25×12 bolt with a new
washer.
7. Install a new sight port cover.

6. Remove the camshaft phase sensor

signal plate.

8. Install the cylinder head cover.

2.8 Replace Camshaft Phase Sensor

Signal Plate

Removal Procedure
1. Remove the air filter.
2. Remove the bolt for the connecting wire
harnesses and relevant wiring harnesses.
3. Remove the cylinder head cover.
4. Remove the camshaft CID signal cover.

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Installation Procedure 2.9 Check Cylinder Head

1.Install the camshaft phase sensor signal
plate. Warping
1. Remove the cylinder head.
2. Check the camshaft.
3. Check whether the cylinder head has
warping. Measure the length of each side and
the diagonal length of the cylinder head, as
shown in the figures below.

 If the warping is less than 0.08mm,

repairing is not necessary;
 If the warping is somewhere between
0.08mm and 0.2mm, the cylinder head shall
be repaired;
2.Hold the camshaft with an open-end wrench,  The maximum repairable warping is 0.2mm
and then tighten the bolt to 34N.m. on the basis of 120mm height.

Cylinder head height

Standard: 119.9mm～120.1mm

Precision ruler

3.Install the camshaft CID signal cover with a

new O-ring.

Camshaft CID signal cover

4. Install the cylinder head cover.

5. Install the wire harness bracket, wire
harnesses and bolts.
6. Install the air filter.

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2.10 Remove Rocker Arm Assembly

1. Remove the cylinder head cover.
2. Loosen the regulating screws of the rocker arms.

Rocker arm regulating screw

Rocker arm regulating screw

3. Loosen the hollow bolts fixing the rocker arms in an alternating pattern, 2 rounds at a time, in the
order shown in the figure below, and repeat this process until all bolts are loosened completely.

4. Remove the hollow bolts, and then remove the rocker arm assemblies.
Notice: to disassemble a rocker arm, first remove the dowel pin, and then detach it from the rocker
arm shaft at the timing chain side.

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2.11 Disassemble/Reassemble
Rocker Arm and Rocker Arm Shaft

Notice:
Dial bore gauge
 Make marks on each part before
disassembling so that you can reassemble
them properly.
 Disassembling/reassembling a rocker arm
from the rocker arm shaft at the silent timing
chain side.
 Check the rocker arm and rocker arm shaft.
 Any reused rocker arm shall be installed at
its original location.
 Before reassembling, please clean all parts
with solvent, dry them in air, and apply
lubricating oil at all contact points.

Washer Rocker arm

4. Measure the inner diameter of the rocker
arm with a dial bore gauge and check its
out-of-roundness.

Rocker arm-rocker arm shaft clearance:

Rocker arm shaft Standard: 0.019mm～0.058mm
Service limit: 0.08mm
2.12 Check Rocker Arm and Rocker
Arm Shaft

1. Remove the rocker arm assemblies.

2. Measure the shaft diameter at the number
one rocker arm.

3. Reset the dial bore gauge according to the

shaft diameter.

5. Repeat the process above for all rocker

arms and shaft. If the clearance of any rocker
arm is beyond the allowable limit, replace it
together with the rocker arm shaft.

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BYD AUTO BYD NEW F3 Maintenance & Repair Manual

2.13 Remove Camshaft

5. Press a dial gauge‘s push-rod on the
1. Remove the air filter. camshaft end, and reset the dial gauge. Push
2. Remove the camshaft sprocket. the camshaft back and forth and get the axial
3. Remove the rocker arm assemblies. clearance reading. If the axial clearance is
4. Remove the bolt for the connecting wire beyond the service limit, replace the thrust
harnesses and relevant wiring harnesses. cover and check again. If it is still beyond the
5. Disconnect the camshaft phase sensor service limit, please replace the camshaft.
connector, and remove the camshaft phase
sensor. Camshaft axial clearance:
6. Remove the camshaft CID signal cover, and Standard: 0.05mm～0.25mm
pull out the camshaft. Service limit: 0.5mm

Camshaft
Camshaft CID
signal cover

2.14 Check Camshaft 6. Support the camshaft with a V-shaped block,

and check its total runout.
1. Remove the camshaft sprocket.
2. Remove the rocker arm assemblies.  If the total runout is beyond the service limit,
3. Set the rocker arm shaft to the cylinder head, replace the camshaft, and check the oil film
and tighten the bolt to the specified torque. clearance between the camshaft and its bore
hole. If the oil film clearance is still beyond the
Specified torque: 29 N·m service limit, please replace the cylinder head.
Apply engine oil to the threaded section and
flange of the bolt.

4. Push the camshaft backwards toward the

cylinder head until it stops.

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BYD AUTO BYD NEW F3 Maintenance & Repair Manual

Total camshaft runout

Standard: maximum 0.03mm
Repairable limit: 0.04mm

7. Measure the cam lobe lift.

Standard lobe lift (new part):

Intake: 35.38
Exhaust: 35.377

2.15 Remove Valve, Valve Spring and

Valve Oil Seal

Make marks on the valve and springs before

disassembling so that you can reassemble
them to their original locations. A standard: 27.4mm～27.6mm
B standard: 118.1mm～118.7mm
1. Remove the cylinder head cover. C standard: 5.470mm～5.485mm
2. Remove the camshaft. C repairable limit: 5.44mm
3. Loosen the valve lock clamp by knocking Exhaust valve dimensions:
the upper valve spring seat with a A standard: 22.9mm～23.1mm
proper-size sleeve and plastic hammer. B standard: 117.3mm～117.9mm
Remove the valve lock clamp, valve spring, C standard: 5.455mm～5.470mm
valve and valve oil seal.
C repairable limit: 5.42mm
Plastic hammer

Sleeve

2.17 Check Valve Tappet-Valve Guide

Clearance

1. Remove the valve.

2.16 Check Valve 2. Slide out the valve from the guide for some
10mm, shake the valve tappet from the normal
Remove the valve and measure the thrust direction (shaking method) and then
dimensions at the locations shown in the figure measure the inner diameter of the guide with a
below: dial bore gauge, and the outer diameter of the
Intake valve dimensions: tappet with a micrometer. The difference
between the two measured values is the valve
tappet-valve guide clearance.

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modified according to the valve guide diameter

 If the result is beyond the service limit, (available in the market) as shown in the figure
install a new valve and measure the clearance below. Normally you can also complete the
again. same operation using the SST and a hammer.
 If the new clearance is within the service 3. Choose proper substitute valve guides, and
limit, proceed with the reassembling process. freeze them in a refrigerator for about 1 hour.
 Go to step 3 if the new clearance is still 4. Heat up the cylinder head to 150℃ with a
beyond the service limit. electric hot plate or oven. Monitor the
temperature with a thermometer. The
Intake valve tappet-valve guide clearance: temperature of the cylinder head shall be kept
Standard: 0.04mm～0.10mm under 150℃. Overheating may cause loose
Service limit: 0.16mm valve seat.
Exhaust valve tappet-valve guide clearance:
Standard: 0.10mm～0.16mm
Service limit: 0.22mm

5. Use a punch and air hammer to push the

valve guide to the combustion chamber for
some 2mm from the camshaft side. This
process can get off some carbon to facilitate
the removal. Keep the air hammer parallel with
3. Measure the inner diameter of the valve
the valve guide to prevent damage to the
guide and the outer diameter of the valve
punch.
tappet at 3 different locations, using the
6. Go the opposite side and knock off the valve
devices mentioned in step 2, and then subtract
guide towards the camshaft side.
the measured inner diameters by the outer
diameters. The difference between the
maximum inner diameter and the minimum
outer diameter shall fall in the service limit.

Intake valve tappet-valve guide clearance:

Standard: 0.02mm～0.05mm
Service limit: 0.08mm
Exhaust valve tappet-valve guide clearance:
Standard: 0.050mm～0.080mm
Service limit: 0.11mm

2.18 Replace Valve Guide

The following SST tools are required:

 Valve guide remover/installer
 Valve guide reamer
1. Check valve tappet-valve guide clearance.
2. Use the pneumatic valve guide punch

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7. If the valve guide cannot move, drill an 8mm

hole and knock again. Drilling is not
recommended because the cylinder may be
damaged if the valve guide is broken during
drilling.
8. Take out one valve guide from the
refrigerator.
9. Apply thin oil film to the outer surface of the
new valve guide. Install the valve guide from 10. Apply cutting oil to both the reamer and
the cylinder head camshaft side; use the SST valve guide.
to knock in the guide to specified installation 11. Rotate the reamer clockwise along the full
height. If all 16 valve guides shall be replaced, length of the valve guide.
you need to heat up the cylinder head again.

Installation height of valve guide: 15.85mm～

16.35mm

12. Rotate the reamer further until it gets

through the valve guide.
13. Flush the valve guide with detergent and
water to clear away all swarf.
14. Insert and slide a valve in the

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intake/exhaust valve guide to check the Service limit: 1.60mm

clearance, and make sure there is no Exhaust:
resistance. Standard: 1.250mm～1.550mm
Service limit: 2.00mm
2.19 Check Valve Seat
6. Check the valve seat flatness upon
1. Check valve tappet-valve guide clearance. completion of surface processing: apply
Any worn valve guide shall be replaced before Prussian blue compound agent to the valve
reaming the valve seat. surface, insert the valve into its original
2. Repair the valve seat in a cylinder with a location in the cylinder head, and then pull up
valve seat reamer. and press down the valve against the valve
seat for several times.

3. Carefully cut a 45° edge on the seat to 7. The valve seat surface indicated by the blue
ensure that the valve seat is smooth and agent in the figure above shall be aligned with
concentric. the center of the valve seat.
4. Mill the upper angle and lower angle as
shown in the figure below. Check the width of  If the valve seat is high (near to the tappet),
the valve seat and adjust it if necessary. use a 67.5° reamer (for the intake valve) or 60°
reamer (for the exhaust valve) to cut it lower,
and then use a 45° reamer again to restore the
valve seat width.
 If the valve seat is low (near to the valve
edge), use a 30° reamer to heighten it, and
o
then use a 45° reamer again to restore the
Air inlet: 67.5 valve seat width.
o
Air outlet: 60
Notice: only 45° milling cutter shall be used for
the final milling process.

8. Insert the intake valve and exhaust valve

into the cylinder head, and measure the
installation height A of the valve tappet.
5. Use a 45° reamer to reaming the seat again
Installation height of the intake valve tappet:
slightly to eliminate burrs resulting from the
previous process. Standard: 46.1mm～46.5mm
Service limit: 46.8mm
Valve seat width Installation height of the exhaust valve tappet:
Intake: Standard: 46.2mm～46.6mm
Standard: 0.850mm～1.150mm Service limit: 46.9mm

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Marked IN Marked EX

Intake valve oil seal Exhaust valve oil seal

Guide oil seal

remover/ installer

Valve oil seal

9. If the tappet height is beyond the service limit,

replace the valve and check again. If it is beyond
the service limit, the cylinder head shall be 5. Install the valve spring. The valve spring
replaced as the valve seat sinks deeply into the end with more winding shall point to the
cylinder head. cylinder head.
6. Install the upper spring seat.
2.20 Install Valve, Valve Spring and 7. Attach the valve spring compressor to
Valve Oil Seal compress the spring, and then install the valve
lock clamp.
The following SST tools are required:

 Tappet oil seal remover/installer

 Valve spring compressor

1. Apply engine oil to the tappet and install the

valve into the valve guide.
2. Check whether the valve moves up and
down smoothly.
3. Install the lower spring seat onto the
cylinder head.
4. Apply grease on the valve guide, and install
a new valve oil seal with the valve guide oil
sealer remover/installer.

Notice: the exhaust valve oil seal is indicated

by EX, and the intake oil seal is indicated by IN.
They are not interchangeable.

8. Use a plastic hammer to slightly knock each

valve tappet for 2 or 3 times so as to ensure
that the valves and valve lock clamps are

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installed correctly. Only knock the tappet in its

axial direction to prevent bending.
Rocker
Dowel
Plastic arm
pin
hammer

2.21 Install Camshaft 2. Tighten all bolts fixing the rocker arms in an
alternating pattern, 2 rounds at a time, in the
1. Install the camshaft onto the cylinder head, order as shown in the figure below, and repeat
and install the camshaft CID signal cover with this process until all bolts are tightened
a new O-ring. properly.
Specified torque: 29 N·m
Camshaft
O-ring Apply engine oil to the threaded section and
Camshaft CID
signal cover
flange of the bolts.

2. Install the camshaft phase sensor with a 3. Adjust the valve clearance.
new O-ring, and then connect the camshaft 4. Install the cylinder head cover.
phase sensor connector.
3. Install the wire harness bracket and its 2.23 Install Cylinder Head
mounting bolts.
4. Install the camshaft sprocket. Install the cylinder head in the reverse
5. Install the rocker arm assemblies. sequence of removal.
6. Install the air filter.
1. Clean the junction surface between the
2.22 Install Rocker Arm Assembly cylinder head and cylinder block.
2. Install the cylinder head gasket and dowel
1. Install the rocker arm assemblies with a pin onto the cylinder block. Only use a new
dowel pin. cylinder head gasket.
Notice: reassembling the rocker arms to the
rocker arm shaft at the silent timing chain side.

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Cylinder head gasket

Dowel pin Mounting bolt

3. Make sure the crankshaft keyslot is facing

upwards. 9. Install the timing chain onto the camshaft
4. Install the cylinder head onto the cylinder sprocket after aligning the reference mark, and
block. then install the camshaft sprocket onto the
5. Apply engine oil to the threaded section of camshaft.
all cylinder head bolts and the bottom side of
all bolt heads. Reference mark
6. Tighten all cylinder head bolts to 29N.m in
the order shown in the figure below. Use a flat
beam torque wrench. If you use a preset
torque-wrench, do tighten the bolts slowly and
within specified torque. If any bolt makes noise
during tightening, loosen it and repeat the
tightening process.

10. Hold the camshaft with an open-end

wrench, and then tighten the bolt.
Specified torque: 56 N·m

7. Tighten all cylinder head bolts for another

130°.
8. Install the mounting bolt of silent timing
chain‘s guide assembly.

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11. Loosely install the crankshaft pulley. block and on the female threads in the bolt
12. Apply engine oil to the sliding surface of holes.
the silent timing chain tensioner support Notice:
through the oil return hole on the cylinder  The sealant shall be 2-3mm wide along the
head. dash line.
 Apply 3-4mm wide sealant to the cylinder
block upper surface of the timing cover.

Cylinder
block upper
surface
contact

13. Fix the crankshaft pulley, and fit the sleeve Dash line
wrench to the camshaft sprocket bolt.
19. Evenly apply sealant to the matching
surface between the timing cover and oil pan
Socket and on the female threads in the bolt holes.
wrench Notice:
 The sealant shall be 2-3mm wide along the
dash line.
Bolt  Apply 5.0mm wide sealant to the shadow
area as shown in the figure below.
 The assembling shall be conducted within 4
minutes of applying the sealant. If not, the
sealant applied in the previous step shall be
cleared away and new sealant shall be applied
again.

Dash line
14. Rotate the camshaft clockwise to
compress tight the silent timing chain's
tensioner assembly, and then remove the
6×1.0mm bolt.
15. Check whether the crankshaft front oil seal
is damaged. If any damage, replace it with a Shadow area
new one.
16. Clear away the old sealant on the timing
cover matching surface, bolt and bolt hole. 20. Align the timing cover edge against the oil
17. Clean and dry the timing cover matching pan cover, and then install the timing cover
surface. onto the cylinder block.
18. Evenly apply sealant to the matching
surface between the timing cover and cylinder Notice: when installing the timing cover, do not

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slide the bottom of the oil pan mounting

surface; otherwise the sealant may be
scratched and lead to deteriorated sealing
performance. O-ring
Water
outlet
part
Timing cover

PCV hose

29. Install the positive crankcase ventilation

(PCV) hose.
30. Install the wire harness bracket and bolts.
31. Install the exhaust manifold.
32. Install the intake manifold.
33. Install the heater hose.

Cylinder block

Timing cover

34. Install the water inlet/outlet hose to the

radiator.

Upper radiator
hose

Oil pan

21. Install wire harness bracket.

22. Install the crankshaft pulley.
Lower radiator hose
23. Install the cylinder head cover.
24. Install the water pump pulley.
25. Install the idler pulley assembly. 35. Install the water inlet/outlet hose to the
26. Install the generator adjusting arm and its throttle body.
mounting bolts.
27. Install the belt and tighten it through
adjusting the generator regulating screw.
28. Install the water outlet pipe using a new
o-ring for water outlet.

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36. Install the air filter.

37. Upon completion of assembling, check
whether all pipes, hoses and connectors are
connected properly.
38. Check for fuel leakage. Turn the ignition
switch to ON without running the starter, run 6. Check the cylinder head cover gasket.
the fuel pump for 2 seconds and increase fuel Replace the gasket if it is damaged or aged.
line pressure. Repeat the process for 2 or 3 7. Tighten bolts by 2 or 3 steps. The tightening
times and check whether there is leakage in torque is 12N.m in the order shown in the
the fuel line. figure below.
39. Refill engine coolant into the radiator, and
meanwhile discharge the air in the cooling
system with the heater valve remaining open.
40. Check idle speed.
41. Check the ignition timing.

2.24 Install Cylinder Head Cover

1. Thoroughly clean the cylinder head cover

gasket and grooves.
2. Install the cylinder head cover gasket into
8. Install 4 ignition coils.
the groove.
9. Install the intake manifold cover.
3. Make sure the matching surface is dry and
10. Check whether all pipes, hoses and
clean.
connectors are connected properly.
4. Apply 3.0mm wide sealant within the timing
11. Upon completion, wait for 30 minutes
cover matching surface.
before filling in engine oil.
Notice: The assembling shall be conducted
within 4 minutes of applying the sealant. If not,
the sealant applied in the previous step shall
be cleared away and new sealant shall be
applied again.
5. After installing the cylinder head cover on
the cylinder head, slightly slide the cylinder
head cover back and forth so that the gasket
can be fit in place.

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Section 3 Cylinder Block

Component Layout (a)

Main bearing cap axle

Main bearing cap

Crankshaft

Flywheel bolt

Flywheel
Main bearing bush
Thrust plate
Crankshaft oil seal

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Component Layout (b)

Piston ring

Piston

Connecting rod body

Piston pin

Cylinder block

Connecting rod bearing shell

Connecting rod bolts

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3.1 Check Connecting allowance range, replace the thrust plate and
Rod-Crankshaft Axial Clearance check the clearance again. If it is still out of the
allowance range, replace the crankshaft.
1. Remove the oil pump.
2. Measure the axial clearance between the 3.2 Replace Crankshaft Main Bearing
connecting rod and crankshaft with a feeler Bush
gauge.
Check main bearing bush clearance
Connecting rod axial clearance: 1. When checking the oil film between the
Standard range: 0.15mm ～0.30mm main bearing bush and journal, you shall
Service limit: 0.40mm remove the main bearing cap and bush.
2. Clean the main journal and bush with a
piece of clean service cloth.
3. Place plastic clearance gauges between
main journals.
4. Reinstall the bearing bush and crankshaft
main bearing cap, and tighten the bolt to
25N.m +40°.

Notice: do not rotate the crankshaft during the

check procedure.

5. Remove the crankshaft main bearing cap

and bush again, and measure the plastic
clearance gauges at the widest location.

3. If the axial clearance is beyond the Main bearing bush-journal oil film
allowance range, install a new connecting rod clearance:
and check the clearance again. If it is still out Standard range: 0.018mm～0.036mm
of the allowance range, replace the crankshaft. Service limit: 0.050mm
4. Push the crankshaft as far away from the
dial gauge as possible, reset the dial gauge
while pressing it against the crankshaft end,
and then pull back the crankshaft to press
against the dial gauge tightly: the reading of
the gauge shall be in the service limit.
Crankshaft axial clearance:

Standard range: 0.10mm ～0.35mm

Service limit: 0.45mm

6. If the clearance measured with the plastic

clearance gauge is too large or small, remove
the crankshaft and the upper bearing bush.
Install a new complete bearing bush with the
same grouping code, and check the clearance
again. It is prohibited to adjust the clearance
by filing, filling or grinding the bearing bush or
cover.

5. If the axial clearance is beyond the

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7. If the clearance indicated by the gauges is still beyond range, try to use a larger or smaller
bearing bush (the color above or below the current cell in the table below) correspondingly and
check again. If using of the appropriate bush still cannot get a proper clearance, replace the
crankshaft and repeat the check procedure.

Choose main bearing bush

Location of crankshaft hole grouping code

1.Grouping indicator representing 5 main journals are embossed on the end of the crankshaft.
Take notice of the crankshaft hole's grouping code. If the code is coved by dirty or dust, do not use
a wire brush or scraper. Only clean it with solvent or detergent.

st th
1 gear journal 5 gear journal
(pulley side) (gearbox side)

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Location of Main Journal Grouping Code

2. Main journal grouping code is embossed on the crankshaft.

st nd rd th th
1 gear journal 2 gear journal 3 gear journal 4 gear journal 5 gear journal

th
st 5 gear journal
1 gear journal

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3. Choose a proper bearing bush from the table below by reference to the grouping code of the
crankshaft hole and crankshaft journal.

Notice: the grouping code is located on the edge of the main bearing bush.

Assembling Relationship between Main Shaft

Hole, Bush and Diameter

Main shaft hole

diameter increase
Shaft hole

Shaft Bush
diameter
increase
Shaft diameter

Grouping
code
Bush thickness
increase

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3.3 Replace Connecting Rod Bearing get a proper clearance, replace the
Shell crankshaft and repeat the check procedure.

Check connecting rod bearing clearance Choose connecting rod bearing shell

1. Check the oil film clearance between the 1. Check each connecting rod for crack and
connecting rod bearing and journal. thermal damage.
Remove the main bearing cap.
2. Remove the connecting rod cover and Location of connecting rod big-end hole
connecting rod bearing shell. code
3. Clean the crankshaft connecting rod journal 2. Depending on the size of the connecting rod
and bearing shell with a piece of clean big-end hole, the tolerance for each
service cloth. connecting rod is 0 - 0.015mm, with an
4. Place a plastic clearance gauge on the increment of 0.008mm. The code is
connecting rod journal. embossed in numbers or bar codes. You
5. Reinstall the bearing shell and connecting can find a variety combination of numbers
rod cover and tighten the bolts. and bar codes on the engine (half of them
Tightening torque: 9.8N.m+90° printed on the bearing cap and another half
Notice: do not rotate the crankshaft during on the connecting rod).
the check procedure. If the code is coved by dirty or dust, do not
6. Remove the connecting rod cover and use a wire brush or scraper. Only clean it
bearing shell, and measure the plastic with solvent or detergent.
clearance gauge at the widest location. Standard hole size: 43.0mm
Connecting rod bearing shell-journal oil film
clearance:
Grouping code
Standard range: 0.020mm ～0.038mm
Service limit: 0.050mm

7. If the clearance measured with the plastic

clearance gauge is too large or small,
remove the upper bearing shell. Install a
new complete bearing shell with the same
grouping color code, and check the
clearance again. It is prohibited to adjust
the clearance by filing, filling or grinding the
bearing or cover.
8. If the clearance indicated by the gauges is
still beyond range, try to use a larger or
smaller bearing bush (the color above or
below the current cell in the table)
correspondingly and check again. If using
of the appropriate bearing shell still cannot

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Location of connecting rod journal grouping code

3. Connecting rod journal grouping code is embossed on the crankshaft.

Location of connecting rod journal grouping code

st nd rd th
1 gear journal 2 gear journal 3 gear journal 4 gear journal

st th
1 gear connecting 4 gear connecting
rod journal rod journal

4. Depending on the big-end hole code and connecting rod journal code, choose an appropriate
substitute bearing shell from the table below.
Notice: the grouping code is located on the edge of the bearing shell.

Assembling Relationship between Bore, Connecting Rod

Bearing Shell and Connecting Rod Shaft Diameter

Bore increase

Shaft hole

Shaft
Bush
diameter
increase
Shaft diameter

Grouping
code
Bush thickness
increase

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3.4 Remove Oil Pan

1. Completely drain engine oil in the engine.

2. Remove the dipstick tube.

6. Remove the oil pan and place it carefully

with the joint surface with the cylinder block
facing upwards.

Oil dipstick tube

3. Remove the clutch back plate and then

remove 2 bolts (A) fixing the gearbox.

Clutch back plate

4. Remove the bolts fixing the oil pan.

5. Attached a slotted screwdriver as shown in
the figure, and then detach the oil pan from
the cylinder block.

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3.5 Remove Crankshaft and Piston

1. Remove the engine.

2. Remove the gearbox.
3. Remove the silent timing chain.
4. Remove the cylinder head.
5. Remove the oil collector and then remove the oil pump.

Oil collector

Oil pump

6. Remove the main bearing cap bolts. To prevent warping, loosen the bolts in alternating pattern,
1/3 round at a time, in the order shown in the figure below. Repeat the process until all bolts are
loosened.

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7. Remove the main bearing cap.

8. Remove the connecting rod cover/bearing Wooden handle
shell and place them carefully in good
order. Piston
9. Take out the crankshaft from the cylinder
block with care, as impact with the cylinder
block may cause damage, especially to the
journal.

13. Install the main bearing cap and bush onto

the cylinder block again in proper order.
14. Remove the piston rings and connecting
rod assemblies, and then install the
connecting rod bodies and covers again.
15. To prevent wrong installation, mark each
piston/connecting rod assembly with its
cylinder number.

10. Remove the upper shells from the Notice: the existing mark on a connecting rod
connecting rod, and place them together represents its connecting rod hole size, not its
with their corresponding bearing shell. position.
11. Check the top inside of the cylinder liner for
metal protruding or accumulated carbon
and, if any, remove them with a reamer
following the manufacturer‘s instructions. If
the protruding matter is not removed, the
piston may be damaged when you pull it
out.

12. Push out the piston with the hammer‘s

wooden handle. Hold the piston with
another hand during this process.

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3.6 Check Crankshaft

Out-of-roundness and conicity

1. Remove the crankshaft from the cylinder block.

2. Clean the crankshaft oil way with a tuber cleaner or an appropriate brush.
3. Clean the keyslot and threads.
4. Measure the roundness at 2 positions where each connecting rod journal and main journal
center are perpendicular to each other, and the measured difference of each journal cannot
exceed the service limit.
Journal out-of-roundness:
Standard: maximum 0.005mm
Service limit: 0.010mm

Connecting rod journal

Main journal

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5. Measure the conicity at the edge of each

connecting rod and main journal, and the Piston diameter
measured difference of each journal cannot
exceed the service limit.
Journal conicity:
Standard range: Maximum 0.005mm
Service limit: 0.010mm

Verticality Measuring
6. Place the cylinder block on the marking-off point
table.
7. Clean the bearing bush and install it on 1#
and 5# journal of the cylinder block.
8. Lower the crankshaft and place it into the
cylinder block.
9. Measure the runout on all main journals.
Rotate the crankshaft for 2 rounds and then
measure the runout. The difference
between all measured values shall be
within the service limit.
Crankshaft total runout:
Standard range: Maximum 0.03mm
Service limit: 0.04mm

Oversized piston diameter:

0.25: 73.205mm～73.225mm

3.7 Check Cylinder Body and Piston

1. Remove the crankshaft and piston.

2. Check whether the piston is deformed or
cracked.
3. Measure the piston diameter at the bottom
of the piston skirt, at the location as shown
in the figure below.
Piston diameter:
Standard range: 72.955mm～72.975mm
Service limit: 72.945mm

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4. Measure the wear and conicity of each

cylinder in X and Y direction, at 3 locations
with different height, as shown in the figure
below. If the measured value of any cylinder
is beyond the service limit of oversized
cylinder bore, replace the cylinder block. If
any cylinder block requires reboring, go to
step 7.
Cylinder bore:
Standard range: 73.00mm ～73.019mm
Service limit: 73.07mm

Oversized dimension:
0.25: 73.25mm～73.269mm
Reboring limit: maximum 0.25mm
Bore conicity:
Limit: 0.05mm (the difference between the
first and third measured value)

First measurement
Second measurement
Precision ruler
Third measurement

7. Measure the cylinder bore and piston

diameter and calculate their difference. If
the difference is near or over the service
limit, check for excessive wear on the piston
and cylinder.
Piston-cylinder clearance:
Standard range: 0.010mm～0.040mm
Service limit: 0.05mm

Piston-cylinder clearance

5. Cylinder with scratched damage shall be

honed.
6. Check the top of the cylinder block for
warping. Measure the edge and diagonal
line of the cylinder block as shown in the
figure below.
Cylinder block warping:
Standard range: Maximum 0.07mm
Service limit: 0.10mm Cylinder honing process
Honing is applicable only to the cylinder bores
with scratch damage.
1. Measure cylinder bore
After honing a cylinder block, measure the
cylinder bore again before reusing it.
2. Using honing oil and honing stone (400 grit)
to hone the cylinder bore in a 60° cross

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hatch pattern. Only honing stones with 400 2. Reset the dial bore gauge according to the
or finer grit, such as those from Sunnen, piston pin diameter.
Ammco or other equivalents, shall be used.
Do not use any worn or broken honing
stone.

Cross hatch

3. Clear away all metal particles in the engine

body after honing. Wash the cylinder bore
with hot water and soap. Dry it and apply
engine oil immediately to prevent rusting.
Do not use any solvent in this step, as it
may carry metal particles around the
cylinder wall.
4. If the scratch still exists when honing to
service limit, the cylinder block shall be Replace piston, piston pin and connecting
rebored again. But very slight vertical rod
scratch is acceptable, provides that its 3. Measure the piston pin-connecting rod small
length is less than the cylinder bore and end bore clearance.
your finger is not retarded when moving Piston pin-connecting rod small end bore
across its deepest part. clearance:
Standard value: -0.037mm～-0.015mm
3.8 Replace Piston, Piston Pin and
Connecting Rod

Disassembling
1. Remove the piston from the cylinder block.
2. Remove the piston pin with a SST.

Inspection
1. Measure the diameter of the piston pin.
Piston pin diameter:
Standard value: 17.996mm～18.000mm

4. Check the difference between the piston pin

diameter and piston bore diameter.
Piston pin to piston bore clearance
Standard value: 0.005mm～0.015mm

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Replace Piston ring

1. Remove the piston from the cylinder block.

2. Remove the old piston ring with a piston ring
expander.

Piston ring

Piston ring tensioner

3. Clean all the piston ring grooves using a

split ring without cutting edge, or a ring
groove cleaner with a cutting edge
matching with the piston groove.
Groove width of the first air-tight ring:
1.0mm.
Reassembling Groove width of the second air-tight ring:
1. Install the piston and connecting rod, with 1.2mm.
the orientation arrow and connecting rod Groove width of the oil ring: 2.8mm.
mark pointing to the same direction. The cutting edge may be filed if necessary.
Do not use a wire brush to clean the ring
groove, and prevent the cleaning tool from
cutting the ring groove deeper.
Notice: if you need to detach the piston
from the connecting rod, do not install the
new piston ring at this time.
4. Push a new piston ring into the cylinder bore
with the piston, until its distance to the
cylinder bottom is 15mm～20mm.

Orientation arrow

2. Press the piston pin into the piston with a

SST.

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Piston ring Clearance

5. Measure the piston ring end clearance with

a feeler gauge.
Standard
Service limit
clearance
First
0.20mm ～
air-tight 0.79mm Piston ring diameter Air-tight ring 1
ring 0.35mm (standard)
Second A: 2.45 mm
0.35mm ～ B: 1.0 mm
air-tight 0.75mm
ring 0.50mm Air-tight ring 2 (standard)
oil control 0.20 ～ A: 3.0 mm
0.80mm B: 1.2 mm
ring 0.70mm

If the measured value is over the biggest end 7. Check whether the piston rings rotate
clearance, replace the piston ring and smoothly in the groove.
measure again.

If the measured value is still over the biggest

end clearance, replace the cylinder block.

6. Install the first air-tight ring (A) and second

air-tight ring (B) as shown in the figure
below. When installing the piston ring, make
sure the side (C) with manufacturer mark is
facing upwards.

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8. Set the end clearance of the piston rings as shown in the figure below:

Lower lid of oil scraper ring gap

nd
2 air-tight ring gap

Assembling
position arrow
Bush ring gap
facing engine
free end

st
1 air-tight ring gap Upper lid of oil
scraper ring gap

9. Measure the clearance between ring grooves after installing a set of new piston rings.
Air-tight ring 1 clearance:
Standard value: 0.075mm～0.100mm
Service limit: 0.17mm
Air-tight ring 2 clearance:
Standard value: 0.030mm～0.055mm
Service limit: 0.13mm

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Install piston 8. Apply engine oil to the bolt threads. Install

If the crankshafts are installed: the connecting rod cover with a bearing
1. Set the crankshaft in each cylinder to BDC shell. Tighten the bolt to 9.8 N·m+90°.
in turn. If the crankshafts are not installed:
2. Remove the connecting rod cover, install the 1. Remove the connecting rod cover, install the
piston ring compressor and then make sure piston ring and make sure the bearing shell
the bearing bush is fixed in place firmly. is fixed in place.
3. Place the orientation mark towards the 2. Place the orientation mark towards the
engine silent timing chain (front end). engine timing chain (front end).
3. Place the piston into the cylinder, and knock
it with the hammer's wooden handle (A) or
similar wooden objects. Keep downward
pressure on the piston ring compressor (B)
before installation in the cylinder bore to
prevent the piston ring opening.
4. Set all pistons to TDC.

3.9 Check Connecting Rod Bolt

1. Measure the connecting rod bolt diameter at

Orientation arrow
location A & B with a micrometer, as shown
in the figure below.

4. Place the piston into the cylinder, and knock

it with the hammer's wooden handle (A) or
similar wooden objects. Keep downward
pressure on the piston ring compressor (B)
before installation in the cylinder bore to 2. Calculate the difference of the diameter at A
prevent the piston ring opening. & B.
Diameter difference = diameter A – diameter
B
Diameter difference allowance: 0～0.05mm
3. If the difference is beyond the allowance,
replace the connecting rod bolt.
3.10 Install Crankshaft
1. Check the clearance of the connecting rod
bearing with a plastic clearance gauge.
2. Check the clearance of the main bearing
with a plastic clearance gauge.
3. Check the connecting rod bolt.
4. Install bearing bush and shells on the
cylinder block and connecting rod.
5. After the compressor rebounds, check 5. Apply engine oil to the main bearing bush
whether the connecting rod-crankshaft and connecting rod bearing shell.
journal alignment is correct before pushing 6. Hold the crankshaft to keep the number 2
the piston in place. and 3 journal pointing straightly upwards,
6. Check the clearance of the connecting rod and then place the crankshaft into the
bearing shell with a plastic clearance cylinder block.
gauge. 7. Install a thrust plate at the number 4 journal
7. Check the connecting rod bolts. of the cylinder block.

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15. Install the integrated main bearing cap,

Indicator A and keep the orientation mark in proper
direction.
16. Clear off the old sealant on the matching
surface of the main bearing cap rear end
(5# bearing cap).
17. Clean and dry out the matching surface of
Indicator B the main bearing cap rear end (5# bearing
cap).
18. Apply 3mm wide sealant along the dash
line in the figure below.
Notice: The assembling shall be conducted
8. Apply engine oil to the thread and flange of within 4 minutes of applying the sealant. If not,
the connecting rod bolt. the sealant applied in the previous step shall
9. Fit the connecting rod journal to number 1 be cleared away and new sealant shall be
and 4 connecting rod. Align the marks on applied again.
the connecting rod and cover, and then
tighten the connecting rod cover and bolt
manually.
10. Rotate the crankshaft clockwise, and fix
the journal in number 2 and 3 connecting
rods. Align the marks on the connecting rod
and cover, and then tighten the connecting
rod cover and bolt manually.
11. Tighten the connecting rod bolt to 9.8N.m. Sealant application path
12. Tighten the connecting rod bolt for
additional 90°. 19. Place the main bearing cap on the cylinder
13. Install the crankshaft rear oil seal assembly. block.
Before installation to the crankshaft, apply 20. Apply engine oil to the threaded section
lubricating grease to the oil seal inner and flange of the main bearing cap bolts.
groove. 21. Tighten the bolts to 25N.m in the order
14. Measure the distance between the shown in the figure below.
crankshaft and oil seal.
Oil seal installation height: 7mm～8mm.

22. Tighten the bolts for additional 40°.

23. Clear off the needless sealant on the
cylinder block.
24. Install the dowel pin (A) and a new O-ring
(B) to the oil pump (C), align the inner rotor
with the crankshaft, and then install the oil

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pump. matching surface between the oil pan and

cylinder block and in the bolt holes.
Notice: apply 2mm～3mm wide sealant
along the dash line in the figure below.
Apply 5.0mm wide sealant to the shadow
area B shown in the figure below.
Notice: The assembling shall be conducted
within 4 minutes of applying the sealant. If
not, the sealant applied in the previous step
shall be cleared away and new sealant shall
be applied again.

25. Install the oil collector (D) with a new

washer (E).
26. Install the cylinder head.
27. Install the silent timing chain.
28. Install the gearbox.
29. Install the engine.
Notice: after replacing the crankshaft or
connecting rod bearing shell, keep the engine
running idle until it reaches the normal working
temperature, and then let it run for additional
15 minutes.
5. Install the oil pan A with a dowel pin B and a
3.11 Install Oil Pan new O-ring C.

1. Clear off the old sealant on the matching

surface of the oil pan, the bolt and bolt
holes.
2. Clean and dry out the matching surface
between the oil pan and cylinder block.
3. Install a new crescent sealing ring on the oil
pan.

Crescent sealing ring

6. Tighten the bolts by 2 or 3 steps.

Tightening torque: (see indication below)
Indicated by A: 25N·m
Indicated by B: 12N·m

4. Evenly apply special-purpose sealant to the

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7. Install the clutch back plate, and then tighten the 2 bolts fixing the gearbox. The tightening
torque for the bolts is shown below:

Clutch back plate

8. Install the dipstick tube (A) with a new O-ring (B). The tightening torque is shown in the figure.

9. After completing the installation, wait for at least 30 min before filling engine oil into the engine.

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Part 2 Lubricating System

Component Layout

Gasket Oil drain plug

Oil pan
Oil filter

Oil filter thread

pipe
O-ring
Crescent sealing ring Oil collector

Oil collector
Oil dipstick pipe gasket

Breather cover plate Oil pressure warner Dowel pin

O-ring Oil pump

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Section1 Check Oil Pressure

Warner
1. Disconnect the oil pressure warner
connector (A) from the oil pressure waning
device (B).

2. Start the engine and check the oil pressure

gauge. If the reading indicates no oil
pressure, shut down the engine
2. Check the conductivity between the positive immediately. Solve this trouble before going
terminal (C) and engine (grounded). The to the next step.
circuit shall be turned on when the engine 3. When the engine reaches the running
stops running and be turned off when the temperature (cooling fan started at least
engine is running. twice), the oil pressure shall be:
3. If the pressure warning device isn‘t work Oil temperature: 80°C
normally, check the oil level; if the oil level is Oil pressure:
normal, check the oil pressure; if the oil Idle running: minimum 30kPa
pressure is normal, replace the oil pressure At 3000rpm/min: minimum 300kPa
warner. 4. If the oil pressure is beyond the specified
range, check the following items:
Section2 Inspect Oil Pressure  Check whether the oil collector is
blocked;
If oil pressure warning light shall remain on  Check the oil pump.
when the engine is running, check the oil level;
if the oil level is normal: Section3 Change Engine Oil
1. Remove the oil pressure warner, and
connect an oil pressure gauge to its 1. Pre-warm the engine.
mounting hole with a special-purpose 2. Loosen the oil drain plug (A) to completely
adapter. drain the oil in the engine.

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39 N.m Do not tighten it excessively.

3. Install the oil drain plug again with a new

washer (B). 5. After installation, fill engine oil to the
4. Fill new engine oil in the engine. specified oil level, start the engine and let it
When changing oil: 2.9L idle for 3 minutes, and then check the oil
When changing oil (including the oil filter): drain plug and oil filter for leakage.
3.3L
After engine overhaul: 4.0L
5. Keep the engine running for over 3 minutes
Section5 Replace Oil Filter
and check for oil leakage. Thread Pipe

Section4 Replace Engine Oil 1. Remove the oil filter.

2. Install two 20×1.5mm nuts (A) on a new oil
Filter filter thread pipe. Hold the nut with a wrench,
and then tighten one nut.
1. Remove the oil filter with the oil filter wrench
SST.
2. Check the thread (A) and rubber sealing (B)
of a new oil filter, clean the oil pan base,
and then apply a thin oil film on the oil filter
rubber seal ring. Only use an oil filter with
internal bypass system.

3. Tighten the oil filter thread pipe on the oil

pan to 50N.m, and then remove the nuts on
the thread pipe.

3. Install the oil filter manually.

4. Fit the rubber seal ring in place, and lock the
oil filter clockwise with the SST.
Tightening: rotate 3/4 to 1 round clockwise.
Tightening torque: 12N.m

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Section6 Overhaul Oil Pump

Exploded view

Pump housing O-ring

Dowel pin

Oil pump cover

Outer rotor
Inner rotor

Pressure relief valve

The valve shall slide freely in the housing.
Replace the valve if any scratch.
Spring

Sealing bolt
20N.m

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Removal Procedure
1. Remove the silent timing chain.
2. Remove the oil collector (A) and then the oil
pump (B).

4. Check the radial clearance between the

outer rotor (A) and pump housing (B). If the
radial clearance is beyond the service limit,
replace the oil pump.
Pump housing-outer rotor radial clearance:
Standard: 0.06～0.136mm
Service limit: 0.18mm
Inspection
1. Remove the pump cover.
2. Check the radial clearance between the
inner rotor (A) and outer rotor (B). If the
radial clearance is beyond the service limit,
replace the oil pump.
Inner rotor-outer rotor radial clearance:
Standard: 0.075～0.15mm
Service limit: 0.18mm

5. Check the inner rotor, outer rotor and pump

housing for scratch and other damages,
and make replacement if necessary.
6. Install the oil pump cover.
Installation Procedure
1. Install the dowel pin (A) and a new O-ring to
the oil pump (C). Align the inner rotor with
the crankshaft, and install the oil pump.
2. Install the oil collector (D) with a new washer
3. Check the axial clearance between the rotor (E).
(A) and pump housing (B). If the axial 3. Install the silent timing chain.
clearance is beyond the service limit,
replace the oil pump.

Pump housing-rotor axial clearance:

Standard: 0.028～0.065mm
Service limit: 0.085mm

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Section8 Replace Oil Pressure

Warner
1. Disconnect the oil pressure warner
connector (A), and remove the oil pressure
Section7 Install Breather Cover warner (B).
Plate
1. Clean and dry out the matching surface,
bolts and bolt holes of the breather cover
plate.
2. Apply 2-3mm wide sealant along the dash
line (A).
Notice: The assembling shall be conducted
within 4 minutes of applying the sealant. If not,
the sealant applied in the previous step shall
be cleared away and new sealant shall be
applied again.

2. Apply sealant to the threaded section of the

oil pressure warner, and then install it with a
tightening torque of 15N.m.

Part 3 Air Manifold and

Exhaust System
Section1 Remove/Install Intake
Manifold
Removal Procedure
1. Remove the intake manifold cover.
2. Remove the air filter.
3. Install the breather cover plate. 3. Remove the breather pipe (A), power brake
vacuum hose (B) and positive crankcase
ventilation (PCV) hose (C).

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leaving the heater valve open to discharge

the air in the cooling system.

Section2 Remove/Install
Exhaust Manifold
1. Remove the insulation cover and bracket for
the exhaust manifold, and then remove the
exhaust manifold.
2. Install the exhaust manifold and then tighten
the bolts and nuts by 2-3 steps in
alternating pattern, starting from the
innermost bolt.
3. Install the other parts in the reverse
4. Remove the throttle cable. sequence of removal.
5. Remove the wire harness bracket and bolt.
6. Remove the canister control valve
connecting hose.
7. To replace the intake manifold, remove the
throttle body.
8. After the engine coolant is drained
completely, remove the water inlet/outlet
hose from the throttle body.
9. Remove the engine wire harness connector
and wire clip on the intake manifold.
10. Remove the intake manifold bracket and
then the intake manifold.

Installation Procedure
1. Install the intake manifold with a new
sealing washer, and then tighten the bolts
and nuts by 2-3 steps in alternating pattern,
starting from the innermost bolt, with a
tightening torque of 25N.m.
2. Install the intake manifold bracket.
3. If the water inlet/outlet hose have been
removed on the throttle body, install them
properly.
4. If the throttle body is removed, install it with
a new sealing washer for throttle body.
5. Install the canister control valve connecting
hose.
6. Install the wire harness bracket and bolt.
7. Install the throttle cable and adjust it.
8. Install the breather pipe, power brake
vacuum hose and positive crankcase
ventilation (PCV) hose.
9. Install the air filter.
10. Install the intake manifold cover.
11. Upon completion of assembling, check
whether all pipes, hoses and connectors
are connected properly.
12. If the engine coolant is drained completely,
fill the coolant into the radiator again while

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Part 4 Engine Cooling System

Component Layout

Coolant temperature sensor

Water pump

Thermostat

Radiator fan
Radiator

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Section1 Check Thermostat

Replace the thermostat if it opens under the
room temperature.
Test the thermostat when it is in closed
position.
1. Hang the thermostat (A) in a container filled
with water, and keep the thermometer (B)
away from the bottom and wall of the
container.

3. Rotate the water pump pulley anti-clockwise

to check whether the pump can rotate
freely.
4. Check whether seal leakage occurs. It is
normal that there is a little water seepage at
the drain hole (A).

2. Fill in water, and measure the water

temperature for thermostat opening and Section3 Replace Water Pump
thermostat full opening.
3. Measure the lift with the thermostat full 1. Remove the belt.
opening. 2. Drain the engine coolant.
Standard thermostat: 3. Remove the water pump pulley.
Lift: over 8.0mm 4. Remove the 5 bolts fixing the water pump
Opening temperature: 76°C～80°C and then remove the water pump.
Full opening temperature: 90°C 5. Check and clean the O-ring groove and the
matching surface with the cylinder body.
6. Install the water pump with a new O-ring in
Section2 Check Water Pump the reverse sequence of removal.
7. Clear off the overflowing engine coolant.
1. Remove the belt. 8. Refill engine coolant into the radiator, and
2. Remove the water pump pulley. meanwhile discharge the air in the cooling
system with the heater valve remaining
open.

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Section4 Replace Thermostat

Section5 Replace Water
Removal Procedure
1. Remove the thermostat cover (A) and then Temperature Sensor
remove the thermostat (B).
1. Drain the engine coolant.
2. Disconnect the water temperature sensor
connector and then remove the sensor.
3. Apply the sealant on the thread on the water
temperature sensor and then install the
sensor.
4. Clear off the overflowing engine coolant.
5. Refill engine coolant into the radiator, and
meanwhile discharge the air in the cooling
system with the heater valve remaining
open.

Installation Procedure
2. Clear off the old sealant on the matching
surface of the thermostat cover, the bolts
and bolt holes.
3. Apply 2-3mm wide sealant along the dash
line (A).

4. Install the thermostat sealing ring (A) on the

thermostat (B), and then install the
thermostat with the pin (C) facing upwards.

5. Install the thermostat cover (D).

Notice: after assembling, wait for at least 30
minutes and then fill coolant into the engine.

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Part 5 Fuel and Exhaust System

Arrange vacuum hose

Carbon canister interface

assembly
Carbon
canister control
valve

Carbon canister
control valve
connecting hose

PGM-FI system
(1) Install the high pressure pipe and fuel supply pipe
Programmed fuel injection (PGM-FI) system is a multi-point sequential fuel injection system.
Crankshaft position (CKP) sensor
CKP sensor detects the engine speed and determines the ignition timing and fuel injection timing
of each cylinder.
O-ring
Magnet

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Camshaft phase (CMP) sensor Knock sensor

Knock control system can reduce the knock to
CMP sensor detects the position of the minimum by regulating the ignition timing.
number 1 cylinder, which is used as reference
for sequential fuel injection.

O-ring
Magnet

Piezoelectric ceramics
element

Engine coolant temperature (ECT) sensor

ECT sensor is a resistor whose resistance
varies significantly with temperature Throttle position (TP) sensor
(thermistor). Its resistance reduces with the TP sensor is a potentiometer connecting to the
increase of the coolant temperature. throttle shaft. The sensor sends variable
voltage signal to ECM/PCM according to the
Thermistor change in throttle openness. TP sensor shall
be replaced together with the throttle body.

Element Brush holder

Idle stepper motor

Idle stepper motor (IMA) is a resistance device
controlling the idle mixture concentration. Brush

Idle stepper motor

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System description
Throttle body

TP sensor

IAC valve

Positive crankcase ventilation (PCV) system

PCV valve sucks the gas leaked from the piston into the intake manifold, preventing it from
entering the atmosphere.

Vent pipe

PCV valve hose

Intake manifold

PCV valve

Vapor leakage
Fresh air

Idle control system diagram

The engine idle speed is control by the idle stepper motor.

 When the engine starts, the solenoid valve is turned on for some time. The air intake is
increased so as to improve the idle speed.
 When the engine coolant temperature is low, the solenoid valve is turned on to get a higher
idle speed. The bypass air volume is controlled according to the coolant temperature
.

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Throttle body
Intake manifold

Engine
Intake guide coolant

IAC valve
Air filter element
From PGM-FI
main relay

Different sensors

Air intake system

The system provides air supply to the engine. When the air is sucked in, the resonance chamber
in the intake pipe can further reduce the noise level.

Throttle body
Intake manifold

Intake guide Engine

coolant
Air filter element IAC valve

From PGM-FI
Resonance chamber (to air filter ) main relay

Different sensors

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PCV system
1. Check the PCV valve (A) and hose (B) and the connections for leakage or block.

2. At idle speed, slightly press the PCV valve and intake manifold with a finger or pliers to check
whether the PCV valve is giving click sounds.

If no click sound, check the PCV valve retainer for crack or damage. If the retainer is normal,
replace the PCV valve and check again.

Section1 Fuel Tank

1. Removal & installation
Works before removal
● Pump out the fuel.
● Prevent the fuel from splashing on the ground.
● Remove the secondary muffler

Works after installation

● Fill fuel into the tank
● Make sure there is no fuel leakage
● Install the secondary muffler
（1）. See Fig. 5-1 for the removal procedure.

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Fig. 5-1
1－Fuel tank assembly;2－Fuel vapor exhaust hose 3－Elastic hoop;4－Anti-tilt valve assembly;5
－Inlet oil hose I assembly;6－Two hole clip clamp; 7－Inlet oil hose II assembly; 8－Hexagon
combined bolt;9－Hexagon flange bolts;10－Fuel filter bracket;11－Fuel filter;12－Circlip;13－
Fuel pump assembly;14－Fuel pump O ring;15－Elastic hood;16－Oil filler outlet hose II;17－Oil
filler outlet pipe bracket II; 18－Oil filler ventilation rigid tube bracket II; 19－B spring nut;20－
Hexagon flange bolts;21－Oil filler outlet hose I; 22－Two hole clip clamp; 23－Oil filler rigid tube
welded assembly;24－Oil filler shield;25－Oil filler pipe plastic jacket; 26－Wire retainer ring; 27－
Wire retainer ring; 28－Fuel tank head assembly; 29－Bracket I;30－Hexagon combined bolt;31-
Hexagon flange bolt；32-Bracket II;33-Worm clamp;34-Oil filler hose；35- Hexagon combined bolt；
36-Fuel tank fixing band I; 37-Fixing band fender I; 38-Fixing band fender II; 39-Fuel tank fixing
band II.

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2 Precautions on removal of fuel tank

(1) Lift up the vehicle with a lift and support it Oil return pipe
properly. When lifting/supporting the fuel
tank with a jack, apply auxiliary support to
prevent the fuel tank from toppling. Notch
(2) The rubber pipe shall be replaced as a High pressure
whole; do not repair any pipe segment. oil pipe
(3) To service the fuel system, cover the
attachment and plug the hole to prevent dirt
and other contaminants from entering the
system from open pipeline or other
passages. Power fuel
(4) Keep the fuel system parts clean and in Wire harness pump
good order. socket

Notice:
● Reinstall the 4 M10 bolts fixing the fuel tank,
and tighten them with 20N.m tightening torque.
● Tighten the ring clamps and make
replacement if necessary. Fig. 5-2
● Check and make sure the hoses are not Notice: The notch of the power fuel pump shall
damaged or twisted during removal and be aligned to the notch on the fuel tank.
installation.
● Keep the ignition switch at ON for 2 seconds, 2. Replace the fuel filter.
turn it to OFF and remains for 10 seconds, Remove the fuel filter.
then turn it to On again, and finally check for (1) Discharge the pressure in the fuel system.
fuel leakage. (2) Collect the fuel in a proper container.
(3) Take out the fuel filter from the bracket.
Section2 Power Fuel Pump The disassembled fuel filter is shown in Fig.
5-3.
1. Replace the power fuel pump (see Fig. 5-2).

(1) Remove the wire harness connector and

fuel pipe.
(2) Remove the fuel tank.
(3) Remove the fuel pump circlip and then the
power fuel pump.
(4) Install a new power fuel pump, O-seal, and
fuel pump circlip.
(5) Connect the fuel pipe (hose) and wire
harness connector.

Fig. 5-3
3. Install the fuel filter.
(1) Remove the protection cover of a new fuel
filter.
(2) Slowly insert the fuel filter into the bracket,
and tighten the bracket bolts.
(3) Connect the fuel hoses on both ends of the
fuel filter in the fuel circuit.
(4) Tighten the fuel filler cap of the fuel tank.

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(5) Reconnect the battery negative cable.

(6) Keep the ignition switch at ON for 2 seconds, turn it to OFF and remains for 10 seconds, then
turn it to On again, and finally check for fuel leakage.
4. Install and remove nylon tube
(1)Check if there is any mud or foreign matter in the nylon pipe connector nearby and clean it
up.
(2)Press both ends of quick union and remove it backwards.Fig.5-4
(3)Check if there is any damage, mud or foreign matter on the connection of nylon when
installing nylon pipe.
(4)Install the quick union of nylon pipe on the mail connector along the linear direction until it
sounds ―click‖ if nothing is abnormal.

Fig.5-4

Fig.5-5

Notice: After installing the high pressure nylon pipe, pull it slightly to make sure it is installed firmly;
and make sure there is 3mm clearance.

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Chapter 3 473QE Engine Service Manual

Contents
Part 1 Engine .......................................................................................................................... 108
Section 1 Overview .......................................................................................................... 108
1. Major Technical Parameters ................................................................................... 108
2. Technical Parameters for Maintenance ................................................................... 109
3. BYD473QE Engine Tightening Torque Table ............................................................ 111
4. BYD473Q Engine Special-purpose Part List ............................................................113
Section 2 Cylinder Head ...................................................................................................115
1. Adjust Valve Clearance ............................................................................................115
2. Remove/Install Crankshaft Pulley ............................................................................115
3. Remove/Install Silent Timing Chain..........................................................................116
4. Install Crankshaft Front Oil Seal ............................................................................. 120
5. Remove Cylinder Head Cover ................................................................................ 120
6. Remove Cylinder Head........................................................................................... 120
7. Remove/Install Camshaft Sprocket ......................................................................... 123
8. Replace Camshaft Phase Sensor Signal Plate ....................................................... 125
9. Check Cylinder Head Warping ................................................................................ 126
10. Remove Rocker Arm Assembly............................................................................. 126
11. Disassemble/Reassemble Rocker Arm and Rocker Arm Shaft .............................. 127
12. Check Rocker Arm and Rocker Arm Shaft ............................................................ 128
13. Remove Camshaft ................................................................................................ 129
14. Check Camshaft ................................................................................................... 129
15. Remove Valve, Valve Spring and Valve Oil Seal ................................................... 130
16. Check Valve ......................................................................................................... 130
17. Check Valve Tappet-Valve Guide Clearance ......................................................... 130
18. Replace Valve Guide ............................................................................................ 131
19. Check Valve Seat ................................................................................................. 132
20. Install Valve, Valve Spring and Valve Oil Seal ....................................................... 133
21. Install Camshaft .................................................................................................... 134
22. Install Rocker Arm Assembly................................................................................. 135
23. Install Cylinder Head............................................................................................. 135
24. Install Cylinder Head Cover .................................................................................. 139
Section 3 Cylinder Block .................................................................................................. 140
1. Check Connecting Rod-Crankshaft Axial Clearance ............................................... 142
2. Replace Crankshaft Main Bearing Bush.................................................................. 142
3. Replace Connecting Rod Bearing Shell .................................................................. 145
4. Remove Oil Pan ..................................................................................................... 148
5. Remove Crankshaft and Piston .............................................................................. 148
6. Check Crankshaft ................................................................................................... 149
7. Check Cylinder Body and Piston ............................................................................. 150
8. Replace Piston, Piston Pin and Connecting Rod ..................................................... 153
9. Check Connecting Rod Bolt .................................................................................... 157

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10. Install Crankshaft .................................................................................................. 157

11. Install Oil Pan........................................................................................................ 159
Part 2 Lubricating System ....................................................................................................... 161
1. Check Oil Pressure Warner .................................................................................... 162
2. Inspect Oil Pressure ............................................................................................... 162
3. Change Engine Oil ................................................................................................. 162
4. Replace Engine Oil Filter ........................................................................................ 163
5. Replace Oil Filter Thread Pipe ................................................................................ 163
6. Overhaul Oil Pump ................................................................................................. 164
7. Install Breather Cover Plate .................................................................................... 166
8. Replace Oil Pressure Warner ................................................................................. 166
Part 3 Air Intake and Exhaust System ..................................................................................... 167
1. Standard Service Value .......................................................................................... 167
3. Air Intake System Parts Layout ............................................................................... 167
4. Intake manifold ....................................................................................................... 168
5. Intake Pipe and Muffler ........................................................................................... 169
6. Inspection ............................................................................................................... 170
7. Remove/Install intake manifold ............................................................................... 170
8. Remove/Install Exhaust Manifold ............................................................................ 171
Part 4 Engine Cooling System ................................................................................................ 172
1. Check Thermostat .................................................................................................. 173
2. Check Water Pump................................................................................................. 173
3. Replace Water Pump.............................................................................................. 173
4. Replace Thermostat ............................................................................................... 173
5. Replace Coolant Temperature Sensor .................................................................... 174
Part 5 Fuel and Exhaust System ............................................................................................. 175
Section 1 Engine Fuel System ........................................................................................... 180

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Part 1 Engine

Section 1 Overview

BYD473QE engine adopts electronically controlled fuel injection system, which is developed by
BYD and featured by sequential multi-point fuel-injection and advanced self-diagnosis function.
The engine has high power per liter, low fuel consumption, low noise, low pollution and compact
profile. BYD473QE engine can optimize running under all working conditions, allowing good
performance of the BYD F3 AUTO in the aspects of safety, drivability, economic and environmental
performance.

1. Major Technical Parameters

The major technical parameters of BYD473QE are shown below:

Model BYD473QE
Type 4-stroke, water-cooled, in-line, SOHC, EFI
Number of cylinders 4
Cylinder bore (mm) 73
Piston stroke (mm) 89.4
Compression ratio 10.6
Ignition sequence 1-3-4-2
Declared power (kw) 80 (5800r/min)
Maximum torque (N.m) 145 (4800 r/min)
Declared speed (r/min) 5800
Minimum fuel consumption (g/kW·h) 236
Engine oil pressure (kPa) 340~490 (3000r/min±50r/min)
Minimum stable idle speed (r/min) 780±50
Total displacement (L) 1.497
Engine oil/fuel consumption ratio (%) 0.26
Overall dimensions
587×543×700
(L×W×H) (mm)
Net weight (kg) 97
CO≤0.15% HC≤40ppm (780±50r/min)
Idle exhaust emission CO≤0.15% HC≤40ppm (2500±50r/min)
GB18285-2005
Fuel 93# unleaded gasoline (GB17930-1999)
SG grade 10W/30 (year around in the south and
Lubricating oil spring, summer and autumn in the north)
SG grade 5W30 (for winter in the north) (GB11121)
Coolant Ethylene glycol based coolant
Dry-type, single disc, diaphragm spring, atmospheric
Type
style
Clutch Dimensions Clutch driven disk assembly φ200×8.9mm (free state)
(mm) Clutch cover assembly φ255×40.4mm
Weight 4.314kg
Synchromesh transmission, 5 forward gears, 1 reverse
Gearbox Type
gear

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1st gear 3.308

2nd gear 1.826
3rd gear 1.207
Gear ratio
4th gear 0.939
5th gear 0.730
Reverse 3.231
Final drive ratio 4.471
Overall dimensions (mm) (L×W×H) 504×382×363mm
Lubricating oil Gear oil for medium duty vehicle (GL-4 SAE 80W/90)

2. Technical Parameters for Maintenance

Cylinder Head

Measuring
Name Measured Item Standard Value Service limit
Condition
Cylinder Warping 0.08mm
head Height 119.9~120.1mm
Camshaft axial clearance 0.07~0.25mm 0.5mm
Camshaft-bracket oil film
0.025~0.046mm 0.1mm
clearance
Maximum
Total runout 0.04mm
Camshaft 0.03mm
Intake 35.37mm
Variable
Cam lobe lift 30.565mm
intake
Exhaust 35.39mm
Intake 0.18~0.22mm
Clearance (cold)
Exhaust 0.23~0.27mm
Intake 5.470~5.485mm 5.45mm
Valve Tappet outer diameter
Exhaust 5.455~5.470mm 5.42mm
Intake 0.025~0.060mm 0.08mm
Tappet-guide clearance
Exhaust 0.04~0.075mm 0.11mm
Intake 0.85~1.15mm 1.60mm
Width
Exhaust 1.25~1.55mm 2.00mm
Valve seat
Intake 46.1~46.5mm 46.8mm
Tappet installation height
Exhaust 46.2~46.6mm 46.9mm
Intake 50.5mm
Valve spring Free length
Exhaust 57.2mm
Intake 5.51~5.53mm 5.55mm
Inner diameter
Exhaust 5.51~5.53mm 5.55mm
Valve guide
Intake 15.85~16.35mm
Installation height
Exhaust 15.85~16.35mm
Rocker arm-rocker arm shaft Intake 0.02~0.054mm 0.08mm
Rocker arm
clearance Exhaust 0.02~0.054mm 0.08mm

Cylinder Block

Measuring Service
Name Measured Item Standard Value
Condition limit

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Surface warping Maximum 0.07mm 0.10mm

Cylinder Cylinder bore 73~73.019mm 73.07mm
block Cylinder bore conicity ---- 0.05mm
Cylinder reboring limit ---- 0.25mm
Outer diameter at 13mm from
72.955~72.975mm 72.945mm
the piston skirt bottom
Clearance to cylinder 0.035~0.054mm 0.06mm
First
air-tight 1.02~1.04mm 1.07mm
ring
Piston
Second
Piston ring groove air-tight 1.21~1.23mm 1.25mm
ring
Combined
oil-control 2.01~2.03mm 2.05mm
ring
First
air-tight 0.03~0.07mm 0.15mm
ring
Piston ring-groove clearance
Second
air-tight 0.02~0.06mm 0.13mm
ring
First
Piston ring air-tight 0.20~0.35mm 0.6mm
ring
Second
Piston ring gap air-tight 0.35~0.5mm 0.65mm
ring
Combined
oil-control 0.2~0.7mm 0.8mm
ring
Outer diameter 17.996~18mm
Piston pin Piston pin to piston-pin bore
0.005~0.015mm
clearance
Pin-connecting rod small end
0.015~0.037mm
bore clearance
Connecting Connecting rod small end bore 17.963~17.981mm
rod Connecting rod big end bore Normal 43~43.015mm
End play when installed to
0.15~0.3mm 0.4mm
crankshaft
Main journal diameter 49.937~49.955mm
Connecting rod journal
39.940~39.955mm
diameter
Connecting rod/main journal
0.005mm 0.01mm
Crankshaft conicity
Connecting rod/main journal
0.005mm 0.01mm
out-of-roundness
End play 0.1~0.35mm 0.45mm
Runout Maximum 0.03mm 0.04mm
Main shaft bearing-journal oil
0.028~0.049mm 0.055mm
Crankshaft film clearance
bearing Connecting rod bearing
0.022~0.050mm 0.055mm
clearance

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Engine Lubrication

Service
Name Measured Item Measuring Condition Standard Value
limit
Engine overhaul 4.0L
Replace oil (including oil
3.3L
Engine oil Oil capacity filter)
Replace oil (excluding oil
2.9L
filter)
Inner
rotor-outer rotor 0.075mm~0.15mm 0.18mm
clearance
Pump
housing-outer 0.06mm~0.136mm 0.18mm
Oil pump
rotor clearance
Pump
housing-outer
0.028mm~0.065mm 0.085mm
rotor shaft
clearance
Oil pressure Idle Minimum 30KPa
Pressure
under 80°C oil Engine speed at
relief valve Minimum 300KPa
temperature 3000rpm/min

Engine Coolant

Measuring
Name Measured Item Standard Value Service limit
Condition
Coolant capacity Engine
(including engine, overhaul
Radiator 6.8L
heater, hose and water Coolant
tank) replacement
Starting to
76℃~80℃
Opening temperature open
Thermostat Fully opens 90℃
Valve stroke when fully
Above 8mm
open
To ON 91~95℃
Thermoswitch Switching temperature 3~8℃ lower than the actual
To OFF
temperature switching to ON
3 BYD473QE Engine Tightening Torque Table
Tightening torque
No. Part /Location To Tighten Bolt Description
(N·m)
Cylinder head bolt with 29 plus 130°
1 Cylinder head
washer rotation
Main bearing cap bolt 25 plus 40°
2 Main bearing cap
with washer rotation
9.8 plus 90°
3 Connecting rod cover Connecting rod bolt
rotation
4 Flywheel Flywheel bolt 95
5 Spark plug M14×1.25 20

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6 Breather cover plate Bolt M6×12 12

7 Knock sensor Bolt M8×30 25
8 Engine oil pressure switch R2 1/8 15
9 Cylinder head plug Bolt M10×1.25×12 30
10 Tensioner assembly Tensioner pivot bolt 22
Camshaft sprocket bolt
11 Camshaft sprocket 56
assembly
12 Guide assembly Bolt M6×16 12
13 Tensioner seat Bolt M6×30 12
Bolt M6×25 10
14 Oil pump assembly
Bolt M6×35 10
15 Water pump Bolt M6×35 12
Bolt M6×12 10
16 Oil collector
Nut M6 10
Bolt M6×30 12
17 Oil pan Bolt M8×35 25
Bolt M6×50 12
Oil filter 12
18 Oil filter
Corrugated pipe 20
Tightening torque
No. Part /Location To Tighten Bolt Description
(N·m)
Dipstick tube welded
19 Bolt M6×12 10
assembly
20 Water outlet pipe part Bolt M6×12 10
Bolt M8×35 25
21 Intake manifold
Nut M8 25
22 Fuel distributor assembly Bolt M6×12 10
23 Intake air Cross recessed pan 5
temperature/pressure sensor head screw M5×16
Bolt M6×30 12
24 Throttle assembly
Bolt M6×35 12
25 Accelerator cable bracket Bolt M6×12 12
Bolt M10×1.25×20 44
26 Exhaust manifold
Nut M10 44
27 Exhaust manifold heat shield Bolt M6×25 10
Bolt M8×20 25
28 Exhaust manifold bracket
Bolt M8×25 25
29 Front oxygen sensor M18×1.5-6g 45
30 Thermostat cover Bolt M6×20 10
31 Camshaft phase sensor Bolt M6×16 10
32 Coolant temperature sensor M12×1.5-6g 15
33 Cylinder head cover Cylinder head cover 12
bolt assembly
34 Ignition coil Bolt M6×25 10
35 Carbon canister control valve Bolt M6×12 10
bracket
Pulley bolt with washer 37 plus 90°
36 Crankshaft damping pulley
rotation
37 Water pump pulley Bolt M6×12 14
Bolt M8×70 25
38 Generator
Bolt M8×25 25
39 Clutch cover assembly Hexagon socket head 25

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cap screw
Bolt M12×1.25×60 65
40 Gear box Bolt M12×1.25×65 65
Bolt M12×1.25×95 65
41 Starter Bolt M10×1.25×45 44
Bolt M10×1.25×20 44
Bolt M6×16 12
Intake manifold bracket
42 Intake manifold
assembly
bracket washer bolt 12
M6×30
Hexagon head bolt for 25
reamed hole
Bolt M8×50 25
Bolt M8×80 25
43 Timing cover
Bolt M6×30 10

Bolt M12×1.25×12 20

Tightening torque
No. Part /Location To Tighten Bolt Description
(N·m)
44 Clutch back plate Bolt M6×12 10
45 Camshaft thrust cover Bolt M6×20 10
46 Camshaft phase sensor Hexagon socket screw 34
signal plate
47 Cylinder head plug M16×1.5-6h 45
48 EGR valve seat M8 nut 25
49 EGR valve M8 nut 25
50 OCV valve component Bolt M6×55 12
4 BYD473Q Engine Special-purpose Part List

Model
Part No.
BYD473QB BYD473QE BYD473QE-1
Part Name

Cylinder cover BYD473QE-1003400

BYD473QA-1003400 Same as QE
machining assembly
Crankshaft BYD473QB-1005021 BYD473QD-1005021 Same as QE
Rocker arm BYD473QA-1003060 BYD473QE-1003060 Same as QE
Camshaft assembly BYD473QA-1006010 BYD473QE-1006010 Same as QE
Intake manifold BYD473QE-1008020
BYD473QA-1008020 Same as QE
assembly
Intake manifold BYD473QE-1003601
BYD473QA-1003601 Same as QE
bracket
Intake manifold stud BYD473QE-1003054
BYD473QA-1003054 Same as QE
bolt
Fuel distributor BYD473QE-1121010
BYD473QA-1121010 Same as QB
assembly
Carbon canister BYD473QE-1130020
BYD473QA-1130020 Same as QB
control valve
Carbon canister BYD473QE-1130015
BYD473QA-1130015 Same as QB
control valve bracket

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Outlet pipe welding BYD473QE-1303200

BYD473QA-1303200 Same as QE
components II
Throttle body BYD473QA-1132020 BYD473QE-1132110 Same as QB
Throttle position BYD473QE-3611700
BYD473QA-3611030 Same as QB
sensor
Knock sensor BYD473QA-3611040 BYD473QE-3611400 Same as QB
Crankshaft position BYD473QE-3611200
BYD473QA-3611050 Same as QB
sensor
Coolant temperature BYD473QE-3611100
BYD473QA-3611060 Same as QB
sensor
Intake air BYD473QE-3611500
pressure/temperature BYD473QA-3611070 Same as QB
sensor
Front oxygen sensor BYD473QA-3611080 BYD473QE-1211100 Same as QB
Idle speed stepper BYD473QE-1026200
BYD473QA-3611090 Same as QB
motor
Ignition coil assembly IB5-3705100 BYD473QE-3705100 Same as QE
Engine wiring IB5-4016214
IB5-1024217 Same as QE
harness bracket X
Engine wiring IB5-4016215
N/A Same as QE
harness bracket XII
EGR control valve N/A BYD473QE-3615100 Same as QE
EGR valve seat N/A BYD473QE-1003501 Same as QE
Model
Part No.
BYD473QB BYD473QE BYD473QE-1
Part Name
EGR valve gasket N/A BYD473QE-1003507 Same as QE
EGR valve seat BYD473QE-1003502
N/A Same as QE
gasket
EGR valve stud bolt N/A BYD473QE-1003506 Same as QE
EGR valve seat BYD473QE-1003505
N/A Same as QE
support tube
Intake manifold BYD473QE-1008021
N/A Same as QE
transition pad
Intake manifold BYD473QE-1008024
N/A Same as QE
gasket
OCV valve BYD473QE-1003700
N/A Same as QE
component
Cylinder head plug N/A BYD473QE-1003055 Same as QE
Cylinder head plug BYD473QE-1003056
N/A Same as QE
gasket
EGR valve return BYD473QE-1303016
N/A Same as QE
hose

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Section 2 Cylinder Head

Regulating screw
1 Adjust Valve Clearance
Notice: valve can not be adjusted when the
cylinder head temperature is over 38°C.
1. Remove the cylinder head cover.
2. Rotate the crankshaft until the number
one piston is at TDC. ―UP‖ mark on the
camshaft sprocket shall be on the top, and
TDC groove on the camshaft sprocket
shall be aligned with the cylinder head‘s
upper edge.
Lock nut
UP mark

6. Tighten the lock regulating screw and

recheck the valve clearance; repeat the
process above until the clearance is
appropriate.
7. Rotate the crankshaft clockwise. Repeat
the procedure for valve clearance
adjustment to adjust cylinder 3, 4, 2 in
strict order.
8. Install the cylinder head cover.
2. Remove/Install Crankshaft Pulley
DTC groove
Removal Procedure
3. Choose a proper feeler gauge for the
Remove the crankshaft pulley bolt component
valve you will check.
with a ratchet wrench, extension rod and
BYD473QB engine: Intake valve
19mm sleeve.
clearance: 0.23mm~0.27mm; exhaust valve
Installation Procedure
clearance: 0.27mm~0.31mm
1. Clean the crankshaft pulley A, crankshaft
BYD473QE engine: Intake valve
B, bolt C and washer D, and conduct
clearance: 0.18mm~0.2mm; exhaust valve
lubrication process as shown in the figure
clearance: 0.23mm~0.27mm
below:
4. Insert the feeler gauge between the
regulating screw and valve stem end, and
slide the gauge back and forth; a slight Cleaning
resistance shall be felt. Lubricating
5. If the resistance is too large or small,
loosen the lock regulating screw, and
rotate the regulating screw with a
screwdriver until you can fill appropriate
resistance when sliding the feeler gauge.

2. Install the crankshaft damping pulley and

crankshaft pulley bolt component, and
tighten it to 37N.m with a torque wrench
and 19mm sleeve. Do not use an impact
wrench. For a new pulley bolt or new

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crankshaft, tighten the bolt first to 177N.m,

loosen it and then tighten it to 37N.m.
Arrow
3. Tighten the pulley bolt for additional 90°.
3. Remove/Install Silent Timing Chain
Notice: keep the silent timing chain away from
any magnetic field.
Removal Procedure
1. Remove the belt.
2. Remove the mounting bolt 1 from the
generator adjusting arm, and then loosen DTC mark
the generator mounting bolt 2.

Mounting bolt 1

5. Remove the water pump pulley.

6. Remove the cylinder head cover.
7. Remove the crankshaft damping pulley.
8. Remove the oil pan.
9. Place a jack and wooden block under the
cylinder block to support the engine.
10. Keep the engine away from the timing
cover and then remove the timing cover.
Mounting bolt 2

3. Remove the idler pulley assembly.

Timing cover

11. Apply engine oil to the support surface of

the silent timing chain tensioner. Pry open
the hole on the support of the silent timing
4. Rotate the crankshaft pulley until its TDC chain tensioner with a screwdriver, and
mark is aligned with the arrow. then remove bolt 1 and loosen bolt 2.

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Tensioner support

Tensioner assembly

Guide assembly

14. Remove the silent timing chain.

Installation Procedure
Notice: keep the silent timing chain away from
Bolt 1 Bolt 2 any magnetic field.
1. Set the crankshaft to the TDC position.
Align the TDC mark on the crankshaft
12. Remove the support of the silent timing sprocket with the arrow on the oil pump.
chain tensioner.

Arrow TDC mark

2. Set the number one piston to the TDC

position. ―UP‖ mark on the camshaft
sprocket shall be on the top, and TDC
groove on the camshaft sprocket shall be
aligned with the cylinder head‘s upper
edge.
13. Remove the tensioner assembly and
guide assembly.

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DTC groove

Tensioner assembly

UP mark
Tensioner pivot bolt Guide assembly

3. Install the silent timing chain to the 6. Install the tensioner support and tighten
crankshaft sprocket, with the color mark the bolt slightly.
aligned with the TDC mark on the
crankshaft sprocket.

DTC mark

Color mark

4. Install the silent timing chain to the

camshaft sprocket, with the arrow aligned
with the color marks.

3 color marks
7. Apply engine oil to the sliding surface of
the tensioner support.

Arrow

5. Apply engine oil to the threads of the

tensioner pivot bolt, and then install the
tensioner assembly and guide assembly.

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Cylinder block
upper surface
contact

Tensioner support

Dash line

13. Install the timing cover.

8. Rotate the tensioner support clockwise to
press tight the tensioner assembly, and
then install the other bolts to fix it. Timing cover
9. Check whether the crankshaft front oil
seal on the timing cover is damaged.
Replace the crankshaft front oil seal if it is
damaged.
10. Clear away the old sealant on the timing
cover matching surface, bolt and bolt
hole.
11. Clean the timing cover matching surface
and dry it.
12. Evenly apply sealant to the matching
surface between the timing cover and
cylinder block and on the female threads
in the bolt holes.
Notice:
 The sealant shall be 2-3mm wide along 14. Install the oil pan.
the dash line. 15. Install the crankshaft damping pulley.
 Apply 3-4mm wide sealant to the 16. Install the cylinder head cover.
cylinder block upper surface of the 17. Install the water pump pulley.
timing cover. 18. Install the idler pulley assembly.
 The assembling shall be conducted 19. Install the mounting bolt for the generator
within 4 minutes of applying the sealant. adjusting arm.
If not, the sealant applied in the
previous step shall be cleared away
and new sealant shall be applied again.

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2. Remove 4 coils of the ignition device.

3. Remove the cylinder head cover.

20. Install and adjust the belt.

4 Install Crankshaft Front Oil Seal
6. Remove Cylinder Head
The SST assembling tool for front
crankshaft oil seal is required. Notice:
1. Use the SST to push in a new oil seal  Use a fender cover to prevent damage
straightly into the timing cover at the to the paint surface.
specified installation height.  To prevent damage, hold the
2. Measure the distance between the timing connector by the hard part and pull out
cover surface (matching surface with the the wire harness connector carefully.
cylinder block) and the oil seal.  To prevent damage to the cylinder
Oil seal installation height: head, do not loosen the bolts until the
34.5mm~35.2mm engine coolant temperature is lower
than 38℃ (100℉).
 Make proper marks on all cables and
hoses to prevent wrong connection.
Make sure the cables and hoses are
not contacting each other or
interfering with other parts.
 Keep the silent timing chain away
from any magnetic field.
1. Drain the engine coolant.
2. Remove the air filter housing.
3. Remove the water inlet/outlet hose from
the throttle body.

5. Remove Cylinder Head Cover

1. Remove the intake manifold.
4. Remove the water inlet/outlet hose from the

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radiator.

Connecting
pipe

PCV hose

12. Remove the cylinder head cover.

13. Remove the generator bracket mounting
bolts, and then loosen the generator mounting
bolts.
5. Remove the hose from the fan heater.
14. Remove the idler pulley assembly.
15. Rotate the crankshaft pulley until its TDC
mark is aligned with the arrow.
16. Remove the water pump pulley.
17. Remove the crankshaft damping pulley.
18. Place a 300×300×25mm wooden block
and a jack under the oil pan to support the
engine.
Notice: do not locate the jack in the middle of
the oil pan to prevent damage to it.
19. Remove the grounding cable and then
remove the front engine bracket.
20. Keep the engine away from the timing
cover and then remove the timing cover.

6. Remove the belt.

7. Remove the intake manifold.
8. Remove the exhaust manifold.
9. Remove the engine wire harness connector
and wire clip from the cylinder head.
 4 fuel injector connectors
 Engine coolant temperature sensor
connector
 Camshaft phase sensor connector
 Oil pressure alarm device connector
 Knock sensor
10. Remove the bolt for connecting wire
harnesses and wiring harness bracket. 21. Make a reference mark on the camshaft
11. Remove the connecting pipe for the water sprocket and silent timing chain.
outlet pipe, and positive crankcase ventilation
(PCV) hose.

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tensioner assembly, and then tighten the bolt.

26. Hold the camshaft with an open-end
wrench, and then remove the camshaft pulley.

22. Loosely install the crankshaft pulley.

23. Apply engine oil to the sliding surface of
the silent timing chain tensioner support
through the oil return hole on the cylinder
head.

27. Remove the bolt fixing the silent timing

chain‘s guide assembly.

24. Fix the crankshaft pulley, and fit the sleeve

wrench to the camshaft sprocket bolt.

Socket
wrench
Bolt hole
Tensioner
assembly

Bolt

25. Rotate the camshaft clockwise to 28. Remove the cylinder head bolts. To
compress the silent timing chain‘s tensioner prevent warping or deformation, loosen the
assembly, insert a 6×1.0mm bolt into the bolt bolts in an alternating pattern, 1/3 round at a
hole on the cylinder block through the time, in the order shown in the figure below,

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and repeat this process until all bolts are

loosened completely.

Loosen the bolts in the order shown in this figure

29. Remove the cylinder head.

7. Remove/Install Camshaft Sprocket 4. Remove the sight port cover.
Removal Procedure
Notice: keep the silent timing chain away from
any magnetic field.
1. Remove the cylinder head cover.
2. Make a reference mark on the camshaft
sprocket and silent timing chain.

Reference mark

5. Remove the M12×1.25×12 bolt and washer

on the timing cover, hold the crankshaft pulley,
and then attach a sleeve wrench to the
camshaft sprocket bolt.

Socket
wrench
3. Apply engine oil to the sliding surface of the Bolt hole
silent timing chain tensioner support through Tensioner assembly
the oil return hole on the cylinder head.

Bolt

6. Rotate the camshaft clockwise to compress

the silent timing chain‘s tensioner assembly,
insert a 6×1.0mm bolt into the bolt hole on the
cylinder block through the tensioner assembly,
and then tighten the bolt.
7. Hold the camshaft with an open-end wrench,

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and then remove the camshaft pulley.

Notice: hang the silent timing chain with an
iron wire.

3. Apply engine oil to the sliding surface of the

timing chain tensioner support through the oil
Installation Procedure return hole on the cylinder head.
Notice: keep the silent timing chain away from
any magnetic field.
1. Install the timing chain onto the camshaft
sprocket after aligning the reference mark, and
then install the camshaft sprocket onto the
camshaft.

Reference mark

2. Hold the camshaft with an open-end wrench,

and then tighten the bolt. 4. Fix the crankshaft pulley, and fit the sleeve
Specified torque: 56N.m wrench to the camshaft sprocket bolt.

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Socket wrench

Bolt M6X1.0
Washer
Bolt M10X1.25X12

5. Rotate the camshaft clockwise to compress 5. Hold the camshaft with an open-end wrench,
tight the silent timing chain's tensioner and then loosen the hexagon socket screw.
assembly, and then remove the 6×1.0mm
bolt.
6. Install the M12×1.25×12 bolt with a new
washer.
7. Install a new sight port cover.

6. Remove the camshaft phase sensor signal

plate.

8. Install the cylinder head cover.

8. Replace Camshaft Phase Sensor
Signal Plate
Removal Procedure
1. Remove the air filter.
2. Remove the bolt for connecting wire
harnesses and relevant wiring harness.
Installation Procedure
3. Remove the cylinder head cover.
1. Install the camshaft phase sensor signal
4. Remove the camshaft CID signal cover.
plate.

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shown in the figures below.

 If the warping is less than 0.08mm,
repairing is not necessary;
 If the warping is somewhere between
0.08mm and 0.2mm, the cylinder head
shall be repaired;
 The maximum repairable warping is
0.2mm on the basis of 120mm height.
Cylinder head height
Standard: 119.9mm~120.1mm
2. Hold the camshaft with an open-end wrench,
Precision ruler
and then tighten the bolt to 34N.m.

3. Install the camshaft CID signal cover with a

new O-ring.

10. Remove Rocker Arm Assembly

1. Remove the cylinder head cover.
2. Loosen the regulating screws of the rocker
arms.

Rocker arm regulating screw

Camshaft CID
signal cover

4. Install the cylinder head cover.

5. Install the wire harness bracket, wire
harnesses and bolts.
6. Install the air filter.
9 Check Cylinder Head Warping
1. Remove the cylinder head.
2. Check the camshaft. Rocker arm regulating screw
3. Check whether the cylinder head has
warping. Measure the length of each side and
the diagonal length of the cylinder head, as

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3. Loosen the hollow bolts fixing the rocker arms in an alternating pattern, 2 rounds at a time, in the
order shown in the figure below, and repeat this process until all bolts are loosened completely.

4. Remove the hollow bolts, and then remove the rocker arm assemblies.
Notice: to disassemble a rocker arm, first remove the dowel pin, and then detach it from the rocker
arm shaft at the timing chain side.
11. Disassemble/Reassemble Rocker Arm and Rocker Arm Shaft
Notice:
 Make marks on each part before disassembling so that you can reassemble them properly.
 Disassembling/reassembling a rocker arm from the rocker arm shaft at the silent timing chain
side.
 Check the rocker arm and rocker arm shaft.
 Any reused rocker arm shall be installed at its original location.
 Before reassembling, please clean all parts with solvent, dry them in air, and apply lubricating
oil at all contact points.

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Stopper piston
Exhaust rocker arm II Primary piston Exhaust rocker arm I
Stopper piston Stopper spring gasket

Rocker arm gasket

Primary intake rocker arm Auxiliary intake rocker arm

Rocker
arm

Rocker arm hollow bolt

12. Check Rocker Arm and Rocker Arm Shaft

1. Remove the rocker arm assemblies.
2. Measure the shaft diameter at the number one rocker arm.

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3. Reset the dial bore gauge according to the rocker arm is beyond the allowable limit,
shaft diameter. replace it together with the rocker arm
shaft.
13. Remove Camshaft
1. Remove the air filter.
2. Remove the camshaft sprocket.
Dial bore gauge 3. Remove the rocker arm assemblies.
4. Remove the bolt for connecting wire
harnesses and relevant wiring harness.
5. Disconnect the camshaft phase sensor
connector, and remove the camshaft
phase sensor.
6. Remove the camshaft CID signal cover, and
pull out the camshaft.

Camshaft

Camshaft CID signal cover

4. Measure the inner diameter of the rocker

arm with a dial bore gauge and check its
out-of-roundness.
Rocker arm-rocker arm shaft clearance:
Standard: 0.019mm~0.058mm
Service limit: 0.08mm

14. Check Camshaft

1. Remove the camshaft sprocket.
2. Remove the rocker arm assemblies.
3. Set the rocker arm shaft to the cylinder head,
and tighten the bolt to the specified torque.
Specified torque: 29 N·m
Apply engine oil to the threaded section
and flange of the bolt.
4. Push the camshaft backwards toward the
cylinder head until it stops.
5. Press a dial gauge‘s push-rod on the
camshaft end, and reset the dial gauge.
Push the camshaft back and forth and get
the axial clearance reading. If the axial
clearance is beyond the service limit,
replace the thrust cover and check again. If
it is still beyond the service limit, please
replace the camshaft.
Camshaft axial clearance:
Standard: 0.07mm~0.25mm
Service limit: 0.5mm

5. Repeat the process above for all rocker

arms and shaft. If the clearance of any

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the upper valve spring seat with a proper-size

sleeve and plastic hammer. Remove the valve
lock clamp, valve spring, valve and valve oil
seal.

Plastic hammer

Sleeve

6. Support the camshaft with a V-shaped block,

and check its total runout.
 If the total runout is beyond the service
limit, replace the camshaft, and check the
oil film clearance between the camshaft
and its bore hole. If the oil film clearance
is still beyond the service limit, please 16. Check Valve
replace the cylinder head.
Total camshaft runout Remove the valve and measure the
Standard: maximum 0.03mm dimensions at the locations shown in the figure
Service limit: 0.04mm below:
Intake valve dimensions:
A standard: 27.4mm~27.6mm
B standard: 118.1mm~118.7mm
C standard: 5.470mm~5.485mm
C repairable limit: 5.44mm
Exhaust valve dimensions:
A standard: 22.9mm~23.1mm
B standard: 117.3mm~117.9mm
C standard: 5.455mm~5.470mm
C repairable limit: 5.42mm

7. Measure the cam lobe lift.

Standard lobe lift (new part):
Intake: 35.38
Variable intake: 30.565
Exhaust: 35.39
15. Remove Valve, Valve Spring and 17. Check Valve Tappet-Valve Guide
Valve Oil Seal Clearance
Make marks on the valve and springs before 1. Remove the valve.
disassembling so that you can reassemble 2. Slide out the valve from the guide for some
them to their original locations. 10mm, shake the valve tappet from the
1. Remove the cylinder head cover. normal thrust direction (shaking method)
2. Remove the camshaft. and then measure the inner diameter of the
3. Loosen the valve lock clamp by knocking guide with a dial bore gauge, and the outer
diameter of the tappet with a micrometer.

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The difference between the two measured 2. Use the pneumatic valve guide punch
values is the valve tappet-valve guide modified according to the valve guide
clearance. diameter (available in the market) as shown
 If the result is beyond the service limit, in the figure below. Normally you can also
install a new valve and measure the complete the same operation using the SST
clearance again. and a hammer.
 If the new clearance is within the 3. Choose proper substitute valve guides, and
service limit, proceed with the freeze them in a refrigerator for about 1
reassembling process. hour.
 Go to step 3 if the new clearance is 4. Heat up the cylinder head to 150℃ with an
still beyond the service limit. electric hot plate or oven. Monitor the
Intake valve tappet-valve guide clearance: temperature with a thermometer. The
Standard: 0.04mm~0.10mm temperature of the cylinder head shall be
Service limit: 0.16mm kept under 150℃. Overheating may cause
Exhaust valve tappet-valve guide loose valve seat.
clearance:
Standard: 0.10mm~0.16mm
Service limit: 0.22mm

5. Use a punch and air hammer to push the

valve guide to the combustion chamber for
some 2mm from the camshaft side. This
process can get off some carbon to
3. Measure the inner diameter of the valve facilitate the removal. Keep the air hammer
guide and the outer diameter of the valve parallel with the valve guide to prevent
tappet at 3 different locations, using the damage to the punch.
devices mentioned in step 2, and then 6. Go the opposite side and knock off the valve
subtract the measured inner diameters by guide towards the camshaft side.
the outer diameters. The difference
between the maximum inner diameter and
the minimum outer diameter shall fall in the
service limit.
Intake valve tappet-valve guide clearance:
Standard: 0.02mm~0.05mm
Service limit: 0.08mm
Exhaust valve tappet-valve guide
clearance:
Standard: 0.050mm~0.080mm
Service limit: 0.11mm
18. Replace Valve Guide
The following SST tools are required:
 Valve guide remover/installer
 Valve guide reamer
1. Check valve tappet-valve guide clearance.

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7. If the valve guide cannot move, drill an 8mm

hole and knock again. Drilling is not
recommended because the cylinder may be
damaged if the valve guide is broken during
drilling.
8. Take out one valve guide from the
refrigerator.
9. Apply thin oil film to the outer surface of the
new valve guide. Install the valve guide from
the cylinder head camshaft side; use the
SST to knock in the guide to specified
installation height. If all 16 valve guides shall
be replaced, you need to heat up the
cylinder head again.
Installation height of valve guide:
15.70mm~16.30mm

12. Rotate the reamer further until it gets

through the valve guide.
13. Flush the valve guide with detergent and
water to clear away all swarf.
14. Insert and slide a valve in the
intake/exhaust valve guide to check the
clearance, and make sure there is no
resistance.
19. Check Valve Seat
1. Check valve tappet-valve guide clearance.
Any worn valve guide shall be replaced
before reaming the valve seat.
2. Repair the valve seat in a cylinder with a
valve seat reamer.

10. Apply cutting oil to both the reamer and

valve guide.
11. Rotate the reamer clockwise along the full
length of the valve guide.
3. Carefully cut a 45° edge on the seat to
ensure that the valve seat is smooth and
concentric.
4. Mill the upper angle and lower angle as
shown in the figure below. Check the
width of the valve seat and adjust it if

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necessary. reamer again to restore the valve seat

width.
 If the valve seat is low (near to the valve
edge), use a 30° reamer to heighten it,
and then use a 45° reamer again to
restore the valve seat width.
o
Notice: only 45° milling cutter shall be
Air inlet: 67.5 used for the final milling process.
o
Air outlet: 60 8. Insert the intake valve and exhaust valve
into the cylinder head, and measure the
installation height A of the valve tappet.
Installation height of the intake valve tappet:
Standard: 46.1mm~46.5mm
Service limit: 46.8mm
Installation height of the exhaust valve tappet:
5. Use a 45° reamer to reaming the seat again Standard: 46.2mm~46.6mm
slightly to eliminate burrs resulting from Service limit: 46.9mm
the previous process.
Valve seat width
Intake:
Standard: 0.850mm~1.150mm
Service limit: 1.60mm
Exhaust:
Standard: 1.250mm~1.550mm
Service limit: 2.00mm
6. Check the valve seat flatness upon
completion of surface processing: apply
Prussian blue compound agent to the valve
surface, insert the valve into its original
location in the cylinder head, and then pull up
and press down the valve against the valve
seat for several times.

9. If the tappet height is beyond the service

limit, replace the valve and check again. If it is
beyond the service limit, the cylinder head
shall be replaced as the valve seat sinks
deeply into the cylinder head.
20. Install Valve, Valve Spring and
Valve Oil Seal
The following SST tools are required:
 Tappet oil seal remover/installer
7. The valve seat surface indicated by the blue  Valve spring compressor
agent in the figure above shall be aligned with 1. Apply engine oil to the tappet and install the
the center of the valve seat. valve into the valve guide.
 If the valve seat is high (near to the 2. Check whether the valve moves up and
tappet), use a 67.5° reamer (for the intake down smoothly.
valve) or 60° reamer (for the exhaust 3. Install the lower spring seat onto the
valve) to cut it lower, and then use a 45° cylinder head.

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4. Apply grease on the valve guide, and install

a new valve oil seal with the valve guide oil
sealer remover/installer.
Notice: the exhaust valve oil seal is
indicated by EX, and the intake oil seal is
indicated by IN. They are not
interchangeable.

Marked IN Marked EX

Intake valve oil seal Exhaust valve oil seal

Guide oil seal

remover/ installer 8. Use a plastic hammer to slightly knock each
valve tappet for 2 or 3 times so as to ensure
Valve oil seal that the valves and valve lock clamps are
installed correctly. Only knock the tappet in its
axial direction to prevent bending.

5. Install the valve spring. The valve spring Plastic

end with more winding shall point to the hammer
cylinder head.
6. Install the upper spring seat.
7. Attach the valve spring compressor to
compress the spring, and then install the valve
lock clamp.

21. Install Camshaft

1. Install the camshaft onto the cylinder head,
and install the camshaft CID signal cover with
a new O-ring.

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Camshaft
O-ring
Camshaft CID
signal cover

3. Adjust the valve clearance.

4. Install the cylinder head cover.
23. Install Cylinder Head
2. Install the camshaft phase sensor with a Install the cylinder head in the reverse
new O-ring, and then connect the camshaft sequence of removal.
phase sensor connector. 1. Clean the junction surface between the
3. Install the wire harness bracket and its cylinder head and cylinder block.
mounting bolts. 2. Install the cylinder head gasket and dowel
4. Install the camshaft sprocket. pin onto the cylinder block. Only use a new
5. Install the rocker arm assemblies. cylinder head gasket.
6. Install the air filter.
22. Install Rocker Arm Assembly Cylinder head gasket
1. Install the rocker arm assemblies with a
dowel pin.
Notice: reassembling the rocker arms to the
rocker arm shaft at the silent timing chain side.

Rocker
Dowel pin arm
assembly

Dowel pin

3. Make sure the crankshaft key slot is facing

upwards.
4. Install the cylinder head onto the cylinder
block.
5. Apply engine oil to the threaded section of
all cylinder head bolts and the bottom side of
2. Tighten all bolts fixing the rocker arms in an all bolt heads.
alternating pattern, 2 rounds at a time, in the 6. Tighten all cylinder head bolts to 29N.m in
order as shown in the figure below, and repeat the order shown in the figure below. Use a flat
this process until all bolts are tightened beam torque wrench. If you use a preset
properly. torque-wrench, do tighten the bolts slowly and
Specified torque: 29 N·m within specified torque. If any bolt makes noise
Apply engine oil to the threaded section and during tightening, loosen it and repeat the
flange of the bolt. tightening process.

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wrench, and then tighten the bolt.

Specified torque: 56 N·m

7. Tighten all cylinder head bolts for another

130°.
8. Install the mounting bolt of silent timing
chain‘s guide assembly.

11. Loosely install the crankshaft pulley.

12. Apply engine oil to the sliding surface of
the silent timing chain tensioner support
through the oil return hole on the cylinder
head.

Mounting bolt

9. Install the timing chain onto the camshaft

sprocket after aligning the reference mark, and
then install the camshaft sprocket onto the
camshaft.

Reference mark

13. Fix the crankshaft pulley, and fit the sleeve

wrench to the camshaft sprocket bolt.

10. Hold the camshaft with an open-end

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Socket wrench
Cylinder block
upper surface
contact
Bolt

14. Rotate the camshaft clockwise to

compress tight the silent timing chain's
tensioner assembly, and then remove the
6×1.0mm bolt. Dash line
 When rotating the camshaft, the torque
shouldn‘t exceed 56N.m.
19. Evenly apply sealant to the matching
 Do not rotate the camshaft
surface between the timing cover and oil
counterclockwise.
pan and on the female threads in the bolt
15. Check whether the crankshaft front oil seal
holes.
is damaged. If any damage, replace it with a
Notice:
new one.
 The sealant shall be 2-3mm wide along
16. Clear away the old sealant on the timing
the dash line.
cover matching surface, bolt and bolt hole.
 Apply 5.0mm wide sealant to the
17. Clean and dry the timing cover matching
shadow area as shown in the figure
surface.
below.
18. Evenly apply sealant to the matching
 The assembling shall be conducted
surface between the timing cover and cylinder
within 4 minutes of applying the sealant.
block and on the female threads in the bolt
If not, the sealant applied in the
holes.
previous step shall be cleared away
Notice:
and new sealant shall be applied again.
 The sealant shall be 2-3mm wide along
the dash line. Dash line
 Apply 3-4mm wide sealant to the cylinder
block upper surface of the timing cover.

Shadow area

20. Align the timing cover edge against the oil

pan cover, and then install the timing cover
onto the cylinder block.
Notice: when installing the timing cover, do not
slide the bottom of the oil pan mounting
surface; otherwise the sealant may be
scratched and lead to deteriorated sealing
performance.

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29. Install the positive crankcase ventilation

(PCV) hose.
Timing cover
30. Install the wire harness bracket and bolts.
31. Install the exhaust manifold.
32. Install the intake manifold.
33. Install the heater hose.

Cylinder block

34. Install the water inlet/outlet hose to the

Timing cover radiator.

Upper
radiator
hose

Oil pan

21. Install wire harness bracket.

22. Install the crankshaft damping pulley.
23. Install the cylinder head cover. Lower radiator hose
24. Install the water pump pulley.
25. Install the idler pulley assembly. 35. Install the water inlet/outlet hose to the
26. Install the generator adjusting arm and its throttle body.
mounting bolts.
27. Install the belt and tighten it through
adjusting the generator regulating screw.
28. Install the water outlet pipe using a new
o-ring for water outlet.

O-ring

Water
outlet part

36. Install the air filter.

PCV hose

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37. Upon completion of assembling, check whether all pipes, hoses and connectors are connected
properly.
38. Check for fuel leakage. Turn the ignition switch to ON without running the starter, run the fuel
pump for 2 seconds and increase fuel line pressure. Repeat the process for 2 or 3 times and check
whether there is leakage in the fuel line.
39. Refill engine coolant into the radiator, and meanwhile discharge the air in the cooling system
with the heater valve remaining open.
40. Check idle speed.
41. Check the ignition timing.
24. Install Cylinder Head Cover
1. Thoroughly clean the cylinder head cover gasket and grooves.
2. Install the cylinder head cover gasket into the groove.
3. Make sure the matching surface is dry and clean.
4. Apply 3.0mm wide sealant within the timing cover matching surface.
Notice: The assembling shall be conducted within 4 minutes of applying the sealant. If not, the
sealant applied in the previous step shall be cleared away and new sealant shall be applied again.
5. After installing the cylinder head cover on the cylinder head, slightly slide the cylinder head
cover back and forth so that the gasket can be fit in place.

6. Check the cylinder head cover gasket. Replace the gasket if it is damaged or aged.
7. Tighten bolts by 2 or 3 steps. The tightening torque is 12N.m in the order shown in the figure
below.

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8. Install 4 ignition coils.

9. Install the intake manifold cover.
10. Check whether all pipes, hoses and connectors are connected properly.
11. Upon completion, wait for 30 minutes before filling in engine oil.

Section 3 Cylinder Block

Component Layout (a)

Main bearing cap

Crankshaft

Flywheel bolt

Flywheel

Crankshaft thrust plate Main bearing bush

Crankshaft oil seal

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Component Layout (b)

Piston ring

Piston

Connecting rod body

Piston pin

Cylinder block

Connecting rod bearing shell

Connecting rod bolts

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check the clearance again. If it is still out of the

1. Check Connecting Rod-Crankshaft allowance range, replace the crankshaft.
Axial Clearance
2. Replace Crankshaft Main Bearing
1. Remove the oil pump.
Bush
2. Measure the axial clearance between the
connecting rod and crankshaft with a Check main bearing bush clearance
feeler gauge. 1. When checking the oil film between
Connecting rod axial clearance: the main bearing bush and journal, you
Standard value: 0.15mm~0.30mm shall remove the main bearing cap and
Service limit: 0.40mm bush.
2. Clean the main journal and bush with a
piece of clean service cloth.
3. Place plastic clearance gauges
between main journals.
4. Reinstall the bearing bush and
crankshaft main bearing cap, and
tighten the bolt to 25N.m +40°.
Notice: do not rotate the crankshaft during the
check procedure.
5. Remove the crankshaft main bearing
cap and bush again, and measure the
plastic clearance gauges at the widest
location.
Main bearing bush-journal oil film
clearance:
3. If the axial clearance is beyond the Standard value: 0.018mm~0.036mm
allowance range, install a new connecting Service limit: 0.050mm
rod and check the clearance again. If it is
still out of the allowance range, replace the
crankshaft.
4. Push the crankshaft as far away from the
dial gauge as possible, reset the dial
gauge while pressing it against the
crankshaft end, and then pull back the
crankshaft to press against the dial gauge
tightly: the reading of the gauge shall be in
the service limit.
Crankshaft axial clearance:
Standard value: 0.10mm~0.35mm
Service limit: 0.45mm

6. If the clearance measured with the

plastic clearance gauge is too large or
small, remove the crankshaft and the
upper bearing bush. Install a new
complete bearing bush with the same
grouping code, and check the
clearance again. It is prohibited to
adjust the clearance by filing, filling or
grinding the bearing bush or cover.

5. If the axial clearance is beyond the

allowance range, replace the thrust plate and

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7. If the clearance indicated by the gauges is still beyond range, try to use a larger or smaller
bearing bush (the color above or below the current cell in the table below) correspondingly
and check again. If using of the appropriate bush still cannot get a proper clearance,
replace the crankshaft and repeat the check procedure.

Choose main bearing bush

Location of crankshaft hole grouping code

1. Grouping indicator representing 5 main journals are embossed on the end of the
crankshaft. Take notice of the crankshaft hole's grouping code. If the code is coved by dirty
or dust, do not use a wire brush or scraper. Only clean it with solvent or detergent.

st th
1 gear journal 5 gear
(pulley side) journal
(gearbox side)

Location of Main Journal Grouping Code

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2. Main journal grouping code is embossed on the crankshaft.

st nd rd th th
1 gear journal 2 gear journal 3 gear journal 4 gear journal 5 gear journal

st th
1 gear journal 5 gear journal

3. Choose a proper bearing bush from the table below by reference to the grouping code of the
crankshaft hole and crankshaft journal.
Notice: the grouping code is located on the edge of the main bearing bush.

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Assembling Relationship between Main Shaft Hole, Bush and Diameter

Main shaft hole

diameter increase

Shaft hole

Bush
Shaft diameter
increase
Shaft diameter

Grouping code Bush thickness increase

3. Replace Connecting Rod Bearing Shell

Check connecting rod bearing clearance
1. Check the oil film clearance between the connecting rod bearing and journal. Remove the
main bearing cap.
2. Remove the connecting rod cover and connecting rod bearing shell.
3. Clean the crankshaft connecting rod journal and bearing shell with a piece of clean
service cloth.
4. Place a plastic clearance gauge on the connecting rod journal.
5. Reinstall the bearing shell and connecting rod cover and tighten the bolts.
Tightening torque: 9.8N.m+90°
Notice: do not rotate the crankshaft during the check procedure.
6. Remove the connecting rod cover and bearing shell, and measure the plastic clearance
gauge at the widest location.
Connecting rod bearing shell-journal oil film clearance:
Standard value: 0.020mm~0.038mm
Service limit: 0.050mm

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Grouping code

7. If the clearance measured with the plastic Location of connecting rod journal
clearance gauge is too large or small, grouping code
remove the upper bearing shell. Install a 3. Connecting rod journal grouping code is
new complete bearing shell with the same embossed on the crankshaft.
grouping code, and check the clearance Location of connecting rod journal grouping
again. It is prohibited to adjust the clearance code
by filing, filling or grinding the bearing or
cover.
8. If the clearance indicated by the gauges is
still beyond range, try to use a larger or
smaller bearing bush (the color above or
below the current cell in the table)
correspondingly and check again. If using of
the appropriate bearing shell still cannot get
a proper clearance, replace the crankshaft
and repeat the check procedure.
Choose connecting rod bearing bush
1. Check each connecting rod for crack and
thermal damage.
Location of connecting rod big-end hole
code
2. Depending on the size of the connecting
rod big-end hole, the tolerance for each
connecting rod is 0 - 0.015mm, with an
increment of 0.008mm. The code is
embossed in numbers or bar codes. You
can find a variety combination of numbers
and bar codes on the engine (half of them
printed on the bearing cap and another half
on the connecting rod).

If the code is coved by dirty or dust, do not use

a wire brush or scraper. Only clean it with
solvent or detergent.
Standard hole size: 43.0mm

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st nd rd th
1 gear journal 2 gear journal 3 gear journal 4 gear journal

st th
1 gear connecting rod journal 4 gear connecting rod journal

4. Depending on the big-end hole code and connecting rod journal code, choose an appropriate
substitute bearing shell from the table below.
Notice: the grouping code is located on the edge of the bearing shell.

Assembling Relationship between Bore, Connecting Rod Bearing Shell and

Connecting Rod Shaft Diameter

Bore increase

Shaft hole
Bush
Shaft diameter
increase
Shaft diameter

Grouping code

Bush thickness increase

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4. Remove Oil Pan

1. Completely drain engine oil in the engine.
2. Remove the dipstick tube.

6. Remove the oil pan and place it carefully

with the joint surface with the cylinder block
facing upwards.
5. Remove Crankshaft and Piston
1. Remove the engine.
Oil dipstick tube 2. Remove the gearbox.
3. Remove the silent timing chain.
4. Remove the cylinder head.
5. Remove the oil collector and then remove
3. Remove the clutch back plate and then the oil pump.
remove 2 bolts (A) fixing the gearbox.
Oil collector

Oil pump

6. Remove the main bearing cap bolts. To

prevent warping, loosen the bolts in
alternating pattern, 1/3 round at a time, in
the order shown in the figure below.
Clutch back plate Repeat the process until all bolts are
loosened.

4. Remove the bolts fixing the oil pan.

5. Attached a slotted screwdriver as
shown in the figure, and then detach
the oil pan from the cylinder block.

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12. Push out the piston with the hammer‘s

wooden handle. Hold the piston with
another hand during this process.
7. Remove the main bearing cap.
8. Remove the connecting rod cover/bearing
shell and place them carefully in good
order. Wooden handle
9. Take out the crankshaft from the cylinder
block with care, as impact with the cylinder Piston
block may cause damage, especially to the
journal.

13. Install the main bearing cap and bush

onto the cylinder block again in proper
order.
14. Remove the piston rings and connecting
rod assemblies, and then install the
connecting rod bodies and covers again.
15. To prevent wrong installation, mark each
piston/connecting rod assembly with its
10. Remove the upper shells from the cylinder number.
connecting rod, and place them together Notice: the existing mark on a connecting rod
with their corresponding bearing shell. represents its connecting rod hole size, not its
11. Check the top inside of the cylinder liner position.
for metal protruding or accumulated
carbon and, if any, remove them with a 6. Check Crankshaft
reamer following the manufacturer‘s Out-of-roundness and conicity
instructions. If the protruding matter is not 1. Remove the crankshaft from the cylinder
removed, the piston may be damaged block.
when you pull it out. 2. Clean the crankshaft oil way with a tuber
cleaner or an appropriate brush.
3. Clean the key slot and threads.
4. Measure the roundness at 2 positions

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where each connecting rod journal and and 5# journal of the cylinder block.
main journal center are perpendicular to 8. Lower the crankshaft and place it into the
each other, and the measured difference of cylinder block.
each journal cannot exceed the service 9. Measure the runout on all main journals.
limit. Rotate the crankshaft for 2 rounds and then
Journal out-of-roundness: measure the runout. The difference
Standard: maximum 0.005mm between all measured values shall be
Service limit: 0.010mm within the service limit.
Crankshaft total runout:
Standard: maximum 0.03mm
Service limit: 0.04mm

Connecting rod journal

Main journal 7. Check Cylinder Body and Piston

1. Remove the crankshaft and piston.
2. Check whether the piston is deformed or
cracked.
3. Measure the piston diameter at the bottom
of the piston skirt, at the location as shown
in the figure below.
Piston diameter:
Standard value: 72.955mm~72.975mm
Service limit: 72.945mm

Piston diameter

5. Measure the conicity at the edge of each

connecting rod and main journal, and the
measured difference of each journal
cannot exceed the service limit.
Journal conicity:
Standard: maximum 0.005mm
Service limit: 0.010mm Measuring
point
Verticality
6. Place the cylinder block on the marking-off
table.
7. Clean the bearing bush and install it on 1#

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First measurement
Second measurement
Third measurement

Oversized piston diameter:

0.25: 73.205mm~73.225mm
4. Measure the wear and conicity of each
cylinder in X and Y direction, at 3 locations
with different height, as shown in the figure 5. Cylinder with scratched damage shall be
below. If the measured value of any honed.
cylinder is beyond the service limit of 6. Check the top of the cylinder block for
oversized cylinder bore, replace the warping. Measure the edge and diagonal
cylinder block. If any cylinder block line of the cylinder block as shown in the
requires reboring, go to step 7. figure below.
Cylinder bore: Cylinder block warping:
Standard value: 73.00mm~73.019mm Standard: maximum 0.05mm
Service limit: 73.07mm Service limit: 0.10mm
Oversized dimension:
0.25: 73.25mm~73.269mm
Reboring limit: maximum 0.25mm
Bore conicity:
Limit: 0.05mm (the difference between the
first and third measured value)

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Cross hatch

Precision ruler
3. Clear away all metal particles in the engine
body after honing. Wash the cylinder bore
7. Measure the cylinder bore and piston
with hot water and soap. Dry it and apply
diameter and calculate their difference. If
engine oil immediately to prevent rusting.
the difference is near or over the service
Do not use any solvent in this step, as it
limit, check for excessive wear on the
may carry metal particles around the
piston and cylinder.
cylinder wall.
Piston-cylinder clearance:
4. If the scratch still exists when honing to
Standard value: 0.010mm~0.040mm
service limit, the cylinder block shall be
Service limit: 0.05mm
rebored again. But very slight vertical
scratch is acceptable, provides that its
Piston-cylinder clearance length is less than the cylinder bore and
your finger is not retarded when moving
across its deepest part.

Cylinder honing process

Honing is applicable only to the cylinder
bores with scratch damage.
1. Measure cylinder bore
After honing a cylinder block, measure the
cylinder bore again before reusing it.
2. Using honing oil and honing stone (400 grit)
to hone the cylinder bore in a 60° cross
hatch pattern. Only honing stones with 400
or finer grit, such as those from Sunnen,
Ammco or other equivalents, shall be used.
Do not use any worn or broken honing
stone.

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8. Replace Piston, Piston Pin and

Connecting Rod
Disassembling
1. Remove the piston from the cylinder block.
2. Remove the piston pin with a SST.
Inspection
1. Measure the diameter of the piston pin.
Piston pin diameter:
Standard value: 17.996mm~18.000mm

4. Check the difference between the piston

pin diameter and piston bore diameter.
Piston pin to piston bore clearance
Standard value: 0.005mm~0.015mm

2. Reset the dial bore gauge according to the

piston pin diameter.

Replace piston, piston pin and connecting

rod
3. Measure the piston pin-connecting rod
small end bore clearance. Reassembling
Piston pin-connecting rod small end bore 1. Install the piston and connecting rod, with
clearance: the orientation arrow and connecting rod
Standard value: -0.037mm~-0.015mm mark pointing to the same direction.

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Notice: if you need to detach the piston

from the connecting rod, do not install the
new piston ring at this time.
4. Push a new piston ring into the cylinder
bore with the piston, until its distance to the
cylinder bottom is 15mm~20mm.

Orientation arrow

2. Press the piston pin into the piston with a

SST.
Replace Piston ring
1. Remove the piston from the cylinder block.
2. Remove the old piston ring with a piston
ring expander.

Piston ring Clearance

Piston ring

5. Measure the piston ring end clearance with

a feeler gauge.

Piston ring tensioner

3. Clean all the piston ring grooves using a

split ring without cutting edge, or a ring
groove cleaner with a cutting edge
matching with the piston groove.
Groove width of the first air-tight ring:
1.0mm.
Groove width of the second air-tight ring:
1.2mm.
Groove width of the oil ring: 2.0mm.
The cutting edge may be filed if necessary.
Do not use a wire brush to clean the ring
groove, and prevent the cleaning tool from
cutting the ring groove deeper.

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Standard clearance Service limit

First air-tight ring 0.20mm~0.35mm 0.79mm
Second air-tight ring 0.35mm~0.50mm 0.75mm
Oil-control ring 0.20~0.70mm 0.80mm

If the measured value is over the biggest end clearance, replace the piston ring and measure
again.
If the measured value is still over the biggest end clearance, replace the cylinder block.
6. Install the first air-tight ring (A) and second air-tight ring (B) as shown in the figure below. When
installing the piston ring, make sure the side (C) with manufacturer mark is facing upwards.

Piston ring diameter

Air-tight ring 1 (standard)
A: 2.45 mm
B: 1.0 mm
Air-tight ring 2 (standard)
A: 3.0 mm
B: 1.2 mm

7. Check whether the piston rings rotate smoothly in the groove.

8. Set the end clearance of the piston rings as shown in the figure below:

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Lower lid of oil scraper ring gap nd

2 air-tight ring gap

Assembling position arrow

Bush ring gap
Facing engine free end

st
1 air-tight ring gap Upper lid of oil
scraper ring gap

9. Measure the clearance between ring grooves after installing a set of new piston rings.
Air-tight ring 1 clearance:
Standard value: 0.075mm~0.100mm
Service limit: 0.17mm
Air-tight ring 2 clearance
Standard value: 0.030mm~0.055mm
Service limit: 0.13mm

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Install piston gauge.

If the crankshafts are installed: 7. Check the connecting rod bolts.
1. Set the crankshaft in each cylinder to BDC 8. Apply engine oil to the bolt threads. Install
in turn. the connecting rod cover with a bearing
2. Remove the connecting rod cover, install shell. Tighten the bolt to 9.8 N·m+90°.
the piston ring compressor and then make If the crankshafts are not installed:
sure the bearing bush is fixed in place 1. Remove the connecting rod cover, install
firmly. the piston ring and make sure the bearing
3. Place the orientation mark towards the shell is fixed in place.
engine silent timing chain (front end). 2. Place the orientation mark towards the
engine timing chain (front end).
3. Place the piston into the cylinder, and
knock it with the hammer's wooden handle
(A) or similar wooden objects. Keep
downward pressure on the piston ring
compressor (B) before installation in the
cylinder bore to prevent the piston ring
opening.
4. Set all pistons to TDC.

9. Check Connecting Rod Bolt

Orientation arrow 1. Measure the connecting rod bolt diameter
at location A & B with a micrometer, as
shown in the figure below.

4. Place the piston into the cylinder, and

knock it with the hammer's wooden handle
(A) or similar wooden objects. Keep
downward pressure on the piston ring
compressor (B) before installation in the
cylinder bore to prevent the piston ring
opening. 2. Calculate the difference of the diameter at
A & B.
Diameter difference = diameter A –
diameter B
Diameter difference allowance: 0~0.05mm
3. If the difference is beyond the allowance,
replace the connecting rod bolt.
10. Install Crankshaft
1. Check the clearance of the connecting rod
bearing with a plastic clearance gauge.
2. Check the clearance of the main bearing
with a plastic clearance gauge.
3. Check the connecting rod bolts.
5. After the compressor rebounds, check 4. Install bearing bush and shells on the
whether the connecting rod-crankshaft cylinder block and connecting rod.
journal alignment is correct before pushing 5. Apply engine oil to the main bearing bush
the piston in place. and connecting rod bearing shell.
6. Check the clearance of the connecting rod 6. Hold the crankshaft to keep the number 2
bearing shell with a plastic clearance and 3 journal pointing straightly upwards,

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and then place the crankshaft into the

cylinder block. 16. Install the integrated main bearing cap, and
7. Install a thrust plate at the number 4 journal keep the orientation mark in proper
of the cylinder block. direction.
8. 17. Clear off the old sealant on the matching
surface of the main bearing cap rear end
Indicator A (5# bearing cap).
18. Clean and dry out the matching surface of
the main bearing cap rear end (5# bearing
cap).
19. Apply 3mm wide sealant along the dash
line in the figure below.
Indicator B
Notice: The assembling shall be conducted
within 4 minutes of applying the sealant. If
not, the sealant applied in the previous
step shall be cleared away and new
sealant shall be applied again.
9. Apply engine oil to the thread and flange of
the connecting rod bolt.
10. Fit the connecting rod journal to number 1
and 4 connecting rod. Align the marks on
the connecting rod and cover, and then
tighten the connecting rod cover and bolt
manually.
11. Rotate the crankshaft clockwise, and fix the
journal in number 2 and 3 connecting rods. Sealant application path
Align the marks on the connecting rod and
cover, and then tighten the connecting rod 20. Place the main bearing cap on the
cover and bolt manually. cylinder block.
12. Tighten the connecting rod bolt to 9.8N.m. 21. Apply engine oil to the threaded section
13. Tighten the connecting rod bolt for and flange of the main bearing cap bolts.
additional 90°. 22. Tighten the bolts to 25N.m in the order
14. Install the crankshaft rear oil seal shown in the figure below.
assembly. Before installation to the
crankshaft, apply lubricating grease to the
oil seal inner groove.
15. Measure the distance between the
crankshaft and oil seal.
Oil seal installation height: 7mm~8mm

23. Tighten the bolts for additional 40°.

24. Clear off the needless sealant on the
cylinder block.
25. Install the dowel pin (A) and a new O-ring
(B) to the oil pump (C), align the inner
rotor with the crankshaft, and then install
the oil pump.

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Notice: The assembling shall be

conducted within 4 minutes of applying
the sealant. If not, the sealant applied in
the previous step shall be cleared away
and new sealant shall be applied again.

26. Install the oil collector (D) with a new

washer (E).
27. Install the cylinder head.
28. Install the silent timing chain.
29. Install the gearbox.
30. Install the engine.
Notice: after replacing the crankshaft or 5. Install the oil pan A with a dowel pin B and
connecting rod bearing shell, keep the a new O-ring C.
engine running idle until it reaches the
normal working temperature, and then let
it run for additional 15 minutes.
11. Install Oil Pan
1. Clear off the old sealant on the matching
surface of the oil pan, the bolt and bolt
holes.
2. Clean and dry out the matching surface
between the oil pan and cylinder block.
3. Install a new crescent sealing ring on the
oil pan.

6. Tighten the bolts by 2 or 3 steps.

Crescent sealing ring
Tightening torque: (see indication
below)
Indicated by A: 25N·m
Indicated by B: 12N·m

4. Evenly apply special-purpose sealant to

the matching surface between the oil pan
and cylinder block and in the bolt holes.
Notice: apply 2mm~3mm wide sealant
along the dash line in the figure below.
Apply 5.0mm wide sealant to the shadow
area B shown in the figure below. 7. Install the clutch back plate, and then

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tighten the 2 bolts fixing the gearbox. The

tightening torque for the bolts is shown
below:

Clutch back plate

8. Install the dipstick tube (A) with a new

O-ring (B). The tightening torque is shown
in the figure.

9. After completing the installation, wait for at

least 30 min before filling engine oil into the
engine.

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Part 2 Lubricating System

Component Layout

Gasket Oil drain plug

Oil pan

Oil filter

Oil filter thread pipe

O-ring
Crescent sealing ring Oil collector

Oil collector gasket

Oil dipstick pipe

Breather cover plate Dowel pin

Oil pressure warner
O-ring
Oil pump

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1. Check Oil Pressure Warner

1. Disconnect the oil pressure warner
connector (A) from the oil pressure waning
device (B).

2. Start the engine and check the oil

2. Check the conductivity between the pressure gauge. If the reading indicates
positive terminal (C) and engine no oil pressure, shut down the engine
(grounded). The circuit shall be turned on immediately. Solve this trouble before
when the engine stops running and be going to the next step.
turned off when the engine is running. 3. When the engine reaches the running
3. If the pressure warning device isn‘t work temperature (cooling fan started at least
normally, check the oil level; if the oil level twice), the oil pressure shall be:
is normal, check the oil pressure; if the oil Oil temperature: 80°C
pressure is normal, replace the oil Engine oil pressure:
pressure warner. Idle running: minimum 70kPa
At 3000rpm/min:
2. Inspect Oil Pressure
Minimum 300kPa
If oil pressure warning light shall remain on 4. If the oil pressure is beyond the specified
when the engine is running, check the oil level; range, check the following items:
if the oil level is normal:  Check whether the oil collector is blocked;
1. Remove the oil pressure warner, and  Check the oil pump.
connect an oil pressure gauge to its
mounting hole with a special-purpose 3. Change Engine Oil
adapter. 1. Pre-warm the engine.
2. Loosen the oil drain plug (A) to completely
drain the oil in the engine.

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39 N.m Do not
tighten it excessively.

3. Install the oil drain plug again with a new 5. After installation, fill engine oil to the
washer (B). specified oil level, start the engine and let
4. Fill new engine oil in the engine. it idle for 3 minutes, and then check the oil
When changing oil: 2.9L drain plug and oil filter for leakage.
When changing oil (including the oil filter): 5. Replace Oil Filter Thread Pipe
3.3L
After engine overhaul: 4.0L 1. Remove the oil filter.
5. 5. Keep the engine running for over 3 2. Install two 20×1.5mm nuts (A) on a new
minutes and check for oil leakage. oil filter thread pipe. Hold the nut with a
wrench, and then tighten one nut.
4. Replace Engine Oil Filter
1. Remove the oil filter with the oil filter
wrench SST.
2. Check the thread (A) and rubber sealing (B)
of a new oil filter, clean the contact surface
between the oil pan and filter, and then
apply a thin oil film on the oil filter rubber
seal ring. Only use an oil filter with internal
bypass system.

3. Tighten the oil filter thread pipe on the oil

pan to 20N.m, and then remove the nuts on
the thread pipe.

3. Install the oil filter manually.

4. Fit the rubber seal ring in place, and lock
the oil filter clockwise with the SST.
Tightening: rotate 3/4 to 1 round clockwise.
Tightening torque: 12N.m

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6. Overhaul Oil Pump

Exploded View

Pump housing O-ring

Dowel pin

Oil pump cover

Outer rotor
Inner rotor

Pressure relief valve

The valve shall slide freely in
the housing.
Spring Replace the valve if any
scratch.

Sealing bolt 20N.m

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Removal Procedure
1. Remove the silent timing chain.
2. Remove the oil collector (A) and then
remove the oil pump (B).

4. Check the radial clearance between the

outer rotor (A) and pump housing (B). If the
radial clearance is beyond the service limit,
replace the oil pump.

Pump housing-rotor radial clearance:

Standard: 0.06~0.136mm
Inspection Service limit: 0.18mm
1. Remove the pump cover.
2. Check the radial clearance between the
inner rotor (A) and outer rotor (B). If the
radial clearance is beyond the service
limit, replace the oil pump.
Inner rotor-outer rotor radial clearance:
Standard: 0.075~0.15mm
Service limit: 0.18mm

5. Check the inner rotor, outer rotor and pump

housing for scratch and other damages,
and make replacement if necessary.
6. Install the oil pump cover.
Installation Procedure
1. Install the dowel pin (A) and a new O-ring
to the oil pump (C). Align the inner rotor
with the crankshaft, and install the oil
3. Check the axial clearance between the pump.
rotor (A) and pump housing (B). If the axial 2. Install the oil collector (D) with a new
clearance is beyond the service limit, washer (E).
replace the oil pump. 3. Install the silent timing chain.

Pump housing-rotor axial clearance:

Standard: 0.028~0.065mm
Service limit: 0.085mm

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8. Replace Oil Pressure Warner

1. Disconnect the oil pressure warner
connector (A), and remove the oil pressure
warner (B).

7. Install Breather Cover Plate

1. Clean and dry out the matching surface,
bolts and bolt holes of the breather cover
plate.
2. Apply 2-3mm wide sealant along the dash
line (A).
Notice: The assembling shall be conducted
within 4 minutes of applying the sealant. If 2. Apply sealant to the threaded section of the
oil pressure warner, and then install it with
not, the sealant applied in the previous
step shall be cleared away and new a tightening torque of 15N.m.
sealant shall be applied again.

3. Install the breather cover plate.

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Part 3 Air Intake and Exhaust System

1. Standard Service Value

See Table 9-1 for standard values.
Table 6-1
Item Standard Value Service Limit
Deformation of intake manifold < 0.15 0.20
mounting surface (mm)
Deformation of exhaust manifold < 0.15 0.20
mounting surface (mm)

Air Intake System Parts Layout

Front air intake pipe assembly

进气管前段总成

曲轴箱通风管
Crankcase vent pipe
Crankcase vent
曲轴箱通风管护套
pipe sleeve

Air intake
进气软管 hose

Rear air intake pipe

进气管后段总成
assembly

空气滤清器总成
Air filter assembly

3. Air Filter Assembly

Removal & installation:
Notice: when operating the filter element made from waste paper and resin, pay attention to the
following:
1. Avoid severe impact or large load on the filter element after disassembly and reassembly.
2. Ensure there is good fitting between the filter element and the lower filter case.

See Fig. 1 for the removal procedure:

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.
.

Fig. 1
1- inlet pipe assembly, 2-outlet pipe assembly, 3-crankcase vent pipe, 4-air filter assembly,
5-upper filter case, 6-filter element, 7- lower filter case
4. Intake manifold
Removal & installation
Works before removal and after installation
1. Drain and fill the coolant (refer to the relevant section);
2. Remove and install the air filter (refer to the section above on the air filter);
3. Remove and install the throttle body and injection driver. (Refer to the relevant section for
removal procedure)
Tips on removal of intake manifold
Disconnect the intake manifold resonator and remove the intake manifold.
Tips on installation of engine hood:
(1) Pretighten the mounting bolts to the extent that you can move the engine hood manually.
(2) Tighten the mounting bolts with the specified torque.
Tightening torque: 3.0±0.4N·m
4. Check
Check the intake manifold:
(1) Check whether the intake manifold cracks, and replace if necessary.
(2) Check whether the negative pressure exhaust port is blocked, and clean if yes.
(3) Use a ruler or feeler gauge to check deformation in the cylinder head mounting surface, and
replace it if necessary.
Standard value: <0.15mm
Service limit: 0.20mm

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5. Intake Pipe and Muffler

1. Removal and installation (see Fig. 6-2)

2 3

6
8
（50N.m） 6

5 7
4
6 6
6

6 1

9
（50N.m）

10
（50N.m）

Fig. 6-2

1-sealing ring; 2- front exhaust pipe assembly; 3-rear oxygen sensor; 4-middle welded exhaust
pipe assembly;
5- rear exhaust pipe assembly; 6-rubber hanger I; 7-rubber hanger III; 8-connecting bolt I
(shank length 43mm, spring length 40mm); 9-connecting bolt II (shank length 39mm, spring length
43mm);
10. -connecting bolt III (shank length 39mm, spring length 43mm)
Notice: connecting bolt II and III are interchangeable.

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2. Remove/Install Front Exhaust Pipe 6. Remove/Install intake manifold

Assembly
1) Removal Removal Procedure
(1) Firstly remove the rear oxygen sensor on 1. Remove the intake manifold cover.
the front exhaust pipe assembly with an 2. Remove the air filter.
oxygen sensor wrench; 3. Remove the breather pipe (A), power
(2) Remove 2 connecting bolts II and spherical brake vacuum hose (B) and positive
sealing ring; crankcase ventilation (PCV) hose (C).
(3) Remove 2 connecting bolts I and spherical
sealing ring;
(4) Remove the front exhaust pipe assembly.
2) Installation
(1) Install spherical sealing rings;
(2) Tighten two connecting bolts I with a
tightening torque of 50N.m;
(3) Tighten two connecting bolts II with a
tightening torque of 50N.m;
(4) Install the rear oxygen sensor onto the front
exhaust pipe assembly with an oxygen sensor
wrench;

3. Remove/Install Front Muffler Assembly

1) Removal 4. Remove the throttle cable.

(1) Remove 2 connecting bolts III and 5. Remove the wire harness bracket and
spherical sealing ring; bolt.
(2) Remove 2 connecting bolts II and spherical 6. Remove the canister control valve
sealing ring; connecting hose.
(3) Remove 4 rubber hangers. 7. To replace the intake manifold, remove
2) Installation the throttle body.
(1) Install 4 rubber hangers and spherical 8. After the engine coolant is drained
sealing ring; completely, remove the water inlet/outlet hose
(2) Tighten two connecting bolts II with a from the throttle body.
tightening torque of 50N.m; 9. Remove the engine wire harness
(3) Tighten two connecting bolts III with a connector and wire clip from the intake
tightening torque of 50N.m. manifold.
10. Remove the intake manifold bracket and
4. Remove/Install Main Muffler Assembly then the intake manifold.
1) Removal
(1) Remove 2 connecting bolts III and
spherical sealing ring;
(2) Remove 2 rubber hangers.
(2) Remove 2 rubber hangers.
2) Installation
(1) Install 2 rubber hangers and spherical
sealing ring;
(2) Tighten two connecting bolts III with a
tightening torque of 50N.m.
5. Inspection
Check the parts and assemblies for damage
and defect (such as broken welding and crack),
and make replacement if necessary.

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Installation Procedure

1. Install the intake manifold with a new sealing washer, and then tighten the bolts and nuts by
2-3 steps in alternating pattern, starting from the innermost bolt, with a tightening torque of
25N.m.
2. Install the intake manifold bracket.
3. If the water inlet/outlet hose have been removed on the throttle body, install them properly.
4. If the throttle body is removed, install it with a new sealing washer for throttle body.
5. Install the canister control valve connecting hose.
6. Install the wire harness bracket and bolt.
7. Install the throttle cable and adjust it.
8. Remove the breather pipe, power brake vacuum hose and positive crankcase ventilation (PCV)
hose.
9. Install the air filter.
10. Install the intake manifold cover.
11. Upon completion of assembling, check whether all pipes, hoses and connectors are
connected properly.
12. If the engine coolant is drained completely, fill the coolant into the radiator again while leaving
the heater valve open to discharge the air in the cooling system.
7. Remove/Install Exhaust Manifold
1. Remove the insulation cover and bracket for the exhaust manifold, and then remove the
exhaust manifold.
2. Install the exhaust manifold and then tighten the bolts and nuts by 2-3 steps in alternating
pattern, starting from the innermost bolt.
3. Install the other parts in the reverse sequence of removal.

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Part 4 Engine Cooling System

Component Layout

Water temperature sensor

Water pump

Thermostat

Radiator fan
Radiator

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1. Check Thermostat
Replace the thermostat if it opens under the
room temperature.
To test the closed thermostat:
1. Hang the thermostat (A) in a container
filled with water, and keep the
thermometer (B) away from the bottom
and wall of the container.

3. Rotate the water pump pulley

anti-clockwise to check whether the pump can
rotate freely.
4. Check whether seal leakage occurs. It is
normal that there is a little water seepage at
the drain hole (A).

2. Fill in water, and measure the water

temperature for thermostat opening and
3. Replace Water Pump
thermostat full opening. 1. Remove the belt.
3. Measure the lift with the thermostat full 2. Drain the engine coolant.
opening. 3. Remove the water pump pulley.
Standard thermostat: 4. Remove the 5 bolts fixing the water pump
Lift: over 8.0mm and then remove the water pump.
Opening temperature: 76°C~80°C 5. Check and clean the O-ring groove and
Full opening temperature: 90°C the mating surface with the cylinder body.
6. Install the water pump with a new O-ring
2. Check Water Pump
in the reverse sequence of removal.
1. Remove the belt. 7. Clear off the overflowing engine coolant.
2. Remove the water pump pulley. 8. Refill engine coolant into the radiator, and
meanwhile discharge the air in the cooling
system with the heater valve remaining open.
4. Replace Thermostat
Removal Procedure
Remove the thermostat cover (A) and then
remove the thermostat (B).

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coolant temperature sensor and then

install the sensor.
4. Clear off the overflowing engine coolant.
5. Refill engine coolant into the radiator, and
meanwhile discharge the air in the cooling
system with the heater valve remaining
open.

Installation Procedure
1. Clear off the old sealant on the matching
surface of the thermostat cover, the bolt and
bolt holes.
2. Apply 2-3mm wide sealant along the dash
line (A).

3. Install the thermostat sealing ring (A) on

the thermostat (B), and then install the
thermostat with the pin (C) facing upwards.

4. Install the thermostat cover (D).

Notice: after assembling, wait for at least 30
minutes and then fill coolant into the engine.
5. Replace Coolant Temperature
Sensor
1. Drain the engine coolant.
2. Disconnect the coolant temperature
sensor connector and then remove the
sensor.
3. Apply the sealant on the thread on the

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Part 5 Fuel and Exhaust System

Arrange vacuum hose

Carbon canister
control valve
connecting hose

Carbon canister control valve bracket

Carbon canister control valve

PGM-FI system
Programmed fuel injection (PGM-FI) system is a multi-point sequential fuel injection system.
Crankshaft position (CKP) sensor
CKP sensor detects the engine speed and determines the ignition timing and fuel injection timing
of each cylinder.

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O-ring
Magnet

Camshaft phase (CMP) sensor

CMP sensor detects the position of the
number 1 cylinder, which is used as reference Idle stepper motor
for sequential fuel injection.

O-ring
Magnet Knock sensor
Knock control system can reduce the knock to
minimum by regulating the ignition timing.

Engine coolant temperature (ECT) sensor

ECT sensor is a resistor whose resistance
varies significantly with temperature
(thermistor). Its resistance reduces with the
increase of the coolant temperature.
Piezoelectric
ceramics element
Thermistor

Throttle position (TP) sensor

TP sensor is a potentiometer connecting to the
throttle shaft. The sensor sends variable
voltage signal to ECM/PCM according to the
Idle stepper motor change in throttle openness. TP sensor shall
Idle stepper motor (IMA) is a resistance device be replaced together with the throttle body.
controlling the idle mixture concentration.

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Element Brush holder

Brush

System description Throttle body

TP sensor

IAC valve

Positive crankcase ventilation (PCV) system

PCV valve sucks the gas leaked from the piston into the intake manifold, preventing it from
entering the atmosphere.

Vent pipe

Intake manifold PCV valve hose

PCV valve

Vapor leakage
Fresh air

Idle control system diagram

The engine idle speed is control by the idle stepper motor.
 When the engine starts, the solenoid valve is turned on for some time. The air intake is
increased so as to improve the idle speed.
 When the engine coolant temperature is low, the solenoid valve is turned on to get a higher

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idle speed. The bypass air volume is controlled according to the coolant temperature.

Throttle body Intake manifold

Intake guide Engine coolant

IAC valve
Air filter element
From
PGM-FI main
relay

Different sensors

Air intake system diagram

The system provides air supply to the engine. When the air is sucked in, the resonance chamber
in the intake pipe can further reduce the noise level.

Throttle body
Intake manifold

Intake guide
Engine coolant

Air filter element

IAC valve
From
PGM-FI main
Resonance chamber (to air filter) relay

Different sensors

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PCV system

1. Check the PCV valve (A) and hose (B) and the connections for leakage or block.

2. At idle speed, slightly press the PCV valve and intake manifold with a finger or pliers to check
whether the PCV valve is giving click sounds.
If no click sound, check the PCV valve retainer for crack or damage. If the retainer is normal,
replace the PCV valve and check again.

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Section 1 Engine Fuel System

1.1 Fuel tank

1. Removal & installation

Works before removal Works after installation
● Pump out the fuel. ● Fill fuel into the tank
● Prevent the fuel from splashing on the ● Make sure there is no fuel leakage
ground. ● Install the middle exhaust pipe
● Remove the middle exhaust pipe
1) See Fig. 7-1 for the part figure.

Fig. 7-1
1-fuel tank assembly; 2-evaporative emission hose; 3-elastic hoop; 4-anti-tilt valve assembly; 5-oil
inlet hose I assembly; 6-two hole pipe clamp; 7-oil inlet hose II assembly; 8-hexagon combination
bolt; 9-hexagon flange bolt; 10-fuel filter bracket;11-fuel filter; 12-elastic hoop; 13-fuel pump
assembly; 14-oil pump O-ring seal; 15-elastic hoop; 16-air outlet hose II; 17-air outlet pipe bracket
II; 18-refueling ventilation hard tube bracket II; 19-B type spring nut; 20-hexagon flange bolt; 21-air
outlet hose I; 22-two hole pipe clamp; 23-refueling hard tube welding assembly; 24-filler cap shield;
25-fuel filler pipe plastic jacket; 26-wire retaining ring; 27-wire retaining ring; 28-fuel tank cover
assembly; 29-bracket I; 30-hexagon combination bolt; 31-hexagon flange nut; 32-bracket II;
33-worm ring clamp; 34-oil filling hose; 35-hexagon combination bolt; 36- fuel tank band I; 37-band
protective pad I; 38-band protective pad II; 39-fuel tank band II

2 Precautions on removal of fuel tank

(1) Lift up the vehicle with a lift and support it properly. When lifting/supporting the fuel tank with a
jack, apply auxiliary support to prevent the fuel tank from toppling.
(2) The rubber pipe shall be replaced as a whole; do not repair any pipe segment.
(3) To service the fuel system, cover the attachment and plug the hold to prevent dirt and other
contaminants from entering the system from open pipeline or other passages.
(4) Keep the fuel system parts clean and in good order.

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Notice:
● Reinstall the 4 M10 bolts fixing the fuel tank, and tighten them with 40N.m tightening torque.
● Tighten the ring clamps and make replacement if necessary.
● Check and make sure the hoses are not damaged or twisted during removal and installation.
● Keep the ignition switch at ON for 2 seconds, turn it to OFF and remains for 10 seconds, then
turn it to On again, and finally check for fuel leakage.

1.2 Fuel Pump

1. Replace the fuel pump (see Fig. 7-2).
(1) Release the pressure in the fuel
system.
(2) Remove the wire harness connector
and fuel pipe.
(3) Remove the fuel pump circlip and then
the fuel pump.
(4) Install a new fuel pump, O-ring and the
circlip.
(5) Connect the fuel pipe (hose) and wire Fig. 7-3
harness connector.
2. Replace the fuel filter.
Remove the fuel filter.
Oil return pipe (1) Discharge the pressure in the fuel system.
(2) Collect the fuel in a proper container.
(3) Take out the fuel filter from the bracket. The
disassembled fuel filter is shown in Fig. 7-3.
Notch
High
pressure 3. Install the fuel filter
oil pipe (1) Remove the protection cover of a new fuel
filter.
(2) Slowly insert the fuel filter into the bracket,
Wire harness socket Power fuel pump and tighten the bracket bolts.
(3) Connect the fuel hoses on both ends of the
fuel filter in the fuel circuit.
(4) Tighten the fuel filler cap of the fuel tank.
(5) Reconnect the battery negative cable.
(6) Keep the ignition switch at ON for 2 seconds,
Fig. 7-2 turn it to OFF and remains for 10 seconds,
then turn it to On again, and finally check for
fuel leakage.
Notice
The notch of the power fuel pump shall be aligned to the notch on the fuel tank.
Replace a new O-ring seal for the oil pump before the fuel pump is reassembled.

4. Removal/installation of nylon tube

(1) Before the nylon tube is disconnected, check whether there are dirt and other foreign
matters near the nylon pipe fittings, and clean if yes.
(2) Press the right and left ends of the joint, and gently pull back. See Fig. 7-4
(3) Check whether the connector of the nylon tube is damaged or has dirt and other foreign
matters before assembling.
(4) If everything is normal, connect the nylon tube connector to the male connector along a
linear direction, until a ―click‖ is heard. See Fig. 5

181
BYD AUTO BYD NEW F3 Maintenance & Repair Manual

Fig. 7-4

Fig. 7-5

Notice
After install the high pressure nylon pipe, pull it slightly to the opposite direction to
make sure it is installed firmly; and make sure there is 3mm clearance.

182
 Chapter 4 483QA/QB Engine

Contents
Part 1 Gasoline Engine ........................................................................................................... 184
Section 1 Engine Overview .............................................................................................. 184
1.1 Main Parameters .................................................................................................. 184
1.2 Service Technical Data ......................................................................................... 185
1.3 BYD483QA/QB Gasoline Engine Tightening Torque Chart .................................... 187
Section 2 Drive Belt ......................................................................................................... 188
2.1 Drive Belt Tension Inspection ................................................................................ 188
2.2 Drive Belt Adjustment ........................................................................................... 188
Section 3 Valve Clearance ............................................................................................... 188
3.1 Valve Clearance Inspection .................................................................................. 188
3.2 Valve Clearance Adjustment ................................................................................. 189
Section 4 Compression Pressure Inspection .................................................................... 190
Section 5 Timing Belt ....................................................................................................... 191
Section 6 Cylinder Head Gasket Assembly ...................................................................... 194
Section 7 Crankshaft Front Oil Seal ................................................................................. 196
7.1 Crankshaft Front Oil Seal Replacement ................................................................ 196
7.2 Crankshaft Front Oil Seal Removal Instructions .................................................... 196
7.3 Crankshaft Front Oil Installation Instructions ......................................................... 196
Section 8 Crankshaft Rear Oil Seal .................................................................................. 196
Part 2 Lubrication System ....................................................................................................... 198
Section 1 Gasoline Engine Lubrication Circuit Schematic Drawing ................................... 198
Section 2 Oil Pressure Inspection .................................................................................... 199
Section 3 Gasoline Engine Oil ......................................................................................... 199
3.1 Oil Inspection........................................................................................................ 199
3.2 Oil Change ........................................................................................................... 199
Section 4 Oil Filter ........................................................................................................... 200
Section 5 Oil Pan ............................................................................................................. 200
Section 6 Oil Pump .......................................................................................................... 201
6.1 Oil Pump Installation and Removal ....................................................................... 201
6.2 Oil Pump Disassembly/Assembly ......................................................................... 203
6.3 Oil Pump Inspection.............................................................................................. 203
Part 3 Cooling System ............................................................................................................ 204
Section 1 Gasoline Engine Cooling System Schematic Drawing ...................................... 204
Section 2 Thermostat ....................................................................................................... 205
2.1 Thermostat Removal and Installation .................................................................... 205
2.2 Thermostat Inspection .......................................................................................... 205
Section 3 Water Pump ..................................................................................................... 205
Part 4 Flywheel ....................................................................................................................... 206
Section 1 Flywheel Removal ............................................................................................ 206
Section 2 Flywheel Inspection.......................................................................................... 206
Part 5 Engine Fuel System ..................................................................................................... 207
Section 1 Fuel Tank ......................................................................................................... 207
Section 2 Fuel Pump ....................................................................................................... 208

183
Part 1 Gasoline Engine
Section 1 Engine Overview
BYD483QA-4 gasoline engine applies electronic fuel injection system with advanced
self-diagnosis function. This injection system features multi-port sequential injection and achieves
high power, lower fuel consumption, low noise, less emissions and compact construction.

BYD483QA-4 gasoline engine can operate optimally under any condition. This ensures the vehicle
with reliable security, comfortable drivability, best fuel economy and environment-friendly
performance.

1.1 Main Parameters

Type
Paramete
r BYD483QA-4
Item
4-Cylinder, in line, water-cooled, double overhead camshaft,
Type 16-valve, 4-stroke
Closed loop electronic fuel injection gasoline engine
Rated power 90kW（6000r/min）
Max.torque/speedometer 160N·m/（3700～4200）r/min
Min.fuel consumption ≤285g/kW·h
Bore×stroke 83mm×85mm
Displacement 1.839L
Compression ratio 9.3
Valve mechanism Synchronized belt drive, 16-valve DOHC
Combustion chamber type Pent roof
Fuel type Octane No. 93 or higher (Research)
Idle speed （750±50）r/min
Cylinder compress
1.2～1.5MPa（400r/min）
pressure
Fuel supply Electronic sequential multiport fuel injection
Injection pressure
(differential pressure
300kPa
before and after the
ignition)
Ignition order 1—3—4—2
Ignition timing 0°±1°when idling
Lubricating method Forced and splash lubrication
SG 10W-30 (For four seasons in the South and Summer in
Engine oil the North)
SG 5W-30 (For Winter in the North)
Exhaust emission system Two-level three-way catalytic converter
Oil pressure 300～490kPa （3000r/min）
Gasoline engine mass 120kg
Dimension (length × width 600mm×610mm×630mm

184
 × height)
Emission regulation ChinaⅣ

1.2 Service Technical Data

Item Standard Limit value

0.019
Cylinder diameter φ83 0
mm 83.024mm
Cylindricity 0.008mm 0.012mm
Cylinder block Top flatness 0.025/100 0.06mm
Verticality 0.025/100 0.06mm
Cylinder compression 1.08 MPa/（400
1.2～1.5 MPa/（400 r/min）
pressure r/min）
0.026
Piston skirt diameter φ83 0.046
mm
0.011
Piston Piston pin hole diameter φ19  0.005
mm
Mating clearance of the piston
0.036～0.056mm
and cylinder
0
Piston pin diameter φ19  0.006
mm
Piston pin
Mating clearance of the piston
0.005～0.017mm
pin and piston
Piston ring 1st Compression ring 0.20～0.35mm 0.70mm
opening 2nd Compression ring 0.25～0.40mm 0.70mm
clearance Oil ring assembly 0.20～0.70mm 1.00mm
Piston ring side Compression ring (1st, 2nd ) 0.04～0.08mm 0.12mm
clearance Oil ring 0.06～0.18mm 0.23mm
Allowable twist limit 0.05 mm (per 100 mm)
Allowable bent limit 0.05 mm (per 100 mm)
Connecting rod small end hole 0.019
Connecting rod diameter φ19 0.037 mm
Piston pin and connecting rod
Magnitude of interference fit 0.013～0.037mm
range
0.045
Main journal diameter φ56  0.063
mm
Connecting rod journal 0.045
φ48  0.060 mm
diameter
Journal Cylindricity 0.005mm
Crankshaft Crankshaft radial circular
0.03mm
run-out
Connecting rod big end axial
0.160～0.264mm
clearance
Crankshaft thrust clearance 0.06～0.23mm
Flywheel axial circular run-out 0.2mm ≤0.7 mm
Cylinder head lower surface
0.04mm 0.10mm
Cylinder head flatness
Manifold joint face flatness 0.06mm 0.10mm

185
 Cylinder head camshaft bore 0.021
φ26 0 mm
diameter
Cylinder head bolt length 104.2～104.8 mm 105.5mm
Camshaft journals diameter φ26 mm
0.028
Camshaft journal Cylindricity φ26  0.041
mm
Camshaft Gap between the camshaft
0.028～0.062mm 0.10mm
journal and shaft hole
Camshaft axial clearance 0.072～0.126mm 0.15mm
Intake valve diameter 31.5±0.01mm
Exhaust valve diameter 27.6±0.01mm
0.015
Valve stem diameter φ6 0.030
mm
0.03
Valve guide inner diameter φ6  0.01
mm
Valve system
Gap between the valve stem
0.025～0.060mm 0.080mm
and valve guide
Valve spring free length 44mm
Intake and exhaust valve
0.26±0.03mm
clearance (cold)
3.04mm ～ 3.68 mm(0.02mm
Adjust the specification of valve clearance
gasket differentials among adjacent
groups)
Stroke
Thermostat initial and full open temperature 82±2℃,fully open 95℃
9±0.5mm
K6RTC ,0.8～0.9 mm
Spark plug type and gap
3923-8，0.8～0.9 mm
Generator belt tension deformation 98N·m,press 6～9mm
Power steering pump and compressor tension
98N·m,press6～9mm
deformation
Loctite 587
Flat sealant type
Tianshan 1596F

186
1.3 BYD483QA/QB Gasoline Engine Tightening Torque Chart

No. Part name Tightening torque (N·m)

First:18～22
1 Cylinder head bolt Second: +85°～95°
Third: +85°～95°
2 Spark plug 25～30
3 Intake manifold bolt 21～25
4 Exhaust manifold bolt 25～30 (Twice)
5 Camshaft pulley bolt 45～55
6 Crankshaft pulley bolt 122～149
First:22～27
7 Connecting rod bolt
Second: +85°～95°
First:18～22
8 Main bearing cap bolt
Second: +85°～95°
9 Flywheel bolt 86～103
10 Drain plug 45～55
11 Cylinder head cover bolt 9～11 (Twice)
12 Tensioner pulley bolt 45～55
13 Oil pump set bolt 21～25
14 Throttle set bolt 21～25
15 Knock sensor set bolt 21～25
16 Oil filter 25～30
17 Oil pressure siren 15～20
18 Water temperature sensor 25～30

19 Generator hanger bolt 45～55

20 Generator pretension bolt 21～25

21 Cam bearing cap bolt 12～14
22 Skirt rack bolt 21～25

187
Section 2 Drive Belt
2.1 Drive Belt Tension Inspection
Measure the belt tension of drive belt at the
measuring point marked in the diagram below.
The measured value of the old and new belt
should be within the specification as shown in
the table below.
3. Measure the valve clearance.
Measuring Firstly, rotate the crankshaft clockwise to make
Generator
point the piston up to the 1st cylinder TDC.
Dynamometer
Water pump Secondly, measure the valve clearance at the
point A as shown in the illustration. If it
exceeds the clearance specification, replace
the adjusting gasket.
Standard valve clearance (Cold gasoline
engine)
Measuring Intake valve (IN): 0.23 mm～0.29 mm
Exhaust valve (EX): 0.23 mm～0.29 mm
Crankshaft pulley Thirdly, rotate the crankshaft 360º clockwise to
make the piston up to the 4th cylinder TDC.
Drive belt New belt Old belt Fourthly, measure the valve clearance at the
(N) (N) point B as shown in the illustration. If it
Generator + water 750～800 450～550 exceeds the clearance specification, replace
pump the adjusting gasket.

2.2 Drive belt adjustment

1. Loosen the bolt A and B as shown in the
above illustration.
2. Adjust the belt tension within the
specification as shown in the above table by
adjusting bolt C.
3. Tighten the bolt A and B (Tightening torque:
21 N·m～25 N·m) 4. Install the cylinder head cover.
Notice: Firstly, ensure there is no oil, water or other
·If a new belt or the drive belt that operates for foreign materials in the groove of cylinder
less than 5 minutes should be replaced, adjust head cover.
it to the standard extent as a new one. Secondly, check if the cylinder head cover
·If the drive belt that operates for more than 5 gasket is in good condition, and press it in
minutes should be replaced, adjust it to the place.
standard extent as an old one. Thirdly, remove the sealant in the area shown
in the illustration below, and apply Loctite 5699
Section 3 Valve Clearance flat sealant to the seal surface again.

3.1 Valve Clearance Inspection

1. Confirm that gasoline engine has cooled
down.
2. Remove the cylinder head cover.
Firstly, Remove the engine ignition coil,
high-tension pole and connected wires.
Secondly, remove the cylinder head cover
bolts in the order shown in the illustration
below.

188
 Loctite 5699

Bolt A

Loctite 5699

Fourthly, install the cylinder head cover. Align

the installation of cylinder head stud bolt with
the cylinder head cover, and ensure the head
cover contact with sealing area over the front
head cover component (upper). Then press
the cylinder head cover downward lightly to 4. Tighten the bolt A, press the tappet and
contact closely with the cylinder head and the remove the original gasket with nipper.
front head cover component (upper). Tighten
the cylinder head cover bolts (Tightening
torque: 9～11 N·m) in 2 to 3 times in the order
given in the illustration below, and recheck the
torques of bolts in the following order shown in
the illustration.
Bolt A

5. Choose an appropriate adjusting gasket.

3.2 Valve Clearance Adjustment New gasket thickness = used gasket thickness
This procedure is for all the valves that + measured valve clearance – standard valve
need to adjust the clearance. clearance (0.26 mm)
1. Rotate the camshaft clockwise to turn the 6. Put the adjusting gasket into valve tappet.
peach-tip of the camshaft upward and hold
it at a suitable position for adjustment, then 7. Loosen the bolt A for the favor of valve
adjust the tappet opening to the inside of tappet movement.
the cylinder head. 8. Loosen the bolt securing the special tool
2. Unscrew 1 bolt on the outside of camshaft and remove the special tool.
cap. 9. After removing the special tool, retighten
Note: As long as you remove the bolt the cam bearing cap bolt. Tightening torque:
outside of corresponding camshaft cap, 12 N•m - 14N•m.
the gasket can be replaced accordingly. 10. Check the valve clearance according to
3. Press the valve tappet with the special tool 1.3 in this section.
eject-rod and secure the special tool on Caution: When pressing the valve tappet, it is
the camshaft cap with bolt which removed possible to damage the cylinder head.
recently.

189
Section 4 Compression Pressure Inspection
Warning: Oil temperature is very high when the gasoline engine is hot. Be careful not to be burnt
when installing and removing the components.

1. Confirm that the battery has been fully charged.

2. Warm up the engine to the normal operating temperature.
3. Stop and cool the gasoline engine for 10 minutes.
4. Remove the fuel pump relay according to ‖OIL PATH SAFETY INSPECTION PROCEDURE‖.
5. Remove the No.1 cylinder spark plug.
6. Disconnect all the ignition coil connectors.
7. Connect a compression gauge into the No.1 cylinder spark plug hole.
8. Depress the accelerator pedal to the end and start the gasoline engine.
9. Start the gasoline engine and record the max. readings of the compression gauge.

10. Inspect the compression pressure of No.2, No.3 and No.4 cylinder in succession according to
step 5 to 9. If the pressure of one or more cylinders are too low, or the differential pressure
between the cylinders exceeds the specified value largely, drop some gasoline engine oil inside
and recheck the pressure:

-- If the compression pressure increases, the piston, piston ring and cylinder wall may be worn. It
is necessary to overhaul.
-- If the pressure of the adjacent cylinder is low, the cylinder gasket was damaged or the cylinder
head was deformed. It is necessary to overhaul.
-- If the compression pressure is still low, the valves may be stuck or the seal surface has a poor
contact. It is necessary to overhaul.

Item Compression pressure

Standard 1.2～1.5 MPa (400 r/min)

Min. limit 1.08MPa（400r/min）

Differential pressure max. limit between each cylinder 200kPa

11. Remove the compression gauge.

12. Connect the ignition coil.
13. Install the fuel pump relay.
14. Install the spark plug. Tightening torque: 25 N•m.

190
Section 5 Timing Belt
Overview of timing belt removal and installation

1. Disconnect the battery negative cable.

2. Remove the camshaft phase sensor (CMP).
3. Remove the ignition coil and spark plug.
4. Remove each component in the order shown in the illustration.
5. Adjust the belt deformation/tension.
6. Perform the installation in the reverse order of the removal.
7. Start the gasoline engine and check the connection of tensioner pulley, guide pulley and drive
belt.

Timing belt

Cylinder head cover

Oil dipstick and oil

dipstick sleeve weld
assembly Timing pulley
end head

Front head cover

assembly (upper
and lower) Damping
pulley parts
Tensioner spring

Water pump Tensione

pulley r

Drive pulley Loctite 587

Guide pulley

191
Damping pulley components installation spring, which should be ≤36.2mm. If the
instruction value is not within the specified range,
Lock the flywheel with the special tool, then replace the tensioner pulley spring.
remove the damping pulley.
Notice: Do not tap the outer ring of damping
pulley during removing. Tensioner
Tensioner pulley spring
pulley side pin side

1. Install the tensioner pulley.

2. Rotate the tensioner pulley. If there is no
resistance or it can not rotate, replace the
pulley.
Timing belt installation instruction
1. Make sure to align the timing belt mark
with the camshaft pulley mark as shown in
the illustration.

Inlet side Outlet

side

Cylinder head cover removal instruction

For the cylinder head cover removal, please
follow the step 1.2 in SECTION Ⅲ.
Timing belt removal instruction
1. Install the crankshaft pulley bolt. 2. Install the timing belt and press it to the
2. Turn the crankshaft clockwise and mark the tensioner pulley firmly.
timing mark as shown in the illustration below. 3. Rotate the timing belt clockwise for two
3. Rotate the tensioner pulley clockwise with circles and align it with the timing mark.
socket and wrench. 4. Strain the tensioner pulley spring properly
4. Remove the tensioner pulley spring. and rotate the tensioner clockwise with the
Notice: It will damage the belt or shorten its wrench as shown in the illustration.
service life by winding the belt firmly or if it is 5. Rotate the timing belt clockwise for two
adhered with oil or grease. circles and
Note: For correct reinstallation, mark the make sure all of the timing marks are aligned
rotating direction on the timing belt when perfectly. If not, remove the timing belt and
removing. reinstall from the first procedure..

Tensioner pulley and tensioner pulley spring

installation instruction:
Measure the free length of tensioner pulley

192
 Align the location pin sleeve of front head
cover (upper) to the cylinder head location
pin hole, and keep the seal surfaces contact
Guide pulley properly with the front head cover (lower),
then tighten the bolt with the torque 8-10
N·m.

Damping pulley components installation

instruction
Lock the flywheel with the special tool, then
install the damping pulley and crankshaft
pulley bolt torque: 122-149 N•m.

6. Tighten the camshaft pulley bolt, guide pulley

bolt, or recheck the torque of tensioner pulley
bolt (torque: 45-55 N·m).
Drive belt installation instruction
For the drive belt installation, please follow
the instruction in SECTION Ⅱ DRIVE BELT.
Water pump pulley installation instruction
Install the water pump pulley with the ―F‖
mark facing outward.
Notice: After installing the drive belt (engine
belt), tighten the water pump pulley bolt.
Torque: 9-11 N·m.

7. Tighten the camshaft pulley bolt, guide pulley

bolt, or recheck the torque of tensioner pulley
bolt (torque: 45-55 N·m).

Front head cover (lower) installation

instruction
Align the location pin sleeve of front head cover
(lower) to the engine location pin hole, and keep
the seal surfaces contact properly, then tighten
the bolt with the torque 8-10 N·m.
Front head cover (upper) installation
instruction

193
Cylinder head cover installation Camshaft pulley removal instruction
instruction For the removal, lock the hexagon strut on
For the cylinder head cover installation, please the camshaft with wrench as shown in the
follow the step 1.4 in SECTION Ⅲ. illustration.

Section 6 Cylinder Head Gasket

Assembly
Cylinder head gasket assembly replacement
Warning:
For the fuel vapor is easy to catch fire, keep
away from the spark or flame.
Fuel leakage or splash will result in skin burn
and eye damage. To avoid this situation, please
follow the fuel safety inspection procedure for Camshaft removal instruction
fuel and emission control system. Loosen the camshaft bearing seat bolt in 2 or
1. Remove the timing belt. 3 times in the order given in the illustration
2. Remove the front exhaust pipe. below.
3. Remove the air filter.
4. Remove the power steering oil pump and
bracket; Do not release the oil pipe.
5. Remove the accelerator cable.
6. Remove the fuel hose.
7. Drain the gasoline engine coolant.
8. Perform the removal in the order indicated in
the illustration below.
9. Perform the installation in the reverse order
of the removal.
10. Check the gasoline engine oil level.
11. Check the cylinder compression pressure.
12. Start the gasoline engine. Cylinder head removal instruction
(1) Check the run-out and contact condition of Loosen the cylinder head bolt in 2 or 3 times
pulley and drive belt. in the order given in the illustration below.
(2) Check the gasoline engine oil and coolant for
leak.
(3) Check the idling speed.

Camshaft pulley

Loctite 5699 Intake and

Cylinder exhaust
head camshaft

Cylinder head installation instruction

1. Measure the bolt length of each cylinder
head. If it exceeds the standard value,
Cylinder head please replace it.
Intake manifold
gasket assembly
support Standard length: 104mm-104.6 mm
Max. length: 105.5 mm

194
 Loctite 5699

Loctite 5699

2. Tighten the cylinder head bolts in the order

Loctite 5699
given in the illustration below. First tightening
torque: 20±2 N·m.
4. Apply appropriate oil on the camshaft
and bearing seat.
5. Install the rest camshaft bearing caps.
6. Tighten the bolt 1, 2, 11, 12 marked on
the camshaft manually.
7. Tighten the camshaft bolts in 2 to 3 times
in the order given in the illustration below.
8. Confirm the camshaft levelness before
tightening the No.3 camshaft bearing cap
bolt.
9. Add the clean oil to the camshaft oil
3. Mark on each bolt head. groove.
4. Tighten the bolt for the second time as
shown in the illustration and take the marks as a
reference. Rotate 90º±5º.

Step 2

Mark
Step 1

10. Install the oil seal manually whose lip is

applied with gasoline engine oil.
11. Press the oil seal with the special tool and
5. Rotate 90º±5º for the third time. hammer.
Camshaft installation instruction
Caution: For the camshaft installation clearance
Cylinder head
is so small, ensure its levelness when installing.
Otherwise, the contact surface between shaft Hammer
and bearing will generate noise for the reason of
high pressure. Please observe the procedures
below to avoid the situations occur.
1. Install the camshaft into the cylinder head.
2. Install the camshaft bearing cap.
3. Apply the sealant on the areas shown in the
illustration. Pay attention to that the sealant
diameter is Φ1 mm-Φ2 mm, it is even and Special tool
Camshaft oil seal
continuous. Make sure the camshaft surface is
clean to avoid gasoline engine damage.
Camshaft pulley installation instruction
1. Install the camshaft pulley. Place the
location pin on the location shown in the
illustration.

195
 Position pin
7.2 Crankshaft Front Oil Seal
Removal Instructions

1. Cut off the oil seal edge with blade.

2. Remove the oil seal with screwdriver
wrapped with rag.

2. Lock the camshaft and tighten the camshaft

pulley bolt with wrench as shown in the
illustration. Torque: 45-55 N·m.

Oil seal edge

Rag

7.3 Crankshaft Front Oil Installation

Instructions
1. Apply appropriate clean gasoline engine
oil on the oil seal lip.
2. Install the oil seal manually.
3. Press the oil seal with the special tool
and hammer.

Oil pump
Section 7 Crankshaft Front Oil Hammer
Seal
7.1Crankshaft Front Oil Seal
Replacement

1. Remove the timing belt.

2. Perform the removal in the order shown in
the illustration. Special tool
3. Perform the installation in the reverse order Front oil seal
of the removal.

Section 8 Crankshaft Rear Oil

Seal
Gasoline engine disassembly/assembly
1. Disconnect the connection between the
gasoline engine and transmission case.
Front oil seal Remove the air intake system.
2. Remove the exhaust system.
3. Remove the oil filter.
Key
4. Remove the thermostat.
Crankshaft 5. Remove the ignition coil.
timing gear 6. Remove the generator.
7. Perform the disassembly in the order
shown in the illustration.
Perform the assembly in the reverse order of

196
the disassembly. Rear oil seal
Hammer
cap
Heating return pipe

Generator
bracket

Steering
SST
pump Compression Outlet pipe
Rear oil seal
bracket bracket connector
Thermostat

Crankshaft rear oil seal replacement

1. Remove the flywheel.
2. Perform the removal as shown in the
illustration.
Perform the installation in the reverse order of
the removal.

Rear oil seal

Crankshaft rear oil seal removal instructions

1. Cut off the oil seal lip with blade.
2. Remove the oil seal with screwdriver
wrapped with rag.

Rag

Crankshaft rear oil seal installation

instructions
1. Apply appropriate clean gasoline engine oil
on the oil seal lip.
2. Install the oil seal manually.
3. Press the oil seal with the special tool and
hammer.

197
 Part 2 Lubrication System
Section 1 Gasoline Engine Lubrication Circuit Schematic Drawing

Cylinder block main oil path

Cylinder head
Main bearing oil path
By-pass valve

Pressure
limited
Oil filter valve
Connecting rod Injection cooled
bearing piston Camshaft hole

Check valve Tappet hole

Piston
ring Camshaft bearing
Relief valve

for each gear

Oil pump
Piston pin
boss

Oil collector Oil pan

198
Section 2 Oil Pressure 9. Install the oil pressure siren.
Tightening torque: 15-20 N•m
Inspection 10. Install the intake pipe bracket.
Warning: 11. Start the gasoline engine and check for
The oil temperature of the hot engine is very the oil leak.
high. It is easy to be scalded. Start the work
after stopping and cooling the engine.
1. Remove the intake pipe bracket. Section 3 Gasoline Engine Oil
2. Remove the oil pressure siren.
3. Install the special tool to the oil pressure 3.1 Oil Inspection
siren installation hole. 1. Park the vehicle on a level surface.
2. Warm up the engine to the normal
operating temperature, and then stop.
3. Wait for 5 minutes.
4. Pull out the oil dipstick and examine the oil
level and oil condition. Check if the oil level is
between FULL and LOW.
5. Add or change the engine oil as required.
6. Check if the O-ring on the oil dipstick tip is
in good condition.
7. Reinsert the oil dipstick.
3.2 Oil Change
SST Warning:
﹡The oil temperature of the hot engine is very
high. Be careful not to be scalded.
4. Warm up the gasoline engine to the ﹡If the vehicle is not raised to the safe
normal operating temperature. location, it will drop off and result in death.
5. Increase the gasoline engine speed to Thus, it is forbidden to work under or around
the specified value, and pay attention to the the vehicle if it is not supported perfectly.
readings on the oil pressure gauge. ﹡Wash your skin with a soap and clear water
﹡If the pressure is not as specified, find out as the old oil will cause cancer.
the cause and repair or replace as required. 1. Park the vehicle on a level surface.
Notice: 2. Remove the oil filler cap and drain plug.
﹡Oil pressure varies according to the 3. Drain the oil into a proper container.
viscosity and temperature. 4. Install the oil drain plug with a new washer.
Oil Pressure: 300-490 kPa [3,000 r/min];Water Tightening torque: 35-45 N•m
temperature: 83℃～93℃/h 5. Add the engine oil with specified type and
6. Stop and cool the gasoline engine. volume into the engine again.
7. Remove the special tool. 6. Reinstall the oil filler cap.
8. Apply sealant to the oil pressure siren 7. Start the gasoline engine and check for the
thread evenly as shown in the illustration oil leak.
below. 8. Check the gasoline engine oil level and
add oil as required.
Notice:
﹡In some cases, the oil mass filled according
to the oil level differs from the specified actual
mass.

Item Capacity (L)

Oil change 3.0
Oil and oil filter change 3.3

Loctite 5699 Gasoline engine oil grade SG or higher:

199
Oil viscosity choice standard Oil grade Oil pan removal instructions
SG 1. Remove the oil pan bolt.
Above -25℃ 2. Remove the sealants on the thread.
10W-30
-30℃-37℃ SG 5W-30 3. Screw a bolt in the welded nut, leave a
narrow clearance between the oil pan and
floor.
Section 4 Oil Filter
Oil filter replacement
1. Remove the oil filter with the special tool.

Welded nut

SST 4. Remove the oil pan with a remover.

2. Wipe off the oil filter surface with a piece of Remover

clean cloth.
3. Install the oil filter firmly according to the
instruction procedure on the filter or packing
case. Torque: 25-30 N·m.
4. Start the gasoline engine and check for the
oil leak.
5. Check the oil level. Add oil if necessary.

Section 5 Oil Pan

Oil pan installation and removal
1. Disconnect the battery negative. Oil pan installation instructions
2. Drain the oil. Caution:
3. Remove the front pipe. ﹡Remove the sealants on the used thread
4. Perform the removal in the order shown in when reusing. The used sealants will damage
the illustration below. the bolt hole.
5. Perform the installation in the reverse
order of the removal. Crack
6. Start the gasoline engine and check for the
oil leak.

Used sealants

1. Wipe off the sealants on the oil pan and

bolt.
2. Apply continuous sealants around the
inside of the oil pan bolt hole, with the tip
overlapped.

200
 Diameter Φ2.0-Φ3.0 mm
Front oil seal

Oil pan

Loctite 5699
O-ring
Oil pump
Loctite 5699

Loctite 5699

Install the oil pump and tighten the bolt (Torque:

21-25 N·m) in 2 to 3 times in the order given in Oil collector
the illustration below. Then recheck the torque washer
value. Skirt rack

Oil collector

Skirt rack removal instructions

Remove 2 bolts behind the cylinder block.
Loosen the skirt rack bolts in 2 to 3 times in the
order given in the illustration below.

Section 6 Oil Pump Bolt

6.1 Oil Pump Installation and Removal

1. Remove the timing belt.
2. Remove the oil pan.
3. Remove the transmission case.
4. Perform the removal in the order shown in
the illustration below. Remove the skirt rack with remover.
Perform the installation in the reverse order of
the removal.

Remover

Oil pump removal instructions

Remove the front oil seal with screwdriver

201
wrapped with clean rag. Loctite 5699

Loctite 5699

Tighten the skirt rack bolts (Tightening torque:

21-25 N·m) in 2 to 3 times in the order given in
Oil pump installation instructions the illustration below. Finally tighten the bolt A:
1. Apply the clean oil on the outer oil seal. 9-11 N·m.
2. Install the oil seal manually.
3. Press in the oil seal evenly with the special
tool.

Hold-down
SST Device

Oil pump
Front oil seal

Oil collector installation instructions

1. Install the oil collector washer as shown in
4. Apply the sealants to the oil pump edge the illustration.
evenly as shown in the illustration.
Thickness: Φ1.0-Φ2.0 mm

Loctite
5699

In the oil pan

Tighten the bolt as shown in the illustration:

5. Install the oil pump. 9-11 N·m.
Tightening torque: 21-25 N·m

Skirt rack installation instructions

Apply the sealants to the skirt rack evenly
as shown in the illustration.
Thickness: Φ2.0-Φ3.0mm

202
 Max. pump clearance: 0.226 mm
Standard side clearance: 0.035-0.095 mm
Max. side clearance: 0.14 mm

6.2 Oil Pump Disassembly/Assembly

1. Remove the oil pump.
2. Perform the disassembly in the order
shown in the illustration.
3. Install in the reverse order of the
disassembly.

Front cover

Oil pump
cover plate
Outer rotor
Inner rotor
Pressure limited
valve element
Pressure limited
valve element Pressure limited valve spring inspection
Apply pressure to the spring and inspect its
6.3 Oil Pump Inspection height. Replace the spring if necessary.
Pressure: 97.7-107.4 N·m
1. Measure the clearance below. Replace the
Standard height: 33.50 m
rotor or pump if the value is not as specified.
Standard teeth end clearance: 0.130-0.206
mm
Max. teeth end clearance: 0.30 mm

Standard pump clearance: 0.113-0.186 mm

203
Part 3 Cooling System
Section 1 Gasoline Engine Cooling System Schematic Drawing
Gasoline engine cooling system in the whole vehicle pipe line system is as follow :

The coolant pumped by the water pump flows into the cylinder block from the front side and then
into the cylinder head. And it flows out from the cylinder head rear end. The thermostat (opening
temperature is 82℃) is mounted on the water pump inlet. The coolant refilled from the middle of the
cylinder block front side flows in left and right line along the water cavity of the cylinder block
vertically，one line flows vertically and the other flows up to the cylinder head. The coolant from
exhaust side to cylinder head will cool down the 2 exhaust pipes. Then it will be divided into two
parts, one part cools down the cylinder spark plug and the rest conflows to the vertical lines of
spark plug both sides in next cylinder. The coolant from intake side to cylinder head will cool down
the two intake pipes. Then it will be divided into two parts, one part cools down the cylinder spark
plug and the rest conflows to the vertical lines of spark plug both sides in next cylinder. The coolant
to the cylinder head will flow laterally at first. After conflowing into the central path from the intake
and exhaust sides, the coolant will flow vertically.

From the engine bottom

Fluid pressure power steering system

Add water
Power steering reservoir

Heater
Warm air outlet water

Expansion
Warm air tank
Cylinder head

Inlet water
Cylinder Water
pipe
A
/
C
Water Thermostat
Power steering pump pump Steel tube

Hose
Compressor

Water tank Vapor pressure relief hose

A/C radiator

204
Section 2 Thermostat Annual seal convex

2.1 Thermostat Removal and

Installation
1. Disconnect the battery negative cable.
2. Remove the breather tube.
3. Drain the coolant.
4. Perform the removal in the order shown in
the table.
5. Perform the installation in the reverse
order of the removal. Thermostat seat side

2.2 Thermostat Inspection

Inspect the thermostat as follow. If it is not as
specified, replace the thermostat.
- Close the valve under room temperature
Thermostat - Warm up and open the valve
cap

Thermolator Item Gasoline

engine
Open temperature (℃) 82±2
Tank lower pipe
Full open temperature (℃) 95
Full open stroke (mm) ≥9
Thermostat installation instructions
1. Make sure the locking notches on the
movable pin and gasket are aligned as shown Section 3 Water Pump
in the illustration.
2. Align the locking notch on the gasket, Water pump removal and installation
install the thermostat on its seat.

Convex

Movable
pin
Water pump

Thermostat installation precautions Power steering

Align it with the new grommet on the pump regulator
thermostat seat installing annular sealing
convex.
1. Remove the timing belt.
2. Drain the gasoline engine coolant.
3. Perform the removal in the order shown in
the table above.
4. Perform the installation in the reverse
order of the removal. Tightening torque: 21-25
N·m.

205
Water pump installation precautions sealant on its thread before installing the
Install a new grommet, pay attention to keep bolt.
the grommet with annular sealing convex face 3. Pre-tighten the flywheel lock bolt
the water pump. manually.
4. Install the special tool on the flywheel
(shown in the illustration).
Annual seal convex 5. Tighten the lock bolt gradually in the cross
sequence. Torque: 86-103 N·m.

Water pump side

Part 4 Flywheel

Section1 Flywheel Removal

Lock the flywheel with the special tool Pilot bearing installation instructions
1.
(shown in the illustration). NOTICE: Install the pilot bearing according to
Remove the installation bolt evenly in the the instructions below.
2.
Installation depth of pilot bearing: 0-0.4 mm
cross sequence.
3. Remove the flywheel.
Section2 Flywheel Inspection
1. Install dial gauge on the cylinder body.
2. Measure the flywheel axial circular
run-out. If it is not as specified, please
replace the flywheel.
Axial circular run-out: ≤0.7mm

Flywheel installation instructions

1. Install the flywheel on the crankshaft.
2. Clean the thread and hole and apply the

206
Part 5 Engine Fuel System

Section1 Fuel Tank

1. Removal & installation
Works before removal
● Pump out the fuel.
● Prevent the fuel from splashing on the ground.
●Remove the secondary exhaust pipe.

Works after installation

● Fill fuel into the tank
● Make sure there is no fuel leakage
● Install the secondary exhaust pipe.

（1）. See Fig. 5-1 for parts.

Fig.5-1
1－Fuel tank assembly;2－Fuel vapor exhaust hose 3－Elastic hoop;4－Anti-tilt valve assembly;5－
Inlet oil hose I assembly;6－Two hole clip clamp; 7－Inlet oil hose II assembly; 8－Hexagon combined
bolt;9 － Hexagon flange bolts;10 － Fuel filter bracket;11 － Fuel filter;12 － Circlip;13 － Fuel pump
assembly;14－Fuel pump O ring;15－Elastic hood;16－Oil filler outlet hose II;17－Oil filler outlet pipe
bracket II; 18－Oil filler ventilation rigid tube bracket II; 19－B spring nut;20－Hexagon flange bolts;21
－Oil filler outlet hose I; 22－Two hole clip clamp; 23－Oil filler rigid tube welded assembly;24－Oil filler
shield;25－Oil filler pipe plastic jacket; 26－Wire retainer ring; 27－Wire retainer ring; 28－Fuel tank
head assembly; 29－Bracket I;30－Hexagon combined bolt;31- Hexagon flange bolt；32-Bracket
II;33-Worm clamp;34-Oil filler hose；35- Hexagon combined bolt；36-Fuel tank fixing band I; 37-Fixing
band fender I; 38-Fixing band fender II; 39-Fuel tank fixing band II.

207
2 Precautions on removal of fuel tank
(1) Lift up the vehicle with a lift and support it properly. When lifting/supporting the fuel tank with a
jack, apply auxiliary support to prevent the fuel tank from toppling.
(2) The rubber pipe shall be replaced as a whole; do not repair any pipe segment.
(3) To service the fuel system, cover the attachment and plug the hole to prevent dirt and other
contaminants from entering the system from open pipeline or other passages.
(4) Keep the fuel system parts clean and in good order.
Notice:
● Reinstall the 4 M10 bolts fixing the fuel tank, and tighten them with 40N.m tightening torque.
● Tighten the ring clamps and make replacement if necessary.
● Check and make sure the hoses are not damaged or twisted during removal and installation.
● Keep the ignition switch at ON for 2 seconds, turn it to OFF and remains for 10 seconds, then
turn it to On again, and finally check for fuel leakage.

Section2 Fuel Pump

1. Replace the fuel pump (See Fig.5-2)
(1)Release fuel system pressure.
(2)Remove wire harness connector and fuel pipe.
(3)Remove fuel pump circlip and then fuel pump.
(4)Install new fuel pump, O-ring, and fuel pump circlip.
(5)Connect oil pipe (hose) and wire harness connector.

Oil return pipe

High pressure
Notch oil pipe

Power fuel
Wire harness
pump
socket

Fig.5-2
Notice: 1.The notch of the power fuel pump shall be aligned to the notch on the fuel tank.
2. Replace new fuel pump O-ring when reinstalling new fuel pump.
3. Replace the fuel filter.
4.Remove the fuel filter.
(1) Discharge the pressure in the fuel system.
(2) Collect the fuel in a proper container.
(3) Take out the fuel filter from the bracket.
The disassembled fuel filter is shown in Fig. 5-3

208
3. Install the fuel filter.
(1) Remove the protection cover of a new fuel filter.
(2) Slowly insert the fuel filter into the bracket, and tighten the bracket bolts.
(3) Connect the fuel hoses on both ends of the fuel filter in the fuel circuit.
(4) Tighten the fuel filler cap of the fuel tank.
4. Install and remove nylon tube
(1)Check if there is any mud or foreign matter in the nylon pipe connector nearby and clean it up.
(2)Press both ends of quick union and remove it backwards.Fig.5-4
(3)Check if there is any damage, mud or foreign matter on the connection of nylon when installing
nylon pipe.
(4)Install the quick union of nylon pipe on the mail connector along the linear direction until it
sounds ―click‖ if nothing is abnormal.

Fig.5-4

Fig.5-5
Notice: After installing the high pressure nylon pipe, pull it slightly to make sure it is installed firmly;
and make sure there is 3mm clearance.

209
BYD AUTO BYD NEW F3 Maintenance & Repair Manual

Chapter 5 5T-14 Transmission

Contents

Section 1 Structural Parameter .........................................................................................211

1.1 Transmission Structural Parameter ......................................................................211
Section 2 Service Regulations ......................................................................................... 212
2.1 Service Material .................................................................................................. 212
2.2 Service Rules...................................................................................................... 213
Section 3 Service Transmission ....................................................................................... 213
3.1 Disassemble Transmission ................................................................................. 213
3.2 Check Reverse Shaft Fork Clearance ................................................................. 216
3.3 Check Shift Lever Clearance............................................................................... 216
3.4 Disassemble/Reassemble Gear Shift Lever Assembly ........................................ 218
3.5 Disassemble/Reassemble Gear Shift Lever Assembly ........................................ 219
3.6 Check Gearshift Fork Clearance ......................................................................... 220
3.7 Disassembly and Reassembly Gear Shift Fork.................................................... 221
3.8 Check Main Shaft Assembly Clearance ............................................................... 222
3.9 Disassemble Main Shaft ..................................................................................... 224
3.10 Check Main Shaft.............................................................................................. 224
3.11 Reassemble Main Shaft .................................................................................... 225
3.12 Check Countershaft Assembly Clearance ......................................................... 226
3.13 Disassemble Countershaft ................................................................................ 227
3.14 Check Countershaft .......................................................................................... 228
3.15 Reassemble Countershaft ................................................................................. 229
3.16 Check Synchronizer Gear Sleeve and Gear Hub .............................................. 232
3.17 Check Synchronizing Ring and Gear................................................................. 233
3.18 Replace Main Shaft Bearing and Oil Sea. ......................................................... 234
3.19 Replace Countershaft Bearing .......................................................................... 234
3.20 Adjust Main Shaft Engagement Clearance ........................................................ 236
3.21 Reassemble Transmission ................................................................................ 237
Section 4 Differential ........................................................................................................ 240
4.1 Disassemble Differential ..................................................................................... 240
4.2 Check Backlash .................................................................................................. 241
4.3 Removal/Installation of Final Reduction Driven Gear ............................................ 241
4.4 Replace Differential Housing/Vehicle Speed Sensor Driving Gear....................... 241
4.5 Replace Differential Oil Seal ............................................................................... 242
4.6 Replace Differential Adjusting Shim .................................................................... 242

210
Section 1 Structural Parameter
1.1 Transmission Structural Parameter

Transmission model BYD5T-14

Engine model BYD473Q
Configuration 5-gear manual transmission
Final reduction gear ratio 4.471（76:19）
Distance between shafts (mm) 69－118
Overall length (mm) 363
Overall dimension (L×W×H) (mm) 363×515×382
1st gear 3.308（43:13）
2nd gear 1.826（42:23）
Gear ratio 3rd gear 1.207（35:29）
4th gear 0.939（31:33）
5th gear 0.730（23:37）
Reverse 3.231（41:13）
Differential gear ratio 16：10
1st gear 0.98
2nd gear 0.98
3rd gear 0.98
Transmission efficiency
4th gear 0.98
5th gear 0.98
Reverse 0.97
1st gear Φ74.9
Synchronizing Φ74.9
2nd gear
Ring Φ68.8
3rd gear
dimension(mm) Φ68.8
4th gear
Synchronizing Φ62.8
ring pattern 5th gear
Reverse Φ62.8
Gearshift lever ratio 45.55/24.5
Gearshift control
Selector lever ratio 57.4/34.6
Gearshift ratio 19/23
Speed sensor
Pattern Electronic
SAE Viscosity 80W-90(Summer in the North)
classes 75W-90（Winter in the North）
80W-90 or 85W-140（All year around
Gear oil
in the South）
API class GL－4
Oil capacity（L） 1.6L
Net weight(excluding clutch kg） 39

211
 Section 2 Service Regulations
2.1 Service Material
The materials listed below are required to service this transmission. Please get them on hand in
advance. In addition, try to get the specified detergent and lubricating oil.
Auxiliary materials:

SN Material Material & Model in Use Model

&Model
1 Release fork
2 Release bearing
3 Lubricating oil 2#sodium-based grease Input shaft front oil seal
4 Speed sensor assembly
5 Shifting block
6 Differential oil seal
API class GL-4 or above 75W-90 Winter
in the North
7 Gear oil 80W-90 Summer in the North Transmission assembly
80W-90 80orW-140All year around in the
South
8 Sealant Loctite 587 Seal bolt
API class GL-4 or above
9 75W-90 Winter in the North Input shaft needle bearing
Gear oil 80W-90Summer in the North
10 80W-90 or 80W-140 All year around in Output shaft needle bearing
South
11 Sealant TianshanTS1567F Gearbox body joint surface
API class GL-4 or above
75W-90 Winter in the North
Gearshift fork and shift lever
12 Gear oil 80W-90Summer in the North
assembly
80W-90 or 80W-140 All year around in
South

Tianshan TS1567F Manual gearshift

13
assembly
Sealant mounting surface
Reverse shaft fork assembly
14 Tianshan kesaixin 262 bolt
Reverse lock cam assembly

212
2.2 Service Rules
(1) Prepare part box and rack to place removed, disassembled parts .Mark the parts properly and
put them in good order to avoid any disorder and misplacement.
(2) Check the aluminum alloy parts carefully to avoid any damage to the surface.
(3) Prepare sufficient auxiliary materials for use during servicing.
(4) Use SST tools to properly tighten the bolts and fasteners that have standard tightening
torque.
(5) After serving, the disposable items should be replaced with new ones.
(6) Use proper tools for removal and assembling.
(7) Try your best to follow the instructions in this manual carefully.
(8) If you encountered any trouble during servicing, you can contact the with the technical service
staff of BYD after-sales division.

Section 3 Service Transmission

3.1 Disassemble Transmission
Front case—exploded view

(1) Differential assembly (14) Idler gear assembly (25) Hexagon flange bolt
(2) Reverse lock cam (15) Mounting bolts M8×45（25N·m）
assembly （15N·m） (26) Hexagon flange bolt
(3) Mounting bolts（15N·m） (16) Reverse shaft fork M6×22（10N·m）
(4) Gearshift fork assembly assembly (27) Speed sensor assembly
(5) Countershaft assembly (17) Dowel pin (28) O-ring
(6) Main shaft assembly (18) Dust cover (29) Speed sensor driven gear
(7) Magnet assembly (19) Release arm (30) Spring
(8) Slide shaft bush (20) Release arm bolt (31) 8mm washer
(9) Cylindrical roller bearing （30N·m） (32) Circlip
(10) Oil guide plate2 (21) Release arm spring (33) 8mm spring washer
(11) 58mm deep groove ball (22) Release bearing (34) Fork shaft screw（25N·m）
bearing (23) Differential right oil (35)Transmission front case
(12) Main shaft oil seal seal
(13) Reverse gearshaft (24) Cable bracket

213
Rear case-exploded view

(1) Stop bolts（22N·m） (13) Oil guide plate1

(2) Stop spring (14) 72mm washer
(3) Steel ball (15) Oil drain groove plate
(4) 12mm flat washer (16) 80mm
(5) Drain plug（39N·m） (17) Reversing light switch gasket
(6) 14mm flat washer (18) Reversing light switch assembly（30N·m）
(7) Sealing plug（25N·m） (19) Hexagon flange bolt M6×20（10N·m）
(8) Hexagon flange bolt (20) Manual gearshift assembly
M8×40（25N·m） (21) Cylindrical pin
(22) 20mm flat washer
(9) Bolt M8×45（25N·m）
(23) Oil-fill plug（45N·m）
(10) Fastening bracket of clutch high pressure
tubing (24) Differential left oil seal
(11) Fastening bracket of separation pump oil (25) Neutral switch assembly（35N·m） （Note：
pipe applied to the transmission with neutral
(12) Hexagon flange bolt M6×8（10N·m） switch assembly）

214
Notice: use 2 sufficiently high wood-blocks
to support the transmission front case, so
as to prevent the main shaft from impacting
the workbench.
1. Remove Neutral switch assembly(A),
(applied to the transmission with neutral
switch assembly)

4.Remove the drain plug, 14mm flat washer(A),

oil -fill plug, 20mm flat washer (B) and vehicle
speed sensor (C). Check the O-ring (D),
and replace it if any damage.

2．Remove stop bolt (A), 12mm flat washer,

stop spring, steel ball and reversing light
switch assembly (B).

5.Remove the hexagon flange bolts M8×40(C),

fastening bracket of clutch high pressure
tubing (B) and Hexagon flange bolts M8×45 (C)
in alternating order.

3. Remove manual gear shift assembly (A)

and cylindrical pin (B)

6. Remove the sealing plug (A).

215
7.Open the countershaft circlip (B) with
circlip pliers and remove it from the groove.

12. Wrap tape around the main shaft spline,

8. Remove the transmission rear case (C) and
and remove the main shaft assembly (A),
dowel pin (D).
countershaft assembly (B), gearshift fork
assembly (C) from the front case.

3.2 Check Reverse Shaft Fork

Clearance
3.3 Check Shift Lever Clearance

1. Measure the clearance between the

reverse shaft fork assembly (B) and idler gear
assembly (A) with a feeler gauge (C).If the
clearance is beyond the service limit, go to step
Standard: 1.50-1.90mm
Service limit: 2.10mm

9. Remove the idler gear assembly (A) and

reverse gear shaft (B).

10. Remove reverse fork assembly.

2. Measure the reverse shaft fork clearance.

1) If the clearance is beyond the standard,
11. Remove reversing lock cam assembly. replace a new reverse shaft fork \assembly.
2) If the clearance is within the standard,
replace a new idler gear assembly.

216
 2) If the clearance is within the standard,
replace a new selector lever assembly.

Standard: 13.00-13.15mm

Standard: 13.5-13.8mm
1. Measure the clearance between the shift
lever assembly (A) and selector lever
assembly (B) with a feeler gauge (C). If the
clearance is beyond the service limit,
go to step 2.
Standard: 0.05-0.30mm
Service limit: 0.50mm

2. Measure the groove on the selector lever

assembly.
1) If the clearance is beyond the standard,
replace a new shift lever assembly.

217
3.4 Disassemble/Reassemble Gear Shift Lever Assembly
Before reassembling, clean all parts with solvent, dry them out, and apply
lithium-based grease to all contact surfaces (A, B, C & D).

Hexagon flange bolt 10N.m Shift lever assembly

Dust cover

Cylindrical pin Shift lever oil seal

Breather
Selector lever oil seal pipe
assembly

Selector lever assembly

Shift arm cover

Selector lever dust Selector spring ring

cover
Shift lever fork Selector spring

Selector spring plate

Stop steer ball assembly

8mm Speing Washer

Fork shaft screw

218
3.5 Disassemble/Reassemble Gear Shift Lever Assembly
(Note：applied to the transmission with Neutral switch assembly)
Before reassembling, clean all parts with solvent, dry them out, and apply
lithium-based grease to all contact surfaces (A, B, C & D).

Hexagon flange bolt 10N.m Shift lever assembly

Dust cover

Cylindrical pin Shift lever oil seal

Breather
pipe
Selector lever oil seal
assembly

Selector lever assembly

Shift arm cover

Selector lever dust Selector spring ring

cover

Shift lever fork Selector spring

Selector spring plate

Stop steer ball assembly

5x22 groove pin

219
3.6 Check Gearshift Fork Clearance
Notice: replace the synchronizer hub when
replacing the synchronizer gear sleeve.

1. Measure the clearance between gearshift 3. Measure the clearance between the
fork (A)and corresponding synchronizer gearshift fork (A) and gearshift lever fork]
block (B). If the clearance is beyond the
gear sleeve (B).If the clearance is beyond
the service limit ,go to step 2. Service limit got to step 2.
Standard：0.40—0.7mm Standard: 0.2-0.5mm
Service limit：1.0mm Service limit: 0.62mm

2. Measure the thickness of the gearshift 4. Measure the width of gearshift

fork block.
1) If the thickness is beyond the standard, fork block.
replace a new gearshift fork. 1) If the width is beyond the
2) If the thickness is within the standard, standard, replace a new gearshift
replace a new synchronizer gear sleeve. lever fork.
Standard：
2) If the width is within the standard, replace a
1/2/3/4 gear fork：7.4—7.6mm new shift fork.
5 gear fork: 6.7—6.9mm
Standard: 12.9-13.0mm

220
3.7 Disassembly and Reassembly Gear Shift Fork

Before reassembling, clean all parts with solvent, dry them out, and apply
lithium-based grease to all contact surfaces.

5
th speed gearshift fork

th
3rd/4 speed gearshift fork assembly

nd
1st/2 speed gearshift fork assembly

Fork shaft screw

8mm spring washer

Toggle block assembly

221
3.8 Check Main Shaft Assembly 4. Measure the clearance between the 4th
speed gear (A) and distance ring (B) with a dial
clearance gauge (C). If the clearance is beyond the
Notice：Replace synchronizer hub while service limit, got to step 5.
replacing synchronizer sleeve Standard: 0.10-0.25mm
1. Lift up the bearing inner race with an Service limit: 0.40mm
appropriate pipe seat (A), and then push it
down onto the main shaft (B).

2.Measure the clearance between the 2nd .

speed gear and 3rd speed gear with a feeler
gauge (E).
5. Measure the length ①on the distance ring,
as indicated in the figure below.
1) If the clearance is beyond the service limit, 1) If the length is beyond the standard,
go to step 3. replace a new distance ring.
2) If the clearance is within the service limit, go 2) If the length is within the standard, go to
to step 4. step 6.
Standard: 0.10-0.25mm Standard: 24.03-24.08mm
Service limit: 0.40mm
3. Measure the thickness of the 3rd speed
gear.
1) If its thickness is less than the service limit,
replace a new 3rd speed gear.
2) If its thickness is within the service limit,
replace a new 3rd/4th gear synchronizer hub.

Standard: 27.85—27.90mm
Service limit: 27.78mm

222
6. Measure the thickness of the 4th speed gear. step 9.
1) If its thickness is less than the service limit,
replace a new 4th speed gear. Standard: 24.03-24.08mm
2) If its thickness is within the service limit,
replace a new 3rd/4th gear synchronizer hub.

Standard: 26.88-26.93mm
Service limit: 26.81mm

9. Measure the thickness of the 5th speed

gear.
1) If its thickness is less than the service limit,
replace a new 5th speed gear.
2) If its thickness is within the service limit,
replace a new 5th gear synchronizer hub.

7. Measure the distance between the Standard: 28.88-28.93mm

distance ring (A) and 5th speed gear (B) with a Service limit: 28.81mm
dial gauge (C). If the distance is beyond the
service limit, go to step 8.

Standard: 0.10-0.25mm
Service limit: 0.40mm

10. Measure the thickness of the distance

ring. If the thickness is beyond the standard,
replace a new distance ring.
Standard: 12-12.05mm

8. Measure the length ②on the distance ring,

as indicated in the figure below.
1) If the length is beyond the standard,
replace a new distance ring.
2) If the length is within the standard, go to

223
3.9 Disassemble Main Shaft 3.10 Check Main Shaft
1. Remove the deep groove ball bearing, 1.Check the gear surface and bearing surface
main shaft distance ring and 5th speed for wear and damage, and then measure
synchronizer gear sleeve. the main shaft at 5 locations (A, B, C, D & E in
2. Support the 5th speed synchronizer gear the figure below). If the measured value at any
sleeve (A) on iron blocks, and then press out location except location E is less than the
the main shaft from the 5th gear synchronizer service limit, replace a new main shaft.
hub (B). Don‘t use a puller as it may damage Standard:
the gear tooth. A (mounting surface for deep groove ball
bearing): 26.002-26.015mm
B (mounting surface for 3rd/4th gear distance
ring): 29.008-29.021mm
C (mounting surface for needle bearing):
34.975-34.991mm
D (mounting surface for deep groove ball
bearing):26.002-26.015mm
E (guide shaft): 14.81-14.85mm
Service limit:
A: 25.95mm
B: 28.95mm
C: 34.92mm
D: 25.95mm

3.Support the 3rd speed gear (A) on iron blocks,

and then press out the main shaft from the
3rd/4th gear synchronizer hub (B).Using a
puller may damage the gear tooth.
2. Support the main shaft by both ends and
measure its circular runout. Rotate the main
shaft for 2 rounds during measurement. If the
result is beyond the service limit, replace a new
main shaft.
Standard: maximum 0.02mm
Service limit: 0.05mm

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3.11 Reassemble Main Shaft
Exploded view

th
Main shaft 4
speed gear

72mm deep groove ball bearing

th
3rd/4 gear
synchronizing ring

th Conical ring
3rd/4 gear
synchronizer spring
Main shaft distance ring
th
3rd/4 gear
synchronizer gear Reverse synchronizer ring
sleeve
th 5th gear synchronizer spring
3rd/4 gear
synchronizer hub
th 5th gear synchronizer sleeve
3rd/4 gear
synchronizer spring
th
5th gear synchronizer gear
3rd/4 gear hub
synchronizing ring 5th gear synchronizer spring

5th gear synchronizer ring

Main shaft 3rd
speed gear

Main shaft 5th speed gear

Needle bearing
Needle bearing

th
4th/5 speed gear
distance ring

Needle bearing
Main shaft

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3.12 Check Countershaft
Assembly Clearance
1. Measure the clearance between the 1st
speed gear (A) and countershaft (B) with a
feeler gauge (C). If the clearance is beyond the
service limit, got to step 2
Standard: 0.20-0.34mm
Service limit: 0.46mm 4. Measure the thickness of the distance ring.
2. Measure the clearance between the 1) If its thickness is less than the service limit,
2ndspeed gear (A) and 3rd speed gear (B) with a replace a new distance ring.
feeler gauge (C). If the clearance is beyond the 2) If the clearance is within the service limit,
service limit, go to step 4. go to step 5.
Standard: 0.20-0.35mm Standard: 27.5-27.56mm
Service limit: 0.47mm Service limit: 27.45mm

5．Measure the thickness of the 2nd

3. Measure the thickness of the 1st speed gear. Speed gear.
1) If its thickness is less than the service limit, 1) If its thickness is less than the service limit,
replace a new 1st speed gear. replace a new 2nd speed gear.
2) If its thickness is within the service limit, 2) If its thickness is bigger than the service
replace a new 1st/2nd gear synchronizer hub. limit, replace a new 1st/2nd gear synchronizer
Standard: 26. 84-26.9mm hub.
Service limit: 26. 79 mm Standard: 27.21-27.3mm
Service limit: 27.18mm

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3.13 Disassemble Countershaft
1. Firmly fix the countershaft on a bench vise
with wooden blocks.

5. Support the 4-th gear (A) on iron

blocks(B), and press the countershaft (E)
out of the 4-th gear using a pressing tool
2．Pry the lock nut tab (B) from the
(C) and accessory (D).
countershaft groove with a chisel (A).
3. Remove the lock nut (A, left hand thread)
and spring washer (B).

4．Support the 5-th gear (A) on iron blocks (B),

6. Support the 3-th gear (A) on iron blocks
and press the countershaft (E) out of the ball (B), and press the countershaft (E) out of
bearing (F) using a pressing tool (C) and the 3-th gear using a pressing tool (C) and
accessory (D). accessory (D).

227
3.14 Check Countershaft

1. Check the gear surface and bearing

2. Support the countershaft by both ends and
surface for wear and damage, and then measure its runout. Rotate the countershaft for
measure the countershaft at 3 locations(A, 2 rounds during measurement. If the runout is
B&C in the figure below). If the measured beyond the
value at any location is less than the service service limit, replace a new countershaft.
limit, replace a new countershaft.
Standard: maximum 0.02mm
Service limit: 0.05mm
Standard:
A (ball bearing surface): 24.992-25mm
B (needle bearing surface): 37.989-38mm
C (needle bearing surface): 33.995
-34.011mm

Service limit:
A: 24.942mm
B: 37.939mm
C: 33.945mm

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3.15 Reassemble Countershaft
Exploded view
Countershaft distance ring Lock nut

nd 22 mm washer
Countershaft 2 gear shock
absorber

Deep groove ball bearing

nd
1st/2 gear
synchronizer
gear sleeve
5225cylindrical roller bearing

nd
1st/2 gear
synchronizer hub
th
nd
Countershaft 5 speed gear
1st/2 gear
synchronizer spring

1st gear
synchronizing
th
ring Countershaft 4 speed gear

st
Countershaft 1 gear
shock absorber
rd
Countershaft 3 speed gear

st
Countershaft 1
speed gear
nd
Countershaft 2 speed gear
Needle bearing
38X43X22

2nd gear
synchronizing ring

Countershaft nd
1st/2 gear
synchronizer
spring

Needle bearing
40X45X22

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Notice: during the reassembling process,
refer to the exploded view if necessary.

1. Before reassembling, clean all parts with

solvent, dry them out, and apply
lithium-based grease to all contact surfaces.
2. Install the needle bearing (A),
countershaft 1st speed gear (B),
countershaft 1st gear shock absorber (C)
to the countershaft.
3. Install the 1st gear synchronizing ring (D)
and 1st/2nd gear synchronizer spring (E) to the
6. Align the arrow (C) on the countershaft 2nd
countershaft.
gear shock absorber with the groove on the
1st/2nd gear synchronizer hub (D), and then
install the distance ring (A) and countershaft
2nd gear shock absorber (B).

4. Align the arrow (A) on the countershaft

1stgear shock absorber with the groove (B)on
the 1st/2nd gear synchronizer hub, and then 7. Install the needle bearing (A) and 2nd speed
install the synchronizer hub onto the gear (B).
countershaft.

5. Install the reversing gear (A) 2nd gear

synchronizer spring (B) and 2nd gear 8. Install the 3rd speed gear (A) with the SST
synchronizing ring (C) onto the countershaft. and pressing tool (B).

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 12. Install the deep groove ball bearing
9. Install the 4th speed gear (A) with the SST (A)with the SST and pressing tool (B).
and pressing tool (B).

13. Install 22mm spring washer (A) and lock

nut (B, left hand thread).
10. Install the 5th speed gear (A) with the SST
and pressing tool (B).

14. Firmly fix the countershaft on a bench vise

with wooden blocks.
15. Tighten the new lock nut to 110N.m,
11. Install the deep groove ball bearing (A) loosen it, and then tighten it to 110 N.m again.
with the SST and pressing tool (B). Fit the lock nut tab into the groove.

231
3.16 Check Synchronizer Gear Sleeve and Gear Hub
1. Check all teeth on the synchronizer hub and synchronizer gear sleeve for rounded corners,
which indicate severe wear.
2. Install the synchronizer hub (A) into its corresponding synchronizer gear sleeve (B) to check if it
moves freely. Make sure the3 sets of lengthened teeth(C) separated by 120 degree from each other)
match with the grooves (D) on the synchronizer hub. When installing the synchronizer gear
sleeve, prevent its lengthened teeth from entering the narrow slot (E) on the synchronizer hub, as it
may damage the spring washer.

Notice: replace the synchronizer hub when replacing the synchronizer gear sleeve.。

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3.17 Check Synchronizing Ring on each gear hub for wear or
and Gear coarse surface.
1．Check the inside of each synchronizing ring 6. Check the teeth on all gears (F)
(A) for wear. for wear scratch and crack.
7． Apply engine oil to the
conical surface of each gear (E),
and install its synchronizing ring.
Rotate the synchronizing ring to
make sure it is slipping.
8. Measure the clearance between each gear(A)
and its synchronizing ring (B). Measure the
clearance when the synchronizing ring is
nearest to the gear. If the clearance is less
than service limit, replace the synchronizing
ring and gear.
Synchronizing ring-gear
clearance Standard:
0.85-1.10mm
Service limit: 0.4mm

Synchronizing ring gear tooth instance

Normal Worn

Synchronizer gear sleeve and tooth instance

Normal Worn

2． Check the teeth (B) on each synchronizing

ring for wear and rounded corner.
3． Check the teeth (C) on each synchronizer
gear sleeve and the corresponding teeth on
each gear for wear and rounded corner.
4． Check the stressed area (D) on each gear
hub for wear.
5. Check the conical surface (E)

233
3.18 Replace Main Shaft Bearing
and Oil Sea.
1. Remove the differential assembly.
2. Remove the deep groove ball bearing
(A)from the front case (B) with a SST.

3.19 Replace Countershaft

Bearing
1．Remove the cylindrical roller bearing (A)
with a SST and then remove the oil guide plate
2 (C).
3. Remove oil seal (A). Protect the gearbox
against damage when removing the oil seal.

4. Knock in a new oil seal from the gearbox

side with a SST.

2．Locate the oil guide plate 2 (C) and a \

new cylindrical roller bearing (A) in the front
case (B) hole.

5. Knock in a new bearing from the gearbox

side with a SST.

234
235
3.20 Adjust Main Shaft
ID Thickness ID Thickness
Engagement Clearance
A 0.60mm N 1.25mm
1．Measure the height from the front case joint
surface to the main shaft 72mm deep groove B 0.65mm O 1.30mm
ball bearing (A), and then measure the depth
from the rear case joint surface to the C 0.70mm P 1.35mm
mounting hole of the main shaft 72mm deep
D 0.75mm Q 1.40mm
groove ball bearing (B), leaving appropriate
clearance.
E 0.80mm R 1.45mm
Standard: 0.10-0.18mm
F 0.85mm S 1.50mm

G 0.90mm T 1.55mm

H 0.95mm U 1.60mm

I 1.00mm V 1.65mm

J 1.05mm W 1.70mm

K 1.10mm X 1.75mm

L 1.15mm Y 1.80mm

M 1.20mm — —

Basic formula：B-A-(0.10-0.18)=Shim
thickness

3． Install the selected 72mm adjusting shim

(A) and oil guide plate 1 to the rear box (B).

2． Select an appropriate 72mm adjusting

shim from the table below. Adopt the
measurement result in step 1 following the
example below:

236
3.21 Reassemble Transmission 3. Wrap tape around the main shaft
spline(C), and then install the main shaft
Notice: Before reassembling, clean all parts and countershaft (E) to the gearshift fork
with solvent, dry them out, and apply assembly, as they will be installed as a
lithium-based grease to all contact surfaces.
whole.
1.Install the magnet (B) and differential
4.Install the reverse lock cam assembly. and
assembly (A). apply sealant to the thread surface of installing
bolt.

5. Install the reverse shaft fork assembly. and

apply sealant to the thread surface of installing
bolt.

2. Install the 8mm spring washer (A) and fork

shaft screw (B).

A
D
B

B(25N·m)
6. Install the idler gear assembly (A) and
reverse gear shaft (B).

237
7. Select an appropriate 72mm washer (A)
according to the value measured in Adjust Main
Shaft Engagement Clearance. Install the oil
drain groove plate (B), oil guide plate 1 (M)
and 72 mm washer to the transmission rear
case.

10. Open the countershaft circlip (B) with

circlip pliers, and lock it up reliably in the
groove of the countershaft bearing.

8. Clear away the oil stain on the gearbox

body joint surface. Apply the sealant on the 11. Install the dowel pin (A).
joint surface to ensure the sealing around
the bolt hole and prevent oil leakage.

Notice: the assembling shall be

conducted within 5 minutes of
applying the sealant. Wait for at
least 20 minutes before refill oil
into the transmission.

12. Install the hexagon flange bolt (A) M8×40

(25N.m), fastening bracket of clutch high
pressure tubing (B) and hexagon flange bolt
(C) M8×45 (25N.m).

Sealant

9. Apply sealant to the thread of sealing plug

25N.mm (A) and then install it to the
transmission rear case.
C

238
13. Tighten the bolts in alternating order. light switch assembly 30N.mm(B).

14. Clear away the oil stain on the shift lever

17.Install idler switch assembly 35N·m（A）
cover joint surface, and apply sealant.(sealant
width: 2.5mm±0.5mm) (Notice: applied to the transmission with
installed idler switch assembly.)

Sealant

15. Install the cylindrical pin (A) and manual

gear shift assembly (B). 18. Install the drain plug, 14mm flat
washer(A), oil fill plug, 20mm flat washer (B)
and vehicle speed sensor (C). Check the
O-ring (D), and replace it if any damage.

16. Install the stop bolt 22N.mm (A), 12 mm

flat washer, stop spring, steel ball and reversing

239
Section 4 Differential
4.1 Disassemble Differential
Exploded view of differential

Right differential bearing

Speed sensor driving gear

Differential bolt

Final reduction driven gear

Differential housing

Left differential bearing

240
4.2 Check Backlash 4.4 Replace Differential
1. Place the differential assembly on a Housing/Vehicle Speed Sensor
V-shaped block, and install axle shaft on Driving Gear
both ends.
1. Check the differential bearing for abnormal
wear and stuck rotation. If the rotation is
smooth and free of abnormal wear, the bearing
is in good conditions.
2. Detach the left/right bearing separately from
the differential housing with a puller and
bearing remover.

2. Measure the backlash with a dial gauge

by contacting the probe on the planet gear
tooth face. Replace the faulty parts if any
incompliance with the standard.
Standard: 0.05mm～0.25mm.

4.3 Removal/Installation of Final

Reduction Driven Gear
1. Remove the differential bolts in steps and in
alternating pattern, and then remove the final
reduction driven gear from the differential
housing. 3. Remove and install the speed sensor
driving gear.

2. Install the final reduction driven gear, with

the chamfered surface on the inner edge
facing the differential housing, and then tighten Notice: install the differential left/right bearing
the bolts in steps and in alternating pattern. with a SST, with the bearing dust cover facing
Tightening torque: 100N.m. outwards.

241
4.5 Replace Differential Oil Seal
1. Remove the differential assembly.
2. Remove the left differential oil seal from
the transmission rear case.
3. Remove the right differential oil seal from
the transmission front case.

4.6 Replace Differential

Adjusting Shim
4. Install new oil seals to the transmission If any one of the differential housing,
box with a SST.
transmission front case and transmission rear
case is replaced, a new 80mm adjusting shim
shall be selected.
1. Install the differential assembly into the
front case.

242
 Standard clearance：0mm — 0.10mm

1. Adjusting shim thickness:

ID Thickness ID Thickness
2.Close the transmission rear case, and A 0.70mm B 0.75mm
tighten the fixing bolts around the differential C 0.80mm D 0.85mm
in steps and in alternating pattern. E 0.90mm F 0.95mm
Tightening torque: 25N.m G 1.00mm H 1.05mm
3. Knock the differential assembly slightly I 1.10mm J 1.15mm
with the SST to ensure that it is installed in K 1.20mm L 1.25m m
place in the front case. M 1.30mm N 1.35mm
O 1.40mm P 1.45mm
Q 1.50mm - -

2. Remove and install the bolts and

transmission rear case.
3. Reinstall the transmission.

4. Check the clearance between the

differential left bearing end face and rear case,
and accordingly select an appropriate 80mm
adjusting shim to guarantee the clearance
between the shim and left bearing outer race.
5.When replacing shim, shim thickness should
be selected from the table below.

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Chapter 6 CVT Transmission

Contents

Section1 General Introduction .......................................................................................... 245

1.1 Conventional Automatic Transmission vs. Continiously Variable Transmission .... 246
1.2 Transmission Cross Section ................................................................................ 247
1.3 Basic Principles of Continuously Variable Transmission ...................................... 248
1.4 Driving Strategies ................................................................................................ 259
Section2 Service Information ........................................................................................... 261
2.1 Towing of the Vehicle .......................................................................................... 261
2.2 Service Intervals ................................................................................................. 261
2.3 Oil Specification .................................................................................................. 261
2.4 Wiring Diagram ................................................................................................... 262
2.5 Clutch Adaptation Procedure ............................................................................. 268
Section3 Service Instructions ........................................................................................... 270
3.1 Oil Refill/Check Instruction (Refill, Service Transmission,New Oil/Oil Change) .... 270
3.2 Oil Level Check................................................................................................... 271
3.3 Shifter Cable Adjustment..................................................................................... 271
3.4 Exploded View Service Parts .............................................................................. 273
3.5 Service Part List and Torque Information ............................................................. 274
3.6 Special Tools and Replacement of Service Parts .............................................. 283
3.7 Checklist of the Electronic Components in the Transmission ............................... 321
Section4 Trouble Shooting Guide .................................................................................. 322
4.1 Leaks .................................................................................................................. 322
4.2 Noise Problems .................................................................................................. 323
4.3 Shocks and no Creep Problems .......................................................................... 326
4.4 P-codes and Actions ........................................................................................... 327

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Section1 General Introduction

The transmission's continuously variable ratio is achieved by means of a variator. The variator
consists of two cone pulleys located opposite to each other and a steel drive belt that loops around
the two pulleys like a V-belt. The variator ratio is transmitted through an intermediate shaft to the
differential incorporated into the transmission housing.

This Student Information provides an overview of the transmission. The design and function of the
various assemblies of the transmission, the power transmission and the transmission control are
described individually. In addition, an overview is also provided for the transmission fluid cooling
system and the external gearshift mechanism. All spare parts and service tools are described, as
well as the error codes and actions to be carried out.

Repairs and adjustments MUST always be carried out according to the instructions and
specifications in the service manual of the vehicle.

The stepless shifting pattern of the transmission provides a very comfortable drive, as well as
having full vehicle performance, available at any time.

The advantages of using an automatic transmission of this type are:

-Low engine revolutions at constant speeds.

-Improved emission control/fuel consumption.
-Low noise, vibration and harshness levels.
-Smooth acceleration.
-Flexible driving on mountain roads.
Because of its fully electronic control the VT2 pushes the limits of its predecessor even further.

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1.1 Conventional Automatic Transmission vs. Continuously Variable

Transmission
In the figure below the variograms of both a manual or normal stepped automatic transmission and
the CVT are compared with each other. With the conventional automatic transmission, a fixed
number of ratios (gears) is available. When the transmission performs an upshift, it has to follow
the bold or dotted lines of the first image depending of the amount of throttle. With the CVT, the
whole range of ratios between the Low and the Overdrive lines is available for shifting as shown in
the second image. The shift point of both transmissions is related to the amount of throttle that is
applied by the driver. As more throttles is applied, the transmission performs its upshift at a higher
engine speed. With the conventional transmission it is clear that the engine speed drops back
when shifting to a higher gear. This is not the case with the CVT. The CVT will upshift at a constant
engine speed, by moving the pulleys as explained in the next part. However, alternative shifting
strategies are also possible. This can help to create a quicker acceptance by new CVT drivers.

Figure.1, 2 Variogram 4 stepped automatic transmission (left) and CVT transmission (right).

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1.2 Transmission Cross Section

3 5

2
4

10

Figure.3 transmission cross section

1. Torsional damper / Flywheel 6.Steel belt

2.Fluid pump 7.Primary pulley
3.Reverse clutch 8.Secondary pulley
4.Planetary gearing 9.Intermediate shaft
5.Forward clutch 10.Differential

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1.3 Basic Principles of Continuously Variable Transmission

The VT2 consists of a number of elements that can be divided into three groups, depending upon
their function.
Group One – Mechanical Torque Flow
Elements providing the mechanical torque flow through the transmission.
Group Two – Control system
These elements relate to the control system. This system enables the transmission to transmit
power and to vary the ratio in a proper way, according to load conditions and driver demand.
Group Three – External Connections
Some elements have external connections with the transmission. Some of these
elements are either inside the gearbox, or immediately connected to it. Others can be part of the
system, but can be located elsewhere on the vehicle.

1.3.1Group One–Mechanical Torque Flow

1.3.1.1Planetary gear set
The planetary gear set enables the transmission to provide a drive torque in two
directions, forward and reverse. Engine torque always enters the transmission through the input
shaft of the planet carrier. This carrier can be directly connected to the sunwheel by closing the
forward multi-plate clutches. When it does, the epicyclic gear set rotates as one unit, and engine
torque is transmitted directly to the primary pulley. The planet gears do not transmit any torque,
therefore no mechanical loss will occur in the planetary gear set and the primary pulley will rotate
in the same direction as the engine. This is the forward drive mode.
In reverse mode, the annulus of the planetary gear set is held stationary by closing the reverse
multi-plate clutches. Three pairs of planet gears are driven by the planetcarrier, forcing the
sun-wheel to rotate in the opposite direction. There is a small multiplication of torque being
transmitted since the ratio of the epicyclic gear set is1:1.1,in order to compensate for frictional
losses within the planetary gear set itself

1. Planet gears

2. Input shaft 3

3. Sun gear

4. Annular gear

图 4 行星机构
Fig. 4: Planet gears

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1.3.1.2 Multiplate clutches

There are two Multiplate wet clutch packs; one forward and one reverse. Each pack has three
friction plates providing six friction surfaces. The hydraulic pressure controls the clutches to allow
the vehicle to move away smoothly by every throttle opening. By controlling the clutch slip it also
allows the vehicle to be held stationary after the drive gear is engaged. Oil from the oil cooler is
directed to the clutch plates to prevent overheating of the friction surfaces

1. Forward clutch pack

2. Reverse clutch pack

Fig.5 Planetary gear set showing clutch plates

1.3.1.3 Pulleys and steel belts

The main design feature of the CVT is a pair of steel "V " shaped pulleys connected by a steel
drive belt. The distance between centres of the primary and secondary pulley is 155 mm. Each
pulley consists of one fixed half and one axially slideable half, both having 11 degree sloping sides.
The proven 24 mm wide "Van Doorne" push type drive belt is used to transfer torque between the
pulleys (applications for higher torque values can make use of a 30 mm drive belt). The belt is
lubricated and cooled by an oil jet from a nozzle. Both moving halves are situated diagonally
opposite to each other in order to reduce misalignment of the drive belt during shifting. Each
moving half is connected to a hydraulic cylinder/piston. Hydraulic pressure is controlled by the
control system, described in the section titled ‗Hydraulic system‘. Ball splines prevent the moving
halves from rotating relatively to their fixed partners.
Torque transmitted by the planetary gear set acts directly onto the primary pulley, as the sunwheel
is splined to it. The steel drive belt transmits the power from the primary pulley to the secondary
pulley and the power from the secondary pulley is then transmitted to the pinion shaft.
The sizes of the two pulleys are designed to provide a range of ratios from 2.416:1 to 0.443:1
resulting in a ratio spread of 5.45. The high overdrive ratio is particularly advantageous in respect
to fuel consumption.
The steel drive belt has approximately 450 segments and is held together by 24 steel bands, 12 on
each side.

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1. Steel bands

2. Steel segments

Fig.6 Drive belt

1.3.1.4 Intermediate shaft

The intermediate shaft (or pinion shaft) creates a two-set helical gear reduction
between the secondary pulley and the differential. In this way, the rotational direction
of the drive shafts will be correct. The reduction between the secondary pulley and the drive shafts
can be made large enough to give good vehicle performance. The intermediate shaft is supported
by two conical bearings, one in the clutch housing and one in a separate bearing support.

1. Primary shaft drive gear

2. Differential crown wheel
3. Pinion drive gear
4. Transfer gear pinion shaft
5. Secondary shaft drive gear

Fig.7 Crown wheel & pinion

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1.3.1.5 Differential
Drive torque on the crown wheel is transmitted to the vehicle wheels through a differential, just as
in a manual transmission. The crown wheel is bolted to the differential case with 8 bolts. The drive
shafts are fitted to the differential with conventional CV joints and seals. Conical bearings are used
to support the differential.

1.Differential bearing

2.Differential casing

3.Differential cross shaft

4.Differential planet gears

5.Differential crown wheel

Fig. 8: Differential assembly

1.3.1.6 Mechanical operation

1.3.1.6.1 Ratio changes

Unlike conventional planetary automatic transmissions that provide a limited number of gear ratios,
usually four, five or six, the CVT, as its name suggests, continuously varies the gear ratio. A low
gear (low ratio) makes it easier to pull away from a rest position, the drive pulley diameter being
relatively small, while the driven pulley diameter is large by comparison. The drive belt is used to
transmit power and torque. As acceleration takes place it becomes possible to select a higher ratio
by increasing the diameter of the drive pulley while, at the same time, decreasing the diameter of
the driven pulley. This degree of change can be controlled to ensure that the most suitable ratio is
provided.
The CVT uses a primary pulley and a secondary pulley. Both pulleys have one fixed half and one
mobile half, controlled by hydraulic pressure. The position of the drive belt on the pulleys will
determine the ratio. If the mobile half of the pulley is close to its opposite half then the drive belt is
forced to travel around the outer circumference. When the pulley is open wide then this
circumference is reduced. The primary and secondary pulley mobile halves are diagonally
opposed so when the drive belt diameter is reduced on the primary pulley, it increases on the
secondary pulley. To pull away, a low ratio is required. To provide this, the primary pulley is open,
allowing the drive belt to sit down into the pulley and forcing it to run around the outer of the closed
secondary pulley. As vehicle speed increases, a higher gear ratio is required. To do this, the
primary pulley gradually moves towards its fixed partner, increasing the pulley circumference. At
the same time the secondary pulley is forced apart reducing pulley diameter, therefore creating a
higher gear ratio. An overdrive ratio is obtained when the primary pulley is fully closed and the
secondary pulley is fully open. The secondary pulley is now forced to rotate approximately
two and half times for every turn of the primary pulley.

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1 Input from the engine

2 Output to the wheels

3 Drive pulley at minimum

diameter (Low)

4 Driven pulley at maximum

diameter (Low)

Fig.9 Pulleys in low position

1 Input from the engine

2 Output to the wheels

3 Drive pulley at maximum

diameter (overdrive)

4 Driven pulley at minimum

diameter (overdrive)

Fig.10 Pulley positions in high ratio (overdrive)

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1.3.1.6.2 Selector lever in the Neutral or Park position

In this condition motion is not transferred to the wheels as both clutches for reverse (2) and
forward gears (4) are disengaged.
- The transmission input shaft (1) turns at the same speed as the engine.
- The reverse gear clutch (2) is disengaged.
- The forward gear clutch (4) is disengaged.
- The planetary gears (3) idle around the sun gear.
- As the sun gear does not move, neither does the primary pulley (5), the secondary pulley (7)
and, subsequently, the vehicle.

1.Input shaft

2.Reverse gear clutches

3.Planetary gears

4.Forward gear clutches

5.Primary pulley

6.Steel drive belt

7.Secondary pulley

Fig.11 Pulleys & gear train

The engine can only be started in Neutral or Park, as with any automatic transmission. In the Park
position, there is a mechanical lock that prevents the vehicle from moving forward or backward.
The Park position should only be engaged at standstill to avoid transmission damage.

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1.3.1.6.3 Sector lever in drive position

Under this condition, the forward motion is transferred to the wheels as the forward clutch (4) is
engaged.
-The transmission input shaft (1) turns at the same speed as the engine.
-The reverse clutch (2) is disengaged.
-The forward clutch (4) is engaged.
-The planetary gears (3), the sun gear and the annular ring gear of the epicyclic train rotate
together.
-The primary pulley (5) turns at the same speed as the engine in the forward gear direction.
-The secondary pulley (7) turns in the forward gear direction at a speed that depends upon
the belt ratio for that operating condition.

1. Input shaft
2. Reverse gear clutches
3. Planetary gears
4. Forward gear clutches
5. Primary pulley
6. Steel drive belt
7. Secondary pulley
8. Secondary pulley
9. Input shaft

Fig.12 Pulleys & gear train

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1.3.1.6.4 Sector lever in reverse position

Under this condition, the reverse clutch (2) is engaged and makes the annular ring
gear (9) lock to the transmission case. The planetary gears (3) force the sun gear (10), the primary
pulley (5) and the secondary pulley (7) to turn in the opposite direction to the transmission input
shaft (1).
Therefore reverse gear is now selected.
-The transmission input shaft (1) turns at the same speed as the engine.
-The reverse clutch (2) is engaged.
-The forward clutch (4) is disengaged.
- The annular gear (9) is linked with the transmission case by means of the reverse clutch (2).
-The planetary gears (3), which are driven directly by the transmission input shaft (1), turn around
the annular gear (9). Therefore they force the sun gear (10), the pulley (5) and the secondary
pulley (7) to turn in the reverse gear direction.

1. Input shaft

2. Reverse gear clutches

3. Planetary gears

4. Forward gear clutches

5. Primary Pulley

6. Steel drive belt

7. Secondary pulley

8. Secondary pulley

9. Annular gear

10. Sun gear

Fig.13 Pulleys & gear train

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1.3.2 Group Two-Control System

The functions of the control system are:
1.To match the clamping force on the steel drive belt tension with engine torque, preventing belt
slip.
2.To control the operation of the forward and reverse clutches during driving and take off.
3.To provide the optimum transmission ratio for all driving conditions.
4.Provide the necessary lubrication and cooling oil in the gearbox.

1.3.2.1Oil pump
The pump within the transmission is an external gear pump. The engine drives it via a shaft
through the hollow primary pulley shaft. The pump shaft is splined to the planet carrier, which
always runs at engine speed. The discharged volume is about 10 cm³ per revolution. System
pressure can reach 40 to 50 bar depending on input torque.

1.Oil pump drive shaft

2.Oil pump assembly

Fig.14 Oil pump complete

The oil pressure is used both for controlling the transmission hydraulically, and for
lubrication purposes.

1.Oil pump inlet

2.Oil pump oil seals

图 15：油泵进口

Fig.15 Oil pump inlet

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1.3.2.2 Variator control

The variator control ensures the minimum clamping forces necessary to avoid slippage between
belt and variator and in parallel it provides the ratio value (calculated from the in- (or primary) and
output (secondary) speeds of the variator) in accordance to the target ratio value given by the
driving strategy. The deterioration over lifetime of the control behavior is kept in a range that there
is no noticeable deviation on comfort and / or clamping force capability.

1.3.2.3Clamping force control

The clamping force management ensures that the pressure levels necessary to provide the
demanded forces at the variator (to prevent belt slip) have minimized impact on the efficiency of
the transmission, in order to minimize fuel consumption.
Besides "normal driving" the clamping force management also takes into account special driving
situations with torque peaks from input and/or output side of the transmission in order to provide
the maximum protection for the gearbox. The control takes into account the influence of ABS
braking, blocking wheels (when driving without ABS) and other drive line control systems (like ESP,
anti-skid control). It also recognizes and takes into account special road surfaces and conditions
like driving through holes and over curbs, transitions between low and high friction, slipping wheels
(e.g. on low friction road surfaces)
The software also compares the transmissions dynamic torque transmitting capabilities (while
taking into account the systematic delay times of the hydraulic system) with the predicted input
torque for the transmission. If the clamping force management will detect situations, where the
demanded clamping forces cannot be sufficiently covered a request for torque reduction will be
sent to the ECU to bring the engine torque into an appropriate range. This functionality is included
to protect the transmission.
When there is no electronic drive by wire system available in the vehicle platform, the torque signal
comes from the ECU through CAN. If CAN drops out, a predictive torque signal will be generated
by the TCU software itself.

1.3.2.4 Ratio control

The variator ratio is controlled via the balance between the forces induced on the
primary and secondary pulley by the primary and secondary pressure. Via the primary and
secondary speed sensor signals, the ratio can be calculated and the outputs (the pressures) can
be adapted to meet the ratio set point. The minimal pressure levels are determined by the
clamping force strategy. A physical model of the variator helps to adjust the pressure levels quickly
to variable operating points. The control software also takes into account disturbances from other
elements in the transmission and is developed with the aim to minimize delays at tip-in and tip-out
and minimal overshoots to target ratio (in order to improve fuel economy).
In order to ensure that the mechanical and durability limitations of the transmission are met,
several limitations on the driving strategy are set. Besides speed limitations there are also
software functions implemented to keep the ratio gradient (setpoints) within the allowed ranges.
Furthermore, the software avoids engine speeds above certain thresholds depending on vehicle
speed and status of the position Lever (POS). In order to achieve this restriction, the software
sends a request for torque reduction to the engine or provides an up shift if the car is not at
standstill.

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1.3.2.5 Transmission control unit

The software that controls the transmission is integrated in the TCU (Transmission Control Unit). The
TCU is installed in the engine compartment.
For the TCU interface with the transmission is referred to chapter 2.4 of this manual, where the
wiring diagram as well as the interface diagram is shown.

1.3.2.5.1. TCU interfaces

For the TCU interfaces with the transmission are referred to chapter 2.4 of this manual, where the
wiring diagram as well as the interface diagram is shown.

1.3.3 Group three-external connections

1.3.3.1Oil cooler connections
There are two oil cooler pipe connections on the front of the transmission casing. An oil cooler is
fitted alongside the radiator of the engine to maintain the transmission oil temperature below
120°C.
The oil flows out of the transmission out of the right side connector. This transmission oil output
(Oil TR OUT) should be connected to the Input of the oil cooler which is the lower connector on the
oil cooler. The oil flows out of the oil cooler through the top connector of the oil cooler. This top
connector should be connected to the transmission left side connector (Oil TR IN).

Oil TR
IN
Oil Flow
Oil TR
OUT

Out Oil Cooler

In
Oil Flow
Fig.16 Oil cooler pipe connections

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1.3.3.2 Sector shaft

Possible shift positions for the VT2 transmission are Park, Reverse, Neutral, Drive and Sport or
Lowdrive position.
The configuration of the selector lever is customer specific. For safety reasons it is
recommended to implement a shift lock in the mechanism, to provide an idiot start
protection.
It is also possible to have a tip-function included. This means that additional interfaces to the TCU
are to be provided in order to get the tip-signals to the TCU. Also the calibrations for the maximum
engine speeds can be adapted within certain limits.

1.3.3.3 Main connector

The connector consists of 16 pins and is located in the transmission casing. The
harness connection is via a circular connector.

Fig.17 Harness block on gearbox

1.3.3.4 Torsional damper

The engine is connected to the input shaft in the transmission, via a torsional damper, instead of
the torque converter used by more conventional automatic transmissions. This torsional damper is
not a part of the transmission. Punch strongly recommends the use of a so-called Dual Mass Flywheel.

259
1.4 Driving Strategies
1.4.1 Behavior in specific situations
The behavior of a vehicle, fitted with CVT, will now be discussed in the following specific situations:

1.4.1.1Functionality of Park and Neutral

The engine can only be started in Neutral or Park, as with any automatic transmission. In the Park
position, there is a mechanical lock that prevents the vehicle from moving forward or backward.
The Park position should only be engaged at standstill to avoid transmission damage. If, by
accident, the Park position is selected at higher speeds, the park mechanism will not engage until
the vehicle speed has dropped to approximately 5 km/h.

1.Parking pawl

2.Secondary pulley

Fig.18 Parking lock

At starting, the TCU will control the start lock relay which will control the starter engine. The gear
positions are coming from an internal position switch. This position switch is directly related to the
gear shifter.
Mandatory for all Position shifts starting from positions P or N to D (Drive) or R
(Reverse) is the activation of the brake pedal. Without pushing the brake pedal the
position lever stays locked in the starting position (Not for shifter mechanism with
mechanical shift lock) (→see also Shift Lock).

1.4.1.2 Functionality in D (or R) position

1.4.1.2.1 Normal operation

The operation of the transmission, during driving, has no comparison with that of a
conventional automatic transmission. All kinds of tunings are possible. A possible
tuning is that if the accelerator pedal is depressed sharply, the engine rpm will rise
considerably more than in relation to the speed of the vehicle. This functionality is
normal for a CVT but may surprise drivers not familiar with this type of transmission.
Other tunings / variograms are also possible, for example tunings that are closer to that of
a conventional automatic transmission.

259
1.4.1.2.2 Engagements
In both directions there is a clutch adaptation for an optimal engagement over
lifetime.

1.4.1.2.3 Creeping
When the position lever is in Drive (D) or Reverse (R) and the driver releases the brake pedal the
car should start creeping as known from automatic transmissions (with engine running on flat
roads). Creeping is also provided when driving onto slowly ascending (up to 8°) roads. On roads
with higher slopes the car is allowed to roll back slightly - like with automatic transmissions with
torque converter. At high slopes, there is no hold). Independent of the slope of the road the
maximum velocity during creeping is kept below a defined threshold (e.g. 8kph). Especially on
descending roads the clutch control will drive the clutch from slipping to the "closed" mode to allow
braking by use of the engine under coast conditions.

1.4.1.2.4 Idle stop (only in D)

The VT2 transmission has the ability to perform idle stops. These idle stops can take place under
certain conditions, both from vehicle (battery status, A/C on/off) and transmission side (situation
not affecting the transmission‘s durability). If all requirements are met, at standstill, the combustion
engine will be switched off. Only after the brake pedal is no longer applied, the engine is restarted
and within a short time the transmission is operational again and the vehicle will start to move
forward again.
The idle stop functionality is developed especially for hybrid drivelines. Standard drivelines without
special starters or starter generators do not benefit from this functionality on gearbox side.

1.4.1.2.5 Pull-away and stall speed

The objective of the pull away phase is to provide acceleration (performance) in correlation to the
driver demand and aligned to the driving situation. The setpoint trajectory for the engine and
primary speed are aligned to each other to achieve the maximum driving comfort.
The clutch controller also provides certain means to compensate variances in the clutch behavior
due to deterioration over life time (and tolerances between different vehicles) to keep the driving
comfort over lifetime and over the fleet deviations on a constantly high level.

1.4.1.2.6 Pull-away support

For an optimised driving comfort a compromise was found between higher engine
speeds used to provide sufficient traction power (performance) and lower engine
speeds when the vehicle has reached a cruising state with constant velocity (fuel
economy).
The transmission control system provides functionality to follow these requirements by using
co-operative control modes between variator (ratio control) and start-up clutch. So during pull, the
control targets are always focused on the driving performance with higher engine speeds that are
in correlation to the acceleration of the vehicle while during cruising or roll-out the focus is moved
to fuel economy with lowest engine speeds near the characteristic booming noise threshold of the
drive line.
This co-operative control is only provided in combination with Punch‘s driving strategy.

1.4.1.2.7 Stall speed

If the driver keeps the brake activated while pushing the accelerator pedal the engine speed will be
limited to a certain level similar as it is known from automatic transmissions with a torque converter.
To achieve this, the transmission uses the request for torque truncation in co-operation with the
engine control system. The clutch will be controlled in such a way that a fast response is endured if
the driver would suddenly release the brake pedal for start off. Since this situation over longer time
would affect high temperature losses at the clutch with the risk of serious damages at the
transmission, there are monitoring functions implemented to detect the critical situations. If
activated the intrinsic diagnostic system of the transmission will open the clutch. In this case the

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engine speed will rev up to the maximum engine speed if the driver would still keep the accelerator
pedal pushed.
1.4.1.2.8 Roll out and brake down
When the car is decelerating down to standstill the clutch is opened again to avoid stalling of the
engine. The clutch pressure is controlled in such a way that the release of the clutch doesn't cause
torque shocks. Therefore the controller provides different modes to adapt the transition to the
―open" clutch to the gradient of the vehicle speed. The clutch pressure control is also adapted to
the dynamic of the hydraulic control system in dependency from the transmission oil temperature.
After opening the clutch is again quickly prepared for a potential start-off.
To optimize the driving comfort during the transition between brake down and start-off the
transmission software is co-operating with the other driveline controllers. This cooperation can
result in temporarily torque truncation and increased idle speeds.

1.4.1.2.9 Engagements / disengagements during drive

If the clutch (brake) is disengaged during drive there are only small options for the transmission
controller to have an impact on the driving comfort since the release of the clutch is purely realized
by the characteristic of the hydraulic system. Re-applying the clutch under these conditions (low
load or even coast down and low engine speeds) can result in a slightly reduced driving comfort
compared to engagements at standstill.

1.4.1.3 Fault mode

If the software detects an error within the system, a default strategy will be engaged. These
conditions are communicated to the driver via the fault indication in the
instrument cluster. Depending on the severity of the fault, the driver will experience different
default driving modes. In some conditions the main relay is opened. All fault codes are on the
OBD.
Section2 Service Information

2.1 Towing of the Vehicle

The VT2 transmission must not be towed. This is because there is no oil pressure in the primary
pulley unless the engine is running and belt slip would therefore occur. Recovery must be
conducted with the front wheels lifted clear of the ground (suspended tow).

2.2 Service Intervals

At least every 60.000 km it is compulsory to change the oil filter and refill the transmission with
new oil. For this purpose, the gearbox is equipped with an oil drain plug and a top filler plug. The
vehicle manufacturer can reduce the service interval of the transmission to match it with the
standard service intervals for the vehicle.

2.3 Oil Specification

MOBIL (ESSO) EZL799 (A).

The use of other oil might lead to damages in the transmission and will result in rejection of
warranty claims.

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2.4 Wiring Diagram
2.4.1 TCU Interfaces

262
The TCU has following interfaces with the transmission:

Fig. 19: TCU interfaces with the transmission

The TCU communication with the transmission goes through a connector and is transferred through
the internal cable harness. The pin layout of the connector is as shown below:

263
 2.4.2 Transmission connector layout

Fig.20: The transmission connector Layout.

Signal
DMS: Drive Mode Sensor‖ or ―Position / Inhibitor sensor‖
EDS_1: Primary pressure regulator (solenoid)
EDS_2: Secondary pressure regulator (solenoid)
EDS_3: Clutch pressure regulator (solenoid)
P_S2: Secondary pressure sensor
N_ab: Secondary speed sensor
N_S1 or N_Prim: Primary speed sensor

264
2.4.3 TCU wiring diagram

265
2.4.4 TCU connector pin assignment for VT2

VT2 –Signals Pin number

Permanent Supply Kl.30 1; 2

Ignition Kl.15 (wake-up) 6
Ground Kl.31 3; 4
VHSD1 (actuator supply) 5

Speed- & DMSensor supply (8,4V) 30; 77; 78

Pressure sensor supply (5V) 32; 74
GND Drive mode sensor 33
GND: Sensor Ground 41; 64; 86;
Transmission oil temperature 38
N_Prim (primary speed input) 61
N_ab (speed signal) 63

N_MOT (engine speed signal) 87

DMS_A 57
DMS_B 58
DMS_C 79
DMS_D 35
Dig.Inp1 (pull-up K30)（Brake signal） 34
Dig.Inp2 (pull-up K30)(Sport/Manual) 59
Dig.Inp3 (pull-up K30)(Tip up) 81
Dig.Inp4 (pull-up K30)(Tip down) 80

P_S2 (secondary pressure) 75

P cluch (clutch pressure optional) 76
Shift Lock 48

K-Line 85
CAN- High 9
CAN- Low 8

Start Lock(no connection) 92

EDS1 91
EDS2 90
EDS3） 89

Back light relay 71

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2.4.5 Connections of TCU to Transmission connector

Fig.22: The connections of the TCU to the transmission

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2.5 Clutch Adaptation Procedure
Introduction:
After:-uploading new software in the TCU or
-replacement of transmission or
-replacement of TCU,
the clutches need an adaptation to compensate for
tolerances. This can be done by executing shift actions
during idle.
The TCU warning lamp will blink at a 2 second interval until the clutch adaptation
procedure is completed. Once this procedure is completed, lifetime adaptation occurs
automatically.

Pre-conditions:
These preconditions need to be met before starting the clutch adaptation procedure
- Stable torque and rotations per minute (rpm) in idle state are required. Engine
adaptation needs to be completed successfully for this. For more information on
engine adaptation, please refer to the Engine Control Unit (ECU) supplier‘s
documentation.
Engine rpm requirement ECU target value +/- 200 rpm
Engine torque requirement ECU target value +/- 12Nm
- The transmission oil temperature needs to be between 20°C and 60°C.
In case the TCU was adapted before (uploading new software in the TCU or replacement of
transmission); the TCU needs to be reset first. This is done using the MLT tool. Please refer to the
MLT documentation for more information.

Procedure:
Note: There is some variation on the number of cycles required for clutch adaptation.
The expected number of cycles is 5 to 15.

As soon as the procedure is finished (warning lamp stop blinking), the fault code
P0810 (EoL Clutch adaptation not finished) itself will become inactive and
automatically deleted after 3 driving cycles.
1 interval = warning lamp on-off-on or 5sec

268
269
Troubleshooting:

Problem Possible Cause Action

Transmission oil temperature Allow the transmission to heat up

is below 20℃during adaptation (Engine on).
process Restart adaptation procedure.

Warning lamp still blinks Transmission oil temperature Allow the transmission to cool
after 15 or more exceeds 60℃during adaptation down (Engine off).
adaptation cycles process Restart adaptation procedure.
(adaptation process not
Improve engine torque and
completed)
engine rpm stability.
Instable engine torque or
Make sure engine
instable engine rpm during
adaptation is completed
adaptation process.
successfully.
Restart adaptation procedure.

Section3 Service Instructions

3.1 Oil Refill/Check Instruction (Refill, Service Transmission, New
Oil/Oil Change)
This procedure implies whenever the oil has been drained from the transmission or transmission has
been replaced with a new service transmission.
Service transmissions are not pre-filled and need to be filled up after installing in the vehicle with
approximately 4.10 liters of ESSO EZL799 (A).
After the initial fill, the correct way to check the oil level is listed below:
- Start the engine and stay at idle for at least 10 seconds (note: air circulating through the system may
be heard on initial start-up, this is a normal operating condition).
- Shift gear lever into each position (P-R-N-D) and allow the gear to rest in each of its position for 5
seconds before progressing to the next position.
- Move the gear lever into ‗D‘ position.
- Release the foot brake.
- Apply a little throttle to at least 60 km/h (the engine speed must not be higher than 2500 rpm).
- Release the throttle and slightly break to a standstill (all the noises by air circulating in the system
during the first up shifting should be gone).
- To increase the oil temperature, drive carefully around for at least 5 minutes or until the temperature
of the transmission has reached approximately 60°C.
- Place the car on a flat ground.
- Apply the foot brake.
- Wait two seconds
- Move the gear lever into ‗R‘ position.
- Wait 10 seconds.
- Move the gear lever into ‗P‘ position.
- Keep the engine running idle.

270
- Remove the oil level plug (2)
- Make sure minimum 0,2 liters of oil flows out of the oil level tube after removing the level plug
(otherwise the initial amount of oil wasn‘t sufficient).
If not, add another 0,5 litre extra and redo complete procedure.
-Wait a few minutes until the oil that comes out of the level begins to drip
- Refit the oil level plug with new sealing ring (18-24Nm)
- Shutoff the engine.

Oil drain
plug (1)

Oil level
plug (2) Oil filling
Plug (3)

3.2 Oil Level Check

If the initial fill was done properly, the oil level will be at a correct level (―level-plug‖ level) .Due to
tolerances (such as: new transmissions are delivered with a residual oil volume and initial fill
tolerances) the tolerance on the correct ―level-plug‖-level will be ± 0.165 liter.
In case of an oil level check proceed as follow:
- Remove the oil filling plug (3) on top of the transmission - Fill the transmission with exactly 0.5 Litre
- Refit the oil filling plug (3) together with a new sealing ring (18-24Nm)
- To increase the oil temperature, drive carefully around for at least 5 minutes or until the temperature
of the transmission has reached approximately 60°C.
- Place the car on a flat ground.
- Apply the foot brake.
- Wait two seconds
- Move the gear lever into ‗P‘ position.
- Keep the engine running idle.
- Remove the oil level plug (2), while engine running idle
- Collect the drained oil (min 0.235 Litre and max 0.665 Litre)
-Minimum 0.235 litre (0.5ADDED OIL - 0.165tolerances -0.1L= 0.235 Litre) oil will drain out off the
transmission. If the collected amount is less:
the initial level was too low.
-Maximum 0.665 litre (0.5ADDED OIL + 0.165tolerances-0.1L = 0.565 Litre) oil will drain out off the
transmission. If the collected amount is more: the initial level was too high.

Mentioned values are valid for exactly 60deg.

- Refit the oil level plug (2) with new sealing ring (18-24Nm) - Shutoff the engine.

3.3 Shifter Cable Adjustment

This procedure describes how to connect the shifter inside the car correctly with the

271
transmission. If this is not done according following instruction, it is possible that the
transmission is in another state (PRND) than the driver (or shifter) wants.
The dashboard will always indicates what the state is of the transmission, regardless what the position
of the shifter is. For a good cable adjustment the dashboard and shifter will indicate the same position
(PRND).
-Put the shifter in P position
-Make sure the transmission is in P position, shift lever to the complete outer position
like on the picture:

Shift lever in P position for cable adjustment

If the shift lever is not in this position, push the shift lever manually to the outer right position:

Shift lever NOT in P position, NOT OK for cable adjustment

-The P position can be verified by checking the indication on the dashboard.
-Turn both front wheels at the same time till they are locked. Now the transmission is
locked in P position. You can still however turn the shift lever out of P position but do
not do this at this moment.
-If there is a bracket to hold the cable, connect first the cable to the bracket.
-Connect now the cable to the shift lever with screw and nut.
-When tightening the screw, do not bend the cable or the shift lever!

The shifter inside the car is now aligned with the transmission and dashboard will show the same
position like the shifter.

272
3.4 Exploded View Service Parts

273
 Service Part List and Torque Information

Item 4
Oil seal differential

482871

Item 2
Oil seal input shaft

481274

Item 48
Washer shift lever

482584

Item 46
Nm Nut M8 self locking
shift lever
(14,5 +/-1,5 Nm)
481329

Item 49
Oil seal selector shaft
482099

Item 47
Lever selector shaft
482751

274
Item 22
Primary cover

481173

Item 23
Clip primary cover

481189

Item 21
O-ring primary cover 177,47 x 2,62
481253

Item 24
Bolt primary cover M6x16 (9,5 +/-2,5 Nm)

481283

Item 18
O-ring oil pump

481259

Item 20
Bolts oil pump
(10 +/-1 Nm)
481284

Item 15
Primary nut (197,5 +/-17,5 Nm)

481293

275
 Item 17
Sealing ring oil pump
481826

Item 16
Belle-ville washer
481856

Item 19
Oil pump

483323

Item 14
Primary ball bearing
482294

Item 5
M14 Sealing ring plug M14
481247

Item 6
Plug M14
(21 +/-3 Nm)
481248

276
Item 41
Sealing ring plug M10
481249

Item 42
Plug M10
(15 +/-2,25 Nm)
481250

Item 12

Secondary cover
482982

Item 9
O-ring secondary cover 17.12 x 2.62
481254

Item 11
O-ring secondary cover 72.63 x 3.53
481255

Item 10
Sealing ring
secondary cover
481877

Item 13
Secondary cover countersunk head screw
(9,5 +/-0,95 Nm)
482208

277
 Item 33
Oil filter (incl. O-ring)
482456

Item 24
Flanged bolt oil pan M6x16 (9 +/-1 Nm)
481283

Item 29
Gasket oil pan
482504

Item 34
Magnet oil filter
481870

Item 36
Drain plug (11 +/-1 Nm)
482442

Item 35
Oil pan cpl (magnet+drain plug)
482489

Item 30
Valvebody cpl
482589

278
Item 31
Bolt valvebody
(11 +/-1 Nm)
481311

Item 38
Position switch cpl
482493

Item 37
Bolt position switch
(9,5 +/-0,95 Nm)
481090

Item 27
Bracket output speed sensor
482468

Item 26
9.5 +/-0.95 Nm Bolt bracket output
speed sensor (9,5 +/-0,95 Nm)
481289

Item 25
Input/output speed sensor
482410

Item 24
Bolt speed sensors (8,5 +/- 2 Nm)
481283

279
 Item 39
O-ring plug oil cooler connection
481258

Item 40
Plug oil cooler
connection
482121

Item 1
Plug input shaft
482235

Item 3
Plug output shaft
481296

Item 44
Clip main connector
482105

Item 45
Main connector and internal cable
harness
482475

Item 8
Breather pipe assembly
483114

280
Item 7
Breather cover
483420

Item 50
Clip (metal)
481456

Item 51
Clip breather

482253 pipe(plastic)

Item 43
Protection cap

482104
connector

482721
TCU (Ottawa)
482843
TCU (Bilbao)

482755
New Transmission (no TCU)

Remanufactured
482958

Transmission (no TCU)

281
*Extra Note on the oil pump (Vehicle Safety Warning):
There are transmissions with an oil pump of type (482773) and transmissions with an oil
pump of type (483323).
All transmission ID nrs. higher than:
14009832
use the oil pump of type (483323)

It is a vehicle safety requirement that all transmissions with ID nr. lower than
mentioned above can only be replaced with a pump type of (482773)!
It is a same vehicle safety requirement that all transmissions with ID nr. higher
than mentioned above can only be replaced with a pump type of (483323)!

If transmission ID nr. should be missing or be unreadable due to some reason then it is

still possible to determine which type needs to be used when replacing the pump.
When taking out the original oil pump you can determine which type it was and only a
new pump of the same type can be replaced:

A pump of type 483323 as spare part will have a yellow label attached with the same
ID information as mentioned above, this for the attention of the technician.

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3.6 Special Tools and Replacement of Service Parts
3.6.1. Special tools

Plug – Primary bearing (drawing T00222)

Stamp – oil seal selector shaft (drawing 480125)

283
 Stamp – Primary bearing (drawing 480137 + 480126)

Removing tool – primary bearing (drawing 480136)

284
 Stamp – oil seal input shaft (drawing 480130)

Centering bush – oil seal input shaft (drawing 480129)

285
 Removing tool – oil seal selector shaft (drawing 480127)

Centering pin – hydraulic unit (drawing 23K002-099-84312)

286
Stamp – oil seal differential (drawing 23K002-099-84336)

287
 Removing tool – pump (drawing 23K002-099-84295)

Assembly tool - breather pipe (drawing 480140)

Assembly tool drive shaft (drawing 480154)

Note: Pictures can differ from actual tools and drawings

288
3.6.2 Instructions for replacing of the service parts

3.6.2.1. Drive shaft assembly

During the assembly of the drive shafts into the transmission, we strongly recommend to use Punch
Tool 480145 in order to protect the oil seal at the differential.
When the driveshaft should damage the oil seal, oil leakage is the unavoidable consequence.
Using this tool will significantly reduce the chance of damaging the oil seal.
-Remove the protection covers:

Fig. 1-1: Protective covers for differential seal

-Install tool 480145 over the output seal:

Fig. 1-2: Assembly tool drive shaft 480145 mounted

289
-Insert drive shaft for max 4cm into the transmission:

Fig. 1-3: Drive shaft inserted for 4cm

-Stop and leave 2 cm distance between the driveshaft and mounting tool:

Fig. 1-4: 2 cm distance between drive shaft and tool 480145

290
-Remove the tool 480145

Fig. 1-5: Tool 480145 removed

-Push driveshaft completely into the transmission:

Fig. 1-6: Drive shaft mounted

291
3.6.2.2. Replacing differential seal
When:
In case of damage/leakage on seal or half shaft. How:
-Drain the oil of the transmission (see changing oil filter) -Remove half shaft
-use a big screwdriver to pinch out the seal. Be careful not to put screwdriver in too deep，
otherwise the housing can be damaged by the tip of the screwdriver (see Fig. 2-1)
-Discard the old oil seal
-Take a new seal and put it in the housing (see Fig. 2-2)
-Place the special tool (480143) on the seal and use a rubber hammer to knock oil seal into the
housing. Hammer it all the way in until no further is possible .
-The depth of the oil seal should now be 3mm ± 0.3mm from the edge of the housing -Replace
the half shaft if necessary
-Refill transmission according instruction (see 3.1)

Fig. 2-1: Remove oil seal

292
 Fig. 2-2: Installing new seal with special tool

3.6.2.3. Replacing input shaft seal

When:
In case of damage or leakage on seal
How:
-Drain the oil of the transmission (see changing oil filter) -Remove the transmission from the car
-Use a big screwdriver to peel out the seal from the transmission (see Fig. 3-1). Peel out the
seal from the inside of the seal by going around and around. Be careful not to damage the input
shaft
-Discard the old oil seal

Fig. 3-1: Remove input shaft seal

-Place the special guiding tool (480129) on input shaft（see Fig. 3-2)
-Slide a new seal over the guiding tool (see Fig. 2-3)

293
 Fig. 3-2: Put special tool on input shaft (480129)

Fig. 3-3: Press the oil seal

-Place the special stamp tool (480130) on input shaft（see Fig. 3-4)
-Hit the special stamp tool with rubber hammer until no further is
possible -Remove special tools and refit transmission in vehicle
-Refill transmission according instruction (see 3.1)

Fig. 3-4: Installing seal by special stamp (480130)

294
3.6.2.4. Replacing oil seal selector shaft
When:
In case of leakage on oil seal selector
shaft How:
-Drain the oil of the transmission (see changing oil filter)
-Remove the transmission from the car
-Remove lever selector shaft
-Place special tool (480127) over the selector shaft (see Fig. 4-1)
-Screw in the special tool with wrench. Push on top of the wrench so the tool has the
ability to screw itself into the seal (see Fig. 4-2)
-Screw in the screw on top of the special tool to lift out the seal (see Fig. 4-3)
-Discard the seal (see Fig. 4-4)

Fig. 4-1: Put special tool (480127) on shaft

Fig. 4-2: Press and screw tool clockwise

295
 Fig. 4-3: Rotate screw to remove the seal

Fig.4-4: Remove the oil seal

-Put some Vaseline or grease on the tip of the stamp (480125) (see arrow in Fig. 4-5)
-Take a new seal and slide it over the special stamp (480125) (see Fig. 4-5).
-Place special stamp tool (480125) with seal over the selector shaft and hammer in the
seal until no further possible (see Fig. 4-6 and 4-7).
-Pull out the special stamp tool (480125)

296
 Fig. 4-5: Slide the seal over the special stamp (480125)

Fig. 4-6: Place special stamp (480125) with seal over the selector shaft

297
 Fig. 4-7: Hammer down special stamp (480125) with seal till no further is possible

-Remove the stamp while rotating, otherwise there is the possibility the seal comes
back out with the stamp
-Remount the lever selector shaft with new washer (482584) and nut (481329).
-Tighten the nut with 14.5Nm±1.5Nm
-Refit transmission in vehicle
-Refill transmission according instruction (see 3.1)

3.6.2.5. Replacing primary cover

When:
In case of leakage on primary cover
How:
-Drain approx. 1litre of oil out of the transmission (see replacing oil filter)
-The transmission does not need to be removed from the vehicle but may be lowered
together with the engine for easier access
-Loosen the three bolts and clips which are fixing the primary cover to the housing.
-Use a screwdriver to lift out the primary cover. Use some cloth to protect the
transmission from damage (see Fig. 5-1) .
-Remove the big O-ring and discard both O-ring and primary cover
-Take a new O-ring and assemble it
-Replace a new primary cover and fix clips and bolts with a torque of 9.5Nm +/- 2.5Nm
-Refill transmission with 1litre of oil

298
 Fig. 5-1: Remove primary cover from transmission

3.6.2.6. Replacing oil pump

Vehicle Safety Warning: Please read carefully the extra note on the oil pump in section 3.5 Service
Parts
When:
In case the transmission pressure is too low or the driver feel shocks or abnormal
driving behavior, two main parts can cause this problem, hydraulic unit or oil pump. Also analyze the
P-code and follow actions on specific P-code to replace either
hydraulic unit or pump. In most of cases it is unclear which one the problem causes so one by one can
be replaced and see if the problem is solved.
How:
-Follow the steps to remove the primary cover
-Remove the 6 pump bolts and place special tool (480141) (see Fig. 6-1)
-Pull the sliding part of the tool a few times to lift out the pump (see Fig. 6-2).
-Replace the pump with a new one. Make sure you put 2 new O-rings on the new
pump. Do not take out the Belle-ville washer and leave it in its correct position which is biggest
diameter facing the pump (see Fig. 6-3)
-Put the 6 screws back and tighten with (10Nm +/- 1Nm)
-Follow the steps to close back the primary cover, no need to take new primary cover O-ring and
primary cover。

299
 Fig. 6-1: Remove six bolts and place tool

Fig.6-2: Pull the tool to lift out pump

300
 Fig.6-3: Belle-ville washer
3.6.2.7 Replacing primary ball bearing

When:
In case of worn out primary ball bearing. A worn out primary ball bearing gives a big .
noise for which the frequency is dependent on engine speed. This can be easily checked by driving at
a constant speed and shift to sport mode. The engine rpm will go up and if the noise frequency also
goes up, then there is a big possibility that you have a worn out primary ball bearing.
How:
-Follow the steps to remove the oil pump .
-Remove Belle-ville washer .
-Mark the position of the primary nut on the shaft (see Fig. 7-1) .
-Using an air impact wrench with a torque capacity of +/-300Nm, remove the primary nut .
-Lever out the seal of the primary ball bearing using a small screwdriver (see Fig. 7-2) -Place the
special tool primary plug (480139) (see Fig. 7-3) .
-Assemble the bearing puller (480136) underneath the exterior ring of the primary bearing (see Fig.
7-4)
-Remove primary bearing by tightening the centre bolt of the bearing puller (see Fig. 7-5) .
-Discard primary bearing, clean primary shaft, clean sealant from threads in oil pump drive shaft and
clean oil pump housing (see Fig. 7-6).
-Place a new bearing on the primary shaft and use special stamp tool (480137 + 480126) to put
bearing in. Use rubber hammer and hit until no further possible (see Fig. 7-7).
-Fit and tighten nut using an air impact wrench for sufficient duration until the marks on nut and shaft
are in line(+/-5°) .
-Place back the Belle-ville washer, biggest diameter facing the pump -Follow the steps of putting back
the oil pump.

301
 Fig. 7-1: Mark primary nut and shaft

Fig. 7-2: Lever out seal from primary bearing

302
Fig. 7-3: Put special tool on shaft (primary plug T00222)

Fig.7-4: Assemble bearing puller (480136)

303
 Fig. 7-5: Tighten centre bolt of bearing puller to lift out bearing

Fig. 7-6: Remove primary bearing

304
 Fig.7-7: Fit new primary ball bearing

3.6.2.8 Replacing secondary cover

When:
In case of secondary cover damage or leak.
How:
-The transmission does not need to be removed from the vehicle but may be lowered together with the
engine for easier access .
-Loosen the four screws and discard screws
-Take off secondary cover, remove the small and bigger O-ring and the center sealing ring .
-In case of damaged cover, take a new secondary cover
-Replace new O-rings and sealing ring
-Remove the glue (glue from the sealant screws) gently from the transmission housing
-Tighten the secondary cover with 4 new screws, torque 9.5Nm +/- 0.95Nm
3.6.2.9 Replacing oil pan
When:
In case of oil pan damage and or leak.
How:
-Drain the oil by removing the oil drain plug (see Fig. 9-1) -Let all oil drip out, discard old drain plug .
-Remove oil pan by unscrewing all 13 screws from the oil pan (see Fig. 9-2).
-Discard the oil pan gasket and oil pan.
-Take new oil pan and gasket.
-Fix oil pan with new gasket by tightening the screws according to Fig. 9-3 with 9.5Nm +/- 1Nm.
-Refill transmission according to instruction (see 3.1).

305
 Fig.9-1 Remove oil drain plug

Fig.9-2 Removing the oil pan

306
 Fig.9-3: Bolts sequence

3.6.2.10 Replacing oil filter

When:
Oil filter need to be replaced at least every 60000 km. This service interval can be advanced to match
with the standard service of the vehicle.
How:
-Drain the oil by removing the oil drain plug (see Fig. 9-1).
-Let all oil drip out, discard old drain plug .
-Refit new drain plug and tighten with 11Nm +/-1Nm .
-Remove oil pan by unscrewing all 13 screws from the oil pan (see Fig. 9-2) .
-Discard the oil pan gasket.
-Remove the oil filter by pulling it gently, discard oil filter.
-Take new filter with O-ring and lubricate the O-ring with clean ESSO EZL799(A) (see Fig. 10-1).
-Press in gently the new oil filter and position correctly (centre hole of oil filter should match centre bolt
of hydraulic unit) (see Fig. 10-2).
-Clean magnet and surface of oil pan and place a new oil pan gasket .
-Place oil pan with new gasket in place and tighten the 13 screws according to Fig. 9-3 with 9.5Nm +/-
1Nm.
-Refill transmission according instruction (see 3.1).

307
 Fig. 10-1: Lubricate the 0-ring

Fig. 10-2: Fix oil filter in position

3.6.2.11 Replacing drive mode sensor

When:
In case of faulty drive mode sensor. Dedicated error code should indicate problem with drive mode
sensor. Replace drive mode sensor when error code action indicates it.
How:
-Follow steps to remove oil filter.
-Unscrew the 2 bolts of the drive mode sensor (see Fig. 11-1) .

308
-Be careful to remove the drive mode sensor from the hydraulic unit because the back of the sensor is
locked with a pin in the metal slide of the hydraulic unit. Push the sensor down to remove the pin from
the metal slide (see Fig. 11-2).
-Use small screwdriver to unlock the gray lock button of the drive mode sensor.
connector by pushing it forward (see Fig. 11-3). Now it is possible to disconnect the drive mode sensor
from the main cable harness.
-Take a new drive mode sensor, connect the connector to the main cable harness and lock it by
pushing the gray lock button.
-Place drive mode sensor against the metal slide, with the pin on the back of the sensor locked in the
dedicated space on the slide (see Fig. 11-4).
-Align the drive mode sensor so the screw holes align up .
-Tighten the 2 screws with 9.5Nm +/- 0.95Nm.
-Follow the steps to place back the oil filter.

Fig. 11-1: Loosen drive mode sensor bolts

Fig. 11-2: Push sensor down to remove pin from metal slide

309
 Fig. 11-3: Unlock drive mode sensor connector

Fig. 11-4: Pin locked in dedicated space of the metal slide

3.6.2.12 Replacing hydraulic unit

When:
In case there is a problem with the transmission pressure or the driver feel shocks or
abnormal driving behavior, two main parts can cause this problem, hydraulic unit or
oil pump. Also analyze the P-code and follow actions on specific P-code to replace
either hydraulic unit or pump. In most of cases it is unclear which one the problem
causes so one by one can be replaced and see if the problem is solved.
How:

310
-Follow steps to remove the drive mode sensor
-Follow the sequence on Fig. 12-1 in reverse order 20-19-18-17-16-15-14-13-12-11-
10-9-8-7-6-5-4-3-2-1 to unscrew all hydraulic unit bolts
-Take out the hydraulic unit and disconnect the 4 connectors. A small screwdriver can be used
carefully to disconnect easier (see Fig. 12-2 and 12-3)
-Take a new hydraulic unit and connect the 4 connectors. No mistake can be made due to the length of
the cables
-Place the hydraulic unit in place, there is a guiding pin on the back of the hydraulic unit that fits into a
dedicated hole (see Fig. 12-4)
-Make sure that the metal slide fits in the pin of the rooster cam plate (see Fig. 12-5) -Place the center
screw and hand tighten it
-Place the special alignment tool (480142) on the top left screw hole and screw it in (see Fig. 12-6)
-Push the speed sensor cable behind the upper left corner of the hydraulic unit (see Fig. 12-6)
-Place all screws of hydraulic unit, except the upper left one and tighten with 11Nm +/-
1Nm in sequence 1-2-3-4-5-6-7-8-9-10-11-12-13-14-15-16-17-18-19-20 on Fig. 11-1

18 11 15

5 7 19
8
13
12 1
3 2

9
16 6 4
17
20 10 14

Fig. 12-1: Order of the bolts

311
 Fig. 12-2: Use a screwdriver to separate the 4 connectors

Fig. 12-3: Use a screwdriver to separate the 4 connectors

312
Fig. 12-4: Guiding pin on the back of hydraulic unit

Fig. 12-5: Pin of rooster cam needs to fit in metal slide

313
 Fig. 21-6: Special alignment (480142) tool for hydr. unit
3.6.2.13 Replacing output speed sensor and bracket

When:
In case indicated by actions from the error code list How:
-Follow steps to remove the hydraulic unit
-Loosen bolt bracket output speed sensor and discard bolt (see Fig. 13-1)
-Slide out the bracket, there is a dedicated sleeve in the selector shaft! (see Fig. 13-2) -Disconnect
cable from speed sensor with long flat nose pliers (see Fig. 13-3)
-Remove sensor from bracket by unscrewing bolt
-Discard sensor and/or bracket
-Take new sensor and/or bracket and mount together with bolt (Torque 8.5Nm +/-
2Nm)
-Connect wire and slide bracket back in the selector shaft
-Take a new bolt bracket output speed sensor and tighten with 9.5Nm +/- 0.95Nm -Follow steps to
place back the hydraulic unit

314
Fig. 13-1: Loosen bolt bracket output speed sensor

Fig. 13-2: Bracket output speed sensor

Fig. 13-3: Use long flat nose pliers to disconnect

315
3.6.2.14 Replacing primary speed sensor

When:
In case indicated by actions from the error code list How:
-Follow steps to remove the primary cover
-Loosen bolt of speed sensor and take out sensor (see Fig. 14-1) -Disconnect wire and discard sensor
-Take new sensor and screw down with 8.5Nm +/- 2Nm -Connect wire to sensor
-Follow steps to put back primary cover

Fig. 14-1: Primary pulley speed sensor

3.6.2.15. Replacing main connector and internal cable harness

When:
In case indicated by actions from the error code list.
How:
-Follow steps to remove hydraulic unit.
-Disconnect output speed sensor .
-Disconnect the car cable harness connector from the main connector on the transmission .
-Remove the clip with pliers and push the main connector into the transmission (see Fig. 15-1, 15-2).
-The drive mode sensor connector is clipped on the transmission, loosen that one first (see Fig. 15-3) .
-Remove the complete cable harness from the transmission and discard
-Take new cable harness and put into transmission.
-The main connector has a sleeve which should fit over the securing key on Fig. 15-4, 15-5.
-The use of a 45deg angled nose pliers can be helpful to fit in the main connector.
-Push clip back on main connector.
-Push drive mode sensor connector on the transmission (see Fig. 15-6).
-Connect the output speed sensor
-Follow steps to place back the hydraulic unit

316
 Fig. 15-1: Remove the clip from the main connector

Fig. 15-2: Push main connector into the transmission

317
 Fig. 15-3: Remove drive mode sensor connector from transmission

Fig. 15-4: Securing key

318
 Fig. 15-5: Securing key

Fig. 15-6: Push drive mode sensor connector on the transmission

3.6.2.16. Replacing the breather pipe

When:
In case of breather pipe damage which can cause dirt or water to enter the transmission.
How:
-Possibly the air box, the battery and top bracket needs to be removed to have a clear access to the
breather pipe.
-Remove the clip on top of the breather pipe which connects it to the transmission housing.
-Remove the breather pipe with pliers. Connect the pliers at the root (Aluminum piece of the breather

319
pipe) and twist and pull to take it out.
- Place the new breather pipe (483114) into the special tool (480140), see Fig. 16-1. Put a little amount
of Vaseline on the Aluminum piece of the breather pipe.
-Place tool and breather pipe onto the transmission housing so the pipe runs about parallel with the
transmission, Fig. 16-2. Hammer down gently the breather pipe into the transmission house till the end
by using a plastic hammer on top of the special tool.
-Put the plastic clip (482253) around the pipe.
-Put the pins of the plastic clip thru the hole of the metal clip (481456).
-Push the metal clip firmly (till the end) onto the ridge of the transmission house.
-Slide the breather cap (483117) complete over the top of the breather pipe. Fig. 16-3
-Replace air box and battery if needed.

Fig. 16-1: Place the new breather pipe into the assembly tool

Fig. 16-2: Hammer down the tool till the end with plastic hammer

320
 Fig. 16-3: Place the clips and cap

3.7 Checklist of the Electronic Components in the Transmission

In most cases the error codes from the TCU will indicate if there is something wrong with one of the
electronic components inside the transmission.
The following resistor measurements can be performed to check if the electronic components are
faulty or not.
All measurements indicated here are performed on the main harness connector of the transmission.
1.Drive Mode Sensor
Check the internal resistance between the different DMS pins. DMS_GND = pin 6
DMS_A= pin 13
DMS_B= pin 14
DMS_C= pin 15
DMS_D= pin 16
DMS_Supply= pin 9

DMS_Supply DMS_A DMS_B DMS_C DMS_D

DMS_Supply X 17.2MOhm 17.2Mohm 17.2Mohm 17.2Mohm
DMS_A 17.2Mohm X 9Kohm 9Kohm 9Kohm
DMS_B 17.2Mohm 9Kohm X 9Kohm 9Kohm
DMS_C 17.2Mohm 9Kohm 9Kohm X 9Kohm
DMS_D 17.2Mohm 9Kohm 9Kohm 9Kohm
X
DMS_G ND 4.5Kohm 4.5Kohm 4.5Kohm 4.5Kohm

2.Oil Temp Sensor

Check the internal resistance of the Temp. sensor.
Measure between pin 5 and pin 7.
When temp. between 20°C and 40°C, we need to measure a resistance between 942 Ohm and
1121 Ohm.

321
3.Speed Sensor
This is a complicated 'Two Wire' component with no easy way of checking the correct way of
working.
Between pin 9 and pin 11, we need to measure a resistance of app. 24,3 MOhm.
Between pin 9 and pin 12, we need to measure a resistance of app. 24,3 MOhm.
NOTE: this method will not guarantee the correct function of the speed sensor.

4.Oil Pressure Sensor

Between pin 7 and pin 10, we need to measure a resistance of app. 44,3 KOhm.

5.Clutch Pressure Regulator

Between pin 1 and 4, we need to measure a resistance of app. 5,2 Ohm.

6.Primary Pressure Regulator

Between pin 1 and 3, we need to measure a resistance of app. 5,2 Ohm.

7.Secondary Pressure Regulator

Between pin 1 and 2, we need to measure a resistance of app. 5,2 Ohm.

8.TCU
No checking possible.
Remark: Ranges of resistor values can differ in function of the accuracy of the measuring
equipment.
Section4 Trouble Shooting Guide
4.1 Leaks
Fault Action
Leak from gearbox fluid pan gasket Ensure fluid pan bolts are correctly
tightened
Replace fluid pan gasket
Replace drain plug
Leak from gearbox drain plug Replace oil pan cpl
Ensure plug is correctly tightened
Replace drain plug
Leak from primary cover Replace oil pan cpl
Ensure that cover is correctly tightened
Replace O ring
Leak from secondary cover Replace primary cover
Ensure that cover is correctly tightened
Replace cover O-rings
Leak from selector shaft lever Replace secondary cover cpl
Leak from input shaft Replace selector shaft lever seal
Leak from differential oil seal(s) Replace input shaft seal
Leak from fluid cooler pipe connections Replace oil seals
Ensure that pipes are correctly tightened
Replace pipe to fluid cooler connection
sealing rings
Replace pipes

322
4.2 Noise Problems
4.2.1 Secondary gear sound
Sound description:
Sound best heard with a vehicle speed between 60kph to 90kph while slowly
accelerating. When releasing the gas pedal, sound normally is getting smaller, give throttle again,
the sound comes back.
The sound is like a whistle sound. The frequency of the sound goes up with vehicle speed.
This is a normal sound from the CVT which comes from the secondary gear running into the pinion
shaft gear.
4.2.2 Reverse sound
Sound description:
When standing still and shift to Reverse, a small whistle sound can be heard.
When releasing brake and start driving in Reverse the sound gets bigger and turns into a whining
sound.
This is a normal sound from the planetary gear set inside the transmission.
4.2.3 Low speed gear sound
Sound description:
When the vehicle speed is around 40kph, release gas pedal, while car is slowing down, a whistle
sound can be heard. This whistle sound is much lower in frequency than 4.2.1. and is much more
difficult to hear. This is a normal sound from the pinion and crown wheel. .
4.2.4 Primary ball bearing noise and inside bearing noise
Primary Ball bearing noise:
Sound description:
During driving in D, from low speeds on the car makes a noise like ―wengweng‖. The frequency
and volume of the noise gets higher with engine speed!
The noise goes up with engine speed and not with vehicle speed!
How to check and repair:
1. Drive in D at a constant speed, fix gas pedal and vehicle speed around 60kph. Shift to S (Sport)
mode: the engine speed will go up about 500rpm within 1 or 2 seconds while keeping the same
vehicle speed. If the sound also goes up (that means it goes up with engine speed and not with
vehicle speed), than there is a big chance the primary ball bearing is damaged. Replace Primary
ball bearing according 3.6.2.7.
2. Drive in manual mode 4th gear and fix your gas pedal so you have a vehicle speed of around
60kph. Shift to 3rd gear while keeping vehicle speed 60kph. The engine speed will go up about
800rpm. If the sound also goes up (that means it goes up with engine speed and not with vehicle
speed), than there is a big chance the primary ball bearing is damaged.
Replace Primary ball bearing according 3.6.2.7.

NOTE: Noise problems are very hard to evaluate so before to decide to replace a part of the
transmission or change the complete transmission, be sure that the noise is actually coming from
the transmission. Check or replace other parts of the car first which are easier to replace.

323
Use following chart to help to locate the origin of the noise:

―
―wengweng‖ bearing noise

From transmission Transmission inside

side bearing noise
s
i
Go up with engine Go up with vehicle dFrom engine side
speed speed e

s
Primary ball bearing Check parts
i in the
noise car d
e

Change primary ball Change transmission

bearing

Half shaft and wheel

bearing noise

Change half shaft or

wheel bearing

324
4.2.5 Noise due to water or contaminated oil inside transmission

Sound description:
Car standing still, brake and shift to D or R. As soon as you release the brake a ―gegege‖ sound
can be heard. This can be heard from the first mm the car is moving!
From creeping speed (10kph) by giving throttle to accelerate a ―zhi---― sound can be heard
between 10kph to 40kph.
In the beginning stage of water contamination it is possible you only hear the ―gegege― sound and
not yet the „zhi---― sound.
Some cars when taking off can have shocks also, depending on the level of contamination.

How to check and repair:

Drain the oil and remove oil pan and primary cover:

If the inside of primary cover and oil pan shows white stuff inside, than it is fully clear the
transmission has been contaminated with water or other oil or liquid.
Drain the oil as much as possible and discard oil filter.
Place new oil filter and re-fill the transmission according 3.1.
Drive the car for about 5 min at different speeds and accelerations.
Drain the oil and refill again. (Do this 2 or 3 times with driving the car in between until the noise
disappears).
The ―gegege‖ sound should disappear and the ―zhi---― sound as well.
The ―zhi---― sound you can make disappear with heating up the clutch by doing stall test: shift to D
with foot on brake and apply throttle‖
While doing the stall test you can get fault code P2787 (clutch temperature too high) This is just a
self protection of the transmission against over-heating of the clutch. The fault code will disappear
automatically and you can perform the stall test again until the ―zhi---― sound gets better or
disappears.
If the contamination was too big you will not be able to remove the sound and shocks. In that case
the transmission needs to be replaced.

4.2.6 Noise in N or P

1. Frequency and volume of noise goes up with engine speed

Try to find out if the noise comes from engine side or transmission side If engine side, check parts
related to engine
If transmission side, the only part you can check is the pump. Replace pump to check if the noise
is gone.
If noise does not disappear by replacing the pump then either input shaft needle bearing or
planetary gear set can be the source of the noise. In this case the transmission needs to be
replaced.
Frequency and volume of noise does not go up with engine speed
The noise should come from other parts of the car

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Use following chart to help to locate the origin of the noise:

Noise in N or P

Noise goes up Noise not

with goes up with
engine speed the engine
speed

Pump noise Input shaft bearing Noise comes Checking

or planetary gear from
other parts in
noise engine side
the car

Change Check all engine

Change pump transmission parts

NOTE: Noise problems are very hard to evaluate so before to decide to replace a part of the
transmission or change the complete transmission, be sure that the noise is actually coming from
the transmission. Check or replace other parts of the car first which are easier to replace.

4.3 Shocks and no Creep Problems

4.3.1 Shocks

Problem description:
During driving in D the car shows small vibrations in speed or small shocks can be felt.

Check and repair:

There could be many possibilities for this problem:

1. Clutch adaptation not fully finished: check procedure 2.5.

2. Water or contaminated oil inside transmission: check 4.2.5.
3. Primary speed sensor: replace by instruction 3.6.2.14.
4. Hydraulic unit problem: replace by instruction 3.6.2.12. and redo clutch
adaptation procedure 2.5.
5. Secondary speed sensor: replace by instruction 3.6.2.13.
6. If still has the problem after trying 1. to 5., please contact After Sales team

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4.3.2 No creep sequence of actions whenever the problem is
solved.
Problem description:
Shift to D, release brake, the car does not P0710 Oil temperature sensor fault
move. Give throttle and the car start moving Reaction from TCU：
with or without shock from about 2000rpm. Warning lamp，Substitute transmission oil
temperature
Check and repair: Man actions:
1. Measure the oil temperature online with
1. Check if there is a fault code activated: tester tool; if the signal value is feasible, just
check according 4.4. clear the FC and check if it does not come
2. If the problem happens normally in cold back
condition: redo and check clutch adaptation 2. Check wiring (SG, SB, OC), based on this
2.5. replace either transmission cable harness or
3. Brake signal problem: if brake is not vehicle cable harness
applied but brake signal is activated (see with 3. Measure resistance between two pins on
tester tool or MLT). Check brake switch and transmission connector (20deg = 980 to 1000
car cable harness. Ohm) to see if sensor is defective. If it's
4. Hydraulic unit problem: replace hydraulic defective, skip next step and directly replace
unit by instruction 3.6.2.12. and redo clutch transmission cable harness
adaptation procedure 2.5. 4. Replace TCU by known good one 5. replace
5. If still has the problem after trying 1. to 4. transmission
please contact After Sales team
P2765 Primary pulley speed sensor fault
4.4 P-codes and Actions Reaction from TCU：
General remark: High side* off，Warning lamp
Whenever there is an error (DTC) detected by Man actions:
the transmission electronics (TCU), the 1. Measure the primary speed sensor value
warning lamp on the dashboard will be online with tester tool; if the signal value is
activated or flashing. When reading out the feasible, just clear the FC and check if it does
DTCs with the tester tool and a P-code is not come back
found, first check if this P-code is a sporadic 2. Check wiring (SG, SB, OC), based on this
fault that did not occur in the last driving cycle replace either transmission cable harness or
(should be indicated with an „H― from History). vehicle cable harness
If so, just delete the FC and check if it does not 3. Replace TCU by known good one
come back. If not a sporadic fault, but currently 4. Replace speed sensor
active (Should be indicated with a „C― from
Currently), follow the action steps described P0720 Secondary pulley speed sensor fault
below for each error code. Always check if the Reaction from TCU：
latest software is present. If not flash to the
For (Ottawa) F6-S8: High side* off，Warning
latest TCU software and check the fault codes
lamp
again.
For (Bilbao) G3: Warning lamp, Substitute
General Remark: whenever there is a fault
secondary pulley speed Man actions:
code or a problem with the transmission there
1. Measure the secondary speed sensor value
are 3 basic actions to perform first:
online with tester tool; if the signal value is
a. check oil type
feasible, just clear the FC and check if it does
b. check oil level
not come back
c. redo clutch adaptation
2. Check wiring (SG, SB, OC), based on this
Do not perform all „Man actions―, stop the

327
replace either transmission cable harness or vehicle cable harness
vehicle cable harness 4. Replace TCU by known good one
3. Replace TCU by known good one 4. replace
speed sensor P0659 High side* SCB
Reaction from TCU：
P0840 Secondary pressure sensor fault High side* off，Warning lamp
Reaction from TCU： Man actions:
High side* off， Warning lamp Man actions: 1. Measure the HS voltage ，the same voltage
1. Measure the actual and target secondary level as the battery should be read out . If
pressure online with tester tool; if the signal so, check wiring (check if shortcut between
value is feasible, just clear the FC and check if battery + and VHS, transmission connector).
it does not come back。 This means fix the harness (transmission
2. Check wiring based on the values read out harness or vehicle harness) . If not (same as
in step one (SG: 0 bar (actual pressure), SB: battery) but higher than 3.4 V, then exchange
60 bar, OC: 60 bar): replace either the TCU.
transmission cable harness or vehicle cable
harness P0658 High side* SCG or OC
3. Replace TCU by known good one 4. replace Reaction from TCU：
hydraulic unit
High side* off，Warning lamp
P0641 Pressure sensor supply fault Man actions:
Reaction from TCU： 1. Measure the HS voltage: compare it to the
High side* off，Warning lamp Man actions: battery voltage. If the battery voltage is ok,
1. Measure the 5V supply voltage online with and the high side voltage is smaller than 3.4 V,
tester tool; if the signal value is feasible, just then there is a SG. If the battery voltage is ok,
clear the FC and check if it does not come and the high side voltage is higher than 3.4 V,
back。 then it's an OC. In both cases, check the
2. Measure voltage between pressure sensor harness (transmission harness or vehicle
supply and pressure sensor ground, based on harness), dependant on the type of problem
result you get in step 1 (mention the pin nabs). If, after checking, the
3. Check wiring (SG, SB, OC), based on this harness is ok, change the TCU. If the battery
replace either transmission cable harness or voltage was not ok,
vehicle cable harness then check the battery.
4. Replace TCU by known good one
5. Replace hydraulic unit P0702 Watchdog test failed (during init)
Reaction from TCU：
P0651 DMS and speed sensor supply fault
High side* off，Warning lamp Man actions:
Reaction from TCU：
replace TCU
High side* off，Warning lamp Man actions:
1. Measure the 8.4V supply voltage online with
P0962 EDS1* (primary pulley) SCG
tester tool; if the signal value is feasible, just
clear the FC and check if it does not come Reaction from TCU：
back。 High side* off，Warning lamp
2. Measure voltage between pressure sensor Man actions:
supply and pressure sensor ground, based on 1. Measure resistance of EDS1 - should be 5.05
result you get in step 1 Ohm +- 6%.
3. Check wiring (SG, SB, OC), based on this 2. Check wiring (SG), based on this replace
replace either transmission cable harness or

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either transmission cable harness or vehicle Reaction from TCU：
cable harness High side* off，Warning lamp
3. Replace hydraulic unit Man actions:
1. Measure resistance of EDS2
P0963 EDS1* (primary pulley) SCB 2. Check wiring (OC), based on this replace
Reaction from TCU： either transmission cable harness or vehicle
cable harness
High side* off，Warning lamp
3. Replace hydraulic unit
Man actions:
1. Measure resistance of EDS1 P0902 EDS3* (clutch) SCG
2. Check wiring (SB), based on this replace Reaction from TCU：
either transmission cable harness or vehicle
High side* off，Warning lamp
cable harness
Man actions:
3. Replace hydraulic unit
1. Measure resistance of EDS3
2. Check wiring (SG), based on this replace
P0960 EDS1* (primary pulley) OC
either transmission cable harness or vehicle
Reaction from TCU： cable harness
High side* off，Warning lamp 3. Replace hydraulic unit
Man actions:
P0903 EDS3* (clutch) SCB
1. Measure resistance of EDS1
Reaction from TCU：
2. Check wiring (OC), based on this replace
either transmission cable harness or vehicle High side* off，Warning lamp
cable harness Man actions:
3. Replace hydraulic unit 1. Measure resistance of EDS3
2. Check wiring (SB), based on this replace
P0966 EDS2* (secondary pulley) SCG either transmission cable harness or vehicle
cable harness
Reaction from TCU：
3. replace hydraulic unit
High side* off，Warning lamp
Man actions: P0900 EDS3* (clutch) OC
1. Measure resistance of EDS2 Reaction from TCU：
2. Check wiring (SG), based on this replace High side* off，Warning lamp
either transmission cable harness or vehicle Man actions:
cable harness 1. Measure resistance of EDS3
3. Replace hydraulic unit 2. Check wiring (OC), based on this replace
either transmission cable harness or vehicle
P0967 EDS2* (secondary pulley) SCB cable harness
Reaction from TCU： 3. Replace hydraulic unit
High side* off，Warning lamp
Man actions: P1763 Start lock SCG or OC
1. Measure resistance of EDS2 Reaction from TCU：
2. Check wiring (SB), based on this replace High side* off，Warning lamp
either transmission cable harness or vehicle Man actions:
cable harness 1、 Check the wiring of start lock relay 2.
3. Replace hydraulic unit replace TCU

P0964 EDS2* (secondary pulley) OC P1764 Start lock SCB

Reaction from TCU：

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High side* off，Warning lamp 4. Replace transmission
Man actions:
1、 Check the wiring of start lock relay 2. P0730 Ratio control fault
replace TCU Reaction from TCU：
High side* off，Warning lamp
P0930 Shift lock SCG Man actions:
Reaction from TCU： 1. Check signal from speed sensors with the
High side* off，Warning lamp tester tool, as well as
Man actions: target current and actual current for the
1. Check the wiring primary pressure and target and actual
2. Replace TCU primary pressure itself;
2. Depending on previous results, speed
P0931 Shift lock SCB or OC sensor problem or hydraulic pressure problem
Reaction from TCU： 3. Check oil type and oil level
High side* off，Warning lamp 4. Replace speed sensors or hydraulic unit 5.
Man actions: replace pump
1、 Check the wiring of shift lock relay 6. Replace transmission

P1768 Backlight SCG P1765 Secondary pulley pressure too low

Reaction from TCU： Reaction from TCU：
High side* off，Warning lamp High side* off，Warning lamp
Man actions: Man actions:
1、 Check the wiring of back light 1. Measure the actual and the target pressure
in dynamic driving situations like tip ins,
P1769 Backlight SCB or OC launch, ...
Reaction from TCU： 2. Check oil level and oil type
High side* off，Warning lamp Man actions: 3. Do a proper clutch adaptation (this fault
code can come out when clutch adaptation is
1、 Check the wiring of back light
not optimal)
P0868 Operation readiness time-out 4. Check car for anything that could result in
Reaction from TCU： too low torque from engine: spark plugs,
throttle body, catalyst, ... (the older the engine
High side* off，Warning lamp
the easier this fault code could be triggered)
Man actions:
5. Replace hydraulic unit
1. Check oil level and oil type
6. Replace oil pump
2. Replace pump
7. Replace transmission
3. Replace hydraulic unit
4. Replace transmission
P1766 Secondary pulley pressure too high
Reaction from TCU：
P0811 Clutch (forward or reverse) slipping
Warning lamp
Reaction from TCU：
Man actions:
Warning lamp，Clutch open 1. Measure the actual and the target pressure
Man actions: in dynamic driving situations like tip ins,
1. Redo clutch adaptation, this fault code could launch, ...
be triggered in cold conditions, so redo clutch 2. Check oil level and oil type
adaptation in cold condition 3. Replace hydraulic unit
2. Check oil level and oil type 4. Replace oil pump
3. Replace hydraulic unit 5. Replace transmission

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P0701 Double fault requiring high side* 1. Check with the tester tool if other speed
open information (engine speed, output speed,
Reaction from TCU： vehicle speed) is also missing; if so, fix that
High side* off，Warning lamp problem first and check if this FC still occurs
Man actions: 2. Check with the tester tool the n_s1 signal
check other FCs if the clutch is closed and
compare with engine speed (difference
P0218 High oil temperature should be smaller than 200 rpm) - do this for
Reaction from TCU： the whole range of engine speeds (up till 6000
Warning lamp rpm)
Man actions: 3. Check wire harness
1. Check oil cooler 4. Exchange the TCU to make sure
2. Try to reproduce in normal driving condition 5. Check sensor position, angle; same with
- if not reproducible, ask trigger wheel; check if there's no object in
customer about driving conditions when the front of the sensor (piece of the belt, or…)
FC occurred. 6. Replace primary speed sensor
3. While trying to reproduce it, you can check 7. Replace transmission cable harness 8.
the transmission temperature with the tester replace vehicle cable harness
9. Change the transmission
tool。T_trans > 120 (longer than the filter time
P0721 Secondary pulley speed implausible
of 30 minutes!); measures to avoid further
Reaction from TCU：
temperature increase
For (Ottawa) F6-S8: High side* off，Warning
P1767 Critical oil temperature lamp
Reaction from TCU： For (Bilbao) G3: Warning lamp, increased
clamping level 0*, Substitute secondary pulley
High side* off，Warning lamp
speed
Man actions:
Man actions:
1. Try to reproduce in normal driving condition
1. Check with the tester tool if other speed
- if not reproducible, ask
information (engine speed, pulley 1 speed,
customer about driving conditions when the
and vehicle speed) is also missing; if so, fix
FC occurred (uphill driving or high speed
that problem first and check if this FC still
driving?).
occurs
2. Check oil cooler
2. Check with the tester tool the signal (vehicle
3. Check the oil level
speed based on n_ab) and compare with
4. Replace hydraulic unit
vehicle speed (difference should be smaller
5. Replace transmission
than 5 kph) -
3. Check wire harness
P0219 Powertrain speed out of range
4. Exchange the TCU to make sure
Reaction from TCU：
5. Check sensor position, angle; same with
High side* off，Warning lamp trigger wheel; check if there's no object in
Man actions: front of the sensor (piece of the belt, or…)
1. Should never occur in principle 6. Replace primary speed sensor
2. Check the fuel cut off of the engine (does it 7. Replace transmission cable harness 8.
limit the engine speed to 6000 rpm?) replace vehicle cable harness
8. Change the transmission
P2766 Primary pulley speed implausible
Reaction from TCU： P0944 Insufficient clamping force (VSM)
High side* off，Warning lamp Reaction from TCU：
Man actions:

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Warning lamp, Clutch open fault: it has information on battery voltage
Man actions: when this FC occurred (so you can distinguish
The torque of the engine is too big at the if the battery, or the high side caused this FC);
moment the fault code was activated. The if not an historical fault, check it directly = next
ECU does not follow the torque reduction step 2. check with the tester tool the high side
request from TCU. voltage and/or the battery voltage -
1. Check ECU for fault codes threshold depends on temperature: look up in
2. Replace ECU software
3. Check oil level and oil type 3. Now you have distinguished if it is the
4. Do a proper clutch adaptation (this fault battery or the high side. If the battery is the
code can come out when clutch adaptation is problem: check wiring (fuse, main relay) from
not optimal) battery to TCU
5. Check car for anything that could result in 4. If the battery is the problem: replace/check
too low torque from engine: spark plugs, battery
throttle body, catalyst, ... (the older the engine 5. If the high side is the problem: check the
is, the easier this fault code could be triggered) wiring from the gearbox to the TCU 6. replace
6. Replace hydraulic unit TCU
7. Replace oil pump
8. Replace transmission P0883 Battery or high side* voltage too
high
P0810 End of Line (EoL) clutch adaptation Reaction from TCU：
not finished High side* off，Warning lamp
Reaction from TCU： Man actions:
Warning lamp flashing 1. Check the freeze frame if it's a historical
Man actions: fault: it has information on battery
Do clutch adaptation according 2.5 Clutch voltage when this FC occurred (so you can
adaptation procedures. distinguish if the battery, or the
high side caused this FC); if not an historical
P1770 Engine speed too low fault, check it directly = next step
Reaction from TCU： 2. Check with the tester tool the high side
None voltage and/or the battery voltage -
Man actions: threshold depends on temperature: look up in
1、 Indicates a problem with engine or idle software
speed controller, check engine, throttle 3. Now you have distinguished if it is the
body and ECU fault codes battery or the high side. If the battery
is the problem: ask customer if he did a jump
P1762 Current stuck start (= 24V) if the battery is the
Reaction from TCU： problem: check wiring (fuse, main relay) from
High side* off，Warning lamp battery to TCU。
Man actions: 4. If the battery is the problem: replace/check
1. Check FC15 to FC23 + actions battery or alternator
2. Replace TCU with a known good one 5. If the high side is the problem: check the
wiring from the gearbox to the TCU
P0882 Battery or high side* voltage too low 6. Replace TCU
Reaction from TCU：
High side* off，Warning lamp P2787 Clutch temperature too high
Man actions: Reaction from TCU：
1. Check the freeze frame if it's a historical Warning lamp，Clutch open

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Man actions: High side* off，Warning lamp Man actions:
1. Check how many times this FC has 1. Check if the combination of TCU HW and
occurred. If only one (or a few times), look into TCU SW is valid
freeze frame and ask customer about special 2. If there is new SW flashed in ECU or TCU:
driving condition. You can delete the FC. the SW on the newly flashed controller must
2. Check oil level and oil type be wrong (incompatibility between engine and
3. Do a proper clutch adaptation (this fault transmission
code can come out when clutch adaptation is controller)
not optimal)
4. Can only occur when throttle and brake are P0706 Drive mode sensor single line error
applied at the same time for a certain period. Reaction from TCU：
Delete error code and see if it comes back. Warning lamp, Substitute lever position Man
5. Replace TCU actions:
6. Can be sticking throttle valve, replace 1. Check with the tester tool which line is
throttle valve affected and what the problem is; for example
line B short cut battery (this FC indicates one
P0727 Hardwired engine speed implausible of the 4 lines is faulty) 2. check wiring of the
Reaction from TCU： affected line between transmission and TCU
Warning lamp 3. Replace TCU by a known good one
Man actions: 4. Replace drive mode sensor
1. Check if the engine reports an error as well 5. Replace transmission cable harness 6.
(with the tester tool); if so fix this engine replace vehicle cable harness
problem
2. Check wiring input signal TCU - it is a P0705 Drive mode sensor multiple lines
frequency signal (900 rpm engine speed error
should give a 30 Hz signal, 3000 rpm gives Reaction from TCU：
100 Hz) High side* off，Warning lamp Man
3. Replace TCU by a known good one actions:
4. Replace engine speed sensor 1. Check with the tester tool which lines are
affected and what the problem is; for example
P1761 EDS current fault
line B short cut battery and … (this FC
Reaction from TCU： indicates that there is more than one line
High side* off，Warning lamp faulty).
Man actions: 2. Check wiring of the affected line between
1. Check sum of low side currents with high transmission and TCU 3. replace TCU by a
side current, and compare each ED‘s actual known good one
current with its target 3. Replace drive mode sensor
2. With the tester tool, check the actual 4. Replace transmission cable harness 6.
currents of the EDSs with the target currents; if replace vehicle cable harness
you find one of these being different, check the
wiring of this EDS (also inside the gearbox) P0955 Tip mode signals error
3. Replace TCU by a known good one 4. Reaction from TCU：
replace hydraulic unit Warning lamp, No manual mode Man actions:
4. Replace transmission cable harness 6. 1. check wiring from shifter to TCU
replace vehicle cable harness 2. replace shifter
3. replace TCU by a known good one
U0301 Vehicle configuration mismatch
Reaction from TCU： U0001 CAN bus off

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Reaction from TCU：
U1013 CAN accelerator pedal signal error
Warning lamp，Emergency mode* active
Reaction from TCU：
Increased clamping level 1* (highest)，
Substitute
Warning lamp ， Accelerator pedal value fixed
detection function of
Man actions:
blocked and spinning wheels ，No manual Check the EMS controller (accelerator pedal
mode, Activate internal sensor and sensor wiring)
driving strategy ，Substitute engine speed ，
U1014 CAN engine torque signals error
Substitute engine torque
Reaction from TCU：
Substitute engine cooling water temperature，
Warning lamp，Emergency mode* active, No
Brake signal on ，Accelerator pedal value fixed，
manual mode
Substitute front left wheel speed，Substitute
Activate internal driving strategy，Substitute
front right wheel speed，Substitute rear left engine torque
wheel Man actions:
speed，Substitute rear right wheel speed Check the EMS controller
U1016 CAN wheel speed error - front left
Man actions:
(ONLY BILBAO G3)
1、 If this problem is present in all other
Reaction from TCU：
controllers, there is a wiring problem
(shortcut between CAN high and CAN low): Increased clamping level 0*，Substitute
check vehicle harness
2. If the fault is only stored in the TCU: replace detection function of blocked and spinning
TCU by a known good one wheels，Substitute front left wheel speed
Man actions:
U0100 CAN ECU communication failed Check the ABS controller (wheel speed sensor
Reaction from TCU： and sensor wiring)

Warning lamp，Emergency mode* active U1017 CAN wheel speed error - front right
Increased clamping level 0*，No manual mode, (ONLY BILBAO G3)
Reaction from TCU：
Activate internal driving strategy，Substitute
Increased clamping level 0*，Substitute
engine torque，Substitute engine cooling water
detection function of blocked and spinning
temperature，Accelerator pedal value fixed，Stop
wheels，Substitute front right wheel speed
transmitting on CAN
Man actions:
Man actions:
Check the ABS controller (wheel speed sensor
Check the engine controller and the CAN
and sensor wiring)
connection from the engine controller (probably
this fault is reported in other controllers as well)
U1018 CAN wheel speed error - rear left
U1012 CAN engine speed signal error
(ONLY BILBAO G3)
Reaction from TCU：
Reaction from TCU：
Substitute engine speed
Man actions: Increased clamping level 0*，Substitute
Check the MCU controller (motor speed sensor detection function of blocked and spinning
and sensor wiring) wheels，Substitute rear left wheel speed

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 Man actions: wheels，Substitute rear right wheel speed
check the ABS controller (wheel speed sensor
Man actions:
and sensor wiring)
check the ABS controller (wheel speed sensor
and sensor wiring)
U1019 CAN wheel speed error - rear right
(ONLY BILBAO G3)
Note:
Reaction from TCU： -Unless mentioned specifically, all fault codes
Increased clamping level 0*，Substitute are valid for Ottawa F6-S8 and Bilbao G3-New
F3
detection function of blocked and spinning
-High side*: is the supply voltage for the 3 pressure regulators. When error code occurs and High side
is switched off, then the clutch goes open and the vehicle can not move anymore until you do a KEY
ON/OFF.
-Increased clamping level 0*: secondary pressure is at a fixed level, but a higher level than normal
operating conditions, lower than max.
-Increased clamping level 1*: secondary pressure is at a fixed level, maximum
pressure.
-EDS1*: primary pulley pressure regulator
-EDS2*: secondary pressure regulator
-EDS3*: clutch pressure regulator
-Emergency mode*: Also called ―Limp Home Mode‖. Is activated when
-CAN bus is off
-CAN ECU communication failed
-CAN engine torque signals have an error
All engine and ABS related messages will be substituted immediately (safety reactions):
-Throttle pedal = fixed
-Engine torque map instead of the engine torque -Engine cooling temperature = fixed
-Wheel speeds = substituted by the output shaft speed of the gearbox
-Engine speed = substituted by the hard wired engine speed if available
-The clutch will open and close much more brutal, as if there is no calibration on it
-The maximum engine speed will be limited to 3200 rpm, even if the throttle pedal is fully pressed
-The maximum vehicle speed will be about 90 kph
-The gearbox will shift but within 1 basic driving strategy
The overall CVT working principle will become BASIC and this is proven to be suitable enough to get
to the nearest workshop only
-After 2sec, Tip mode (+/- or Sport) will not be possible anymore and warning lamp will be on.

335
 Chapter 7 CVT Management System

Contents

Section 1 Component Layout .................................................................................................. 337

Section 2 CVT Overview ......................................................................................................... 337
Section 3 Diagnostic Procedure .............................................................................................. 338
Section 4 Terminal Detection .................................................................................................. 339
Section 5 Overall Diagnostic Flow ........................................................................................... 341
Section 6 Preparing Tools ....................................................................................................... 385
Section 7 Disassembly and Assembly ..................................................................................... 385

336
Section 1 Component Layout

TCU

Transmission

Section 2 CVT Overview

The transmission‘s continuously variable ratio is achieved by means of a variator. The variator
consists of two cone pulleys located opposite to each other and a steel drive belt that loops around
the two pulleys like a V-belt. The variator ratio is transmitted through an intermediate shaft to the
differential incorporated into the transmission housing.
The stepless shifting pattern of the transmission provides a very comfortable drive, as well as
having full vehicle performance, available at any time.
The advantages of using an automatic transmission of this type are:
 Low engine revolutions at constant speeds.
 Improved emission control/fuel consumption.
 Low noise, vibration and harshness levels.
 Stable acceleration
 Flexible driving on mountain roads
Because of its fully electronic control, the VT2 pushes the limits of it s predecessor even further.

337
Section 3 Diagnostic Procedure
Tips:
 Follow the procedure to diagnose the trouble
 The fourth step applies the diagnostic apparatus to analyze

1 Drive the car into the garage

NEXT

2 Check the battery voltage

Normal work pressure value:

11V~14V
If the voltage value is less than 11V, charge or Replace the battery before proceeding to next step.

NEXT

3 Use trouble diagnostic instrument

Result Go to

Diagnostic instrument with A

output
Diagnostic instrument without B
output

A Go to step 6
B

4 Refer to trouble diagnostic chart

Results Go to
Results listed in the trouble A
diagnostic chart
Results not listed in the trouble B
diagnostic chart

A Go to step 6

5 Overall Analysis System

338
 NEXT

6 Make adjustment, repair and Replace

NEXT

7 Conduct test confirmation

NEXT

8 End

Section 4 Terminal Detection

1. Unplug the connector
2. Measure the voltage or resistance of harness wire end

Normal Value:

Terminals Description Conditions Normal value

1—car body Constant power Always 11-14V
2—car body Constant power Always 11-14V
3—car body Connected to ground Always Less than 1Ω
4—car body Connected to ground Always Less than 1Ω
6—car body Power supply Start power supply 11-14V
8 CAN_L —— ——
9 CAN_H —— ——
59—car Manual transmission Gear shifts turned to Manul Less than 1Ω

339
 body signal
59—car Automatic transmission Gear shifts turned to
Greater than 10kΩ
body signal Automatic
80—car Manual accelaration
Gear shifts turned to Manul + Less than 1Ω
body signal
81—car
Manual reduced signal Gear shifts turned to Manul - Less than 1Ω
body

If there are some mistakes with the measured value, or there are some problems with the wire
harness or the connector, please check the wire harness.
3. Connect the connector and measure the output value of measured terminals.
Normal Value:

Terminals Description Conditions Normal value

5—car body Actuator power supply Always 11-14V
30—car Power supply of speed
Engine start 8.4V
body and parking sensor
32—car Power supply of pressure Engine start
5V
body sensor
33—car Driving mode sensor
Always Less than 1Ω
body ground
34—car Power supply turned to ON,
Brake signal Less than 1V
body and press down the brake
41—car Sensor connected to
Always Less than 1Ω
body ground
64—car Sensor connected to
Always Greater than 10kΩ
body ground
71—car Power supply turned to ON,
Control reversing relay Less than 3V
body gear shift turned to R
74—car Power supply of pressure Engine start
5V
body sensor
77—car Power supply of speed Engine start
8.4V
body and parking sensor
78—car Power supply of speed Engine start
8.4V
body and parking sensor
86—car Sensor connected to
Always Less than 1Ω
body ground

340
Section 5 Overall Diagnostic Flow
1 Read DTC

(a) Connect the fault diagnostic apparatus to DLC3 port.

(b) Clear DTCs in the History column.
(c) Read DTCs.
DTC chart
Diagnostic Fault description Fault range
codes
P0710 Oil temperature sensor fails
P2765 Driving cone wheel speed sensor fails
P0720 Driven cone wheel speed sensor fails
P0840 Driven cone wheel speed sensor fails
P0641 Pressure sensor power supply fails
P0651 Driving mode sensor and speed sensor
power supply fails
P0659 Pressure regulator short out
P0658 Pressure regulator disconnected or
connected to ground
P0963 Driving cone wheel pressure regulator short
out
P0960 Driving cone wheel pressure regulator
disconnected
P0962 Driving cone wheel pressure regulator
connected to ground
P0966 Driven cone wheel pressure regulator
connected to ground
P0967 Driven cone wheel pressure regulator short
out
P0964 Driven cone wheel pressure regulator
disconnected
P0902 Clutch pressure regulator connected to
ground
P0903 Clutch pressure regulator short out
P0900 Clutch pressure regulator disconnected
P0702 TCU internal detecting faults
P0930 Gearshift lock connected to ground
P0931 Gearshift lock short out or disconnected
P1768 Reversing light connected to ground
P1769 Reversing light short out or short out
P0868 Pressure pre-tightening regulating fails
P0811 Clutch (foreword or backward) slips
P0730 Transmission ratio control fails
P1765 Driven cone wheel pressure is too low
P1766 Driven cone wheel pressure is too high
P0701 Two faults occur at the same time
P0218 Oil temperature of gearbox is too high
P1767 Oil temperature of gearbox exceeds range
P0219 Power system speed exceeds range
P2766 Driving cone wheel speed is inconformity
with the actual speed

341
P0721 Driven cone wheel speed is inconformity
with the actual speed
P0944 Insufficient clamping force
P1762 Unchangeable and fixed current value
P0882 Battery or high end voltage is too low
P0883 Battery or high end voltage is too high
P2787 Clutch temperature is too high
P0727 The speed signal spread from ECU to TCU
rigid engine is inconformity with actual
speed
P1761 Pressure regulator fails
P0301 Vehicle configuration fails
P0706 Driving mode sensor singlet line fails
P0705 Driving mode sensor multi-wire fails
P0955 Manual adding or reducing gear signal fails
U0001 CAN bus fails
U0100 ECU CAN communication fails
U1012 Engine speed signal error on CAN bus
U1013 Acceleration pedal signal errors on CAN bus
U1014 Engine torque signal errors on CAN bus

OK: DTCs output

NG Overall diagnostic system
OK

2 Go to DTC corresponding diagnostic module

P0710 Oil temperature sensor fails

Schematic Diagram
Temperature sensor

342
1 Check the transmission oil temperature

(a) Measure oil temperature statistics of

speed box with detector
OK: the statistics is normal

NG Go to Transmission oil
temperature exceeds range

OK

2 Check oil temperature sensor

(a) Unplug the round connector on the CVT
transmission.
(b) Measure the resistance at the terminals
on the transmission.
Measuring temperatu Normal
terminals re resistance
5-7 20-40℃ 942-1121kΩ

NG Replace oil temperature sensor

OK

3 Check the wire harness (CVT-TCU)

(a) Unplug the connector of transmission and

TCU.
(b) Measure the resistance of corresponding
terminals.
Normal resistance
Measuring Wire Normal
conditions Color resistance
A35-5-A33-38 0 Less than 1Ω
A35-7-A33-41 B/O Less than 1Ω
R/Y Greater than
A35-5-car body
10kΩ

NG Replace wire harness or

connector

OK

343
 4 Check TCU

(a) Replace a normal TCU.

(b) Remeasure and check if the faults
appear again.
OK: Faults disappear

NG Replace transmission

OK

5 Replace TCU with faults

P2765 Driving cone wheel speed sensor fails

Schematic Diagram

sensor
Driving cone wheel speed

1 Check transmission oil temperature

(a) Measure transmission oil temperature

statistics with detecting apparatus.
OK: the statistics is normal.

NG Go to Transmission oil
temperature exceeds range
OK

344
 Check CVT module and sensor power supply
2

(a) Unplug the round connector on CVT

transmission
(b) Start engine
(c) Measure the wire harness terminal value.

Normal resistance

Measuring Wire Normal

terminals Color resistance
1-car body R/Y 11-14V
9-car body R/B About 8.4V

NG Go to step 4

OK

3 Check the driving cone wheel speed sensor

(a) Unplug the round connector on the CVT

transmission.
(b) Measure the resistance at the
corresponding terminals.
Normal resistance
Measuring Wire Normal
terminals Color resistance
\ About
12-9
24.3MΩ
N
otes: the sensor is complicated
double-line; such measuring method will
not guarantee if the sensor is in good
condition.

NG Replace speed sensor

OK

4 Check the wire harness (CVT-TCU)

345
 (a) Unplug the connector of transmission and
TCU.
(b) Measure the resistance at the
corresponding terminals.
Normal resistance

Measuring Wire Normal

Conditions Color resistance
A35-12-A33-61 L/B Less than 1Ω
A35-9-A33-30 R/B Less than 1Ω
A35-9-A33-77 R/B Less than 1Ω
A35-9-A33-78 R/B Less than 1Ω
R/B Greater than
9-car body
10kΩ

NG Replace wire harness or

connector

OK

5 Check the TCU

(a) Replace a normal TCU.

(b) Remeasure and check if the faults occur
again.

OK: Faults solved

NG Go to TCU power supply circuit

OK

6 Replace TCU with faults

P0720 Driven cone wheel speed sensor fails

346
Schematic Diagram

sensor
Driven cone wheel speed
1 Check transmission oil temperature

(a) Measure the transmission oil temperature

statistics with detecting apparatus.

OK: the statistics is normal.

NG Go to Transmission oil
temperature exceeds range

OK

2 Check the power supply of CVT module and sensor

(a) Unplug the round connector on the CVT

transmission.
(b) Start engine.
(c) Measure the resistance at wire harness
end.
Normal resistance

Measuring Wire Color Normal

terminals resistance
1-car body R/Y 11-14V
9-car body R/B About 8.4V

347
 NG Go to step 4

OK

3 Check the driven cone wheel speed sensor

(a) Unplug the round connector on the CVT

transmission.
(b) Measure the resistance at the
corresponding terminals.
Normal resistance
Measuring Wire Normal
terminals Color resistance
\ About
11-9
24.3MΩ

Notes: the sensor is complicated

double-line; such measuring method will
not guarantee if the sensor is in good
condition.

NG Replace speed sensor

OK

4 Check the wire harness (CVT-TCU)

a) Unplug the connector of transmission and
TCU.
(b) Measure the resistance at the
corresponding terminals.
Normal resistance
Measuring Wire Normal
Conditions Color resistance
A35-11-A33-61 L/Y Less than 1Ω
A35-9-A33-30 R/B Less than 1Ω
A35-9-A33-77 R/B Less than 1Ω
A35-9-A33-78 R/B Less than 1Ω
R/B Greater than
A35-9-car body
10kΩ

NG Replace wire harness or

connector

OK

5 Check the TCU

348
 (a) Replace a normal TCU.
(b) Remeasure and check if the faults occur
again.
OK: Faults solved

NG Go to TCU power supply circuit

OK

6 Replace the TCU with faults

P0840 Driven cone wheel pressure sensor fails

Schematic Diagram

sensor
Driven cone wheel speed

1 Check the transmission oil pressure

(a) Check the transmission oil pressure

statistics with detecting apparatus
(b) Make comparison with the value of output
pressure of oil pressure sensor.
OK: Statistics is normal

NG Go to step 3

OK

349
 2 Check driven cone wheel pressure sensor

(a) Unplug the round connector on the CVT

transmission.
(b) Start engine
(c) Measure the resistance at wire harness
end.
Normal resistance
Measuring Wire Color Normal
terminals resistance
10-7 \ 44.3kΩ

NG Replace the pressure sensor

OK

3 Check faults of driven cone wheel pressure sensor power supply (Refer to P0641)

OK: Power supply is normal

NG Repair pressure sensor power

supply circuit
OK

4 Check the TCU

(a) Replace a normal TCU.
(b) Remeasure and check if the faults occur
again.
OK: Faults solved

NG
Go to TCU power supply circuit
OK

5 Replace the TCU with faults

P0641 Power supply of pressure sensor fails

350
Schematic Diagram

sensor
Power supply of pressure
1 Check the input voltage

(a) Unplug the round connector on the CVT

transmission.
(b) Start engine
(c) Measure the resistance at wire harness
end.
Normal value
Measuring Wire Color Normal
terminals value
8-car body R/Y About 5V
7-car body B/O Less than 1V

OK Go to step 4

NG

2 Check the voltage at TCU terminal

351
 (a) Unplug the TCU connector
(b) Start engine
(c) Measuring terminal value.
Normal value
Measuring Wire Color Normal
terminals value
32-car body R/Y About 5V
74-car body R/Y About 5V
41-car body B/O Less than 1V
64-car body B/O Less than 1V
86-car body B/O Less than 1V

NG Go to TUC power supply circuit

OK

3 Check the wire harness (CVT-TCU)

(a) Unplug the connector of transmission and

TCU.
(b) Measure the resistance at the
corresponding terminals.
Normal resistance

Measuring Wire Normal

Conditions Color resistance
A35-8-A33-32 R/Y Less than 1Ω
A35-8-A33-74 R/Y Less than 1Ω
A35-7-A33-41 B/O Less than 1Ω
A35-7-A33-64 B/O Less than 1Ω
A35-7-A33-86 B/O Less than 1Ω
A35-8-car R/Y Greater than
body 10kΩ

Replace wire harness or

NG connector
OK

4 Check the TCU

(a) Replace a normal TCU.

(b) Remeasure and check if the faults occur
again.
OK: Faults solved

352
 NG Go to TCU power supply circuit

OK

6 Replace the TCU with faults

P0651 Driving mode sensor and speed sensor fail

Schematic Diagram

speed sensor
Driving mode sensor and

1 Check the input voltage

(a) Unplug the round connector on the CVT

transmission.
(b) Start engine
(c) Measure the resistance at wire harness
end.
Normal value
Measuring Wire Normal
terminals Color value
A35-9-car body R/B About 8.4V
A35-6-car body B/Y Less than 1V

OK Go to step 4

NG

353
 2 Check the voltage at TCU terminals

(a) Unplug the TCU connector

(b) Start engine
(c) Measuring terminal value
Normal value

Measuring Wire Normal

terminals Color value
A33-30-car body R/B About 8.4V
A33-77-car body R/B About 8.4V
A33-78-car body R/B About 8.4V
B/Y Less than
A33-33-car body
1V
NG Go to TUC power supply circuit

OK

3 Check the wire harness (CVT-TCU)

(a) Unplug the connector of transmission and

TCU.
(b) Measure the resistance at the
corresponding terminals.
Normal resistance
Measuring Wire Normal
Conditions Color resistance
A35-9-A33-30 R/B Less than 1Ω
A35-9-A33-77 R/B Less than 1Ω
A35-9-A33-78 R/B Less than 1Ω
A35-6-A33-33 B/Y Less than 1Ω
A35-9-car R/B Greater than
body 10kΩ

NG Replace the wire harness or

connector

OK

4 Check the TCU

(a) Replace a normal TCU.

(b) Remeasure and check if the faults occur
again.
OK: Faults solved

NG Go to TCU power supply circuit

354
 OK

6 Replace the TCU with faults

P0659 Pressure regulator short out

1 Check the HS voltage

(a) Unplug the round connector on CVT

(b) Start engine
(c) Measure the voltage of wire harness end.
Measuring Wire Color Normal
terminals value
1-car body R/Y 11-14V
OK: Statistics is normal

NG Replace the TCU

OK

2 Check the wire harness

(a) Unplug the round connector on CVT

(b) Measure the resistance at wire harness
end.
Normal resistance
Measuring Wire Color Normal
terminals resistance
1-Power R/Y
Greater than
supply
10kΩ
positive pole

NG Repair or replace the wire

harness

OK

3 Replace the TCU

P0658 Pressure regulator breaks circuit or connected to ground

355
 1 Measure the HS voltage

(a) Start engine

(b) Measure the voltage at TCU terminal.

Measuring Wire Color Normal

terminals value
O 5-car body O 11-14V
O
OK: Statistics is normal

OK Go to next DTC

NG

2 Confirm it is broken circuit or connected to ground

(a) Measuring voltage value at terminals.

Measuring Voltage Go to
terminals Value
5-car body >3.4V A
5-car body <3.4V B

B Go to step 5

3 Wire harness broken circuit check the wire harness

(a) Unplug the connector of TCU and CVT.

(b) Measuring the resistance value between
terminals.
Normal resistance

Measuring Wire Normal

terminals Color resistance
1 (Round)-5 R/Y Less than 1Ω

Repair or replace the wire

NG harness

OK

356
4 Next step: check

NEXT

5 Check the wire harness connected to ground

(a) Unplug the connector of TCU and CVT.
(b) Measuring the resistance value between
terminals.
Normal resistance
Measuring Wire Normal
terminals Color resistance
1 (Round)-5 R/Y Less than 1Ω
1 (Round)-car Greater than
R/Y
body 10kΩ

NG Repair or replace the wire

harness

OK

6 Next step: check

P0963 EDS1 driving cone wheel pressure regulator connected to ground

1 Check the driving cone wheel pressure regulator

(a) Unplug the round connector on the CVT

transmission.
(b) Measuring the value of terminals.
Normal resistance
Measuring Wire Normal
terminals Color resistance
3-1 \ 5.05Ω±6%

NG Replace driving cone wheel

pressure regulator

OK

2 Check the wire harness(If it is connected to ground)

357
 (a) Unplug the round connector on the CVT
transmission.
(b) Measure the resistance between wire
harness terminals.
Normal resistance
Measuring Wire Normal
terminals Color resistance
R/Y Greater than
A35-3-car body
10kΩ
B Greater than
A35-1-car body
10kΩ

NG Repair or replace the wire

harness

OK

4 Replace the hydraulic control block

P0963 EDS1 driving cone wheel pressure regulator short out

1 Check the driving cone wheel pressure sensor

(a) Unplug the round connector on the CVT

transmission.
(b) Measure the resistance at wire harness
end.
Normal resistance
Measuring Wire Normal
terminals Color resistance
3-1 \ 5.05Ω±6%

NG Replace the driving cone wheel

pressure sensor

OK

2 Check the wire harness (If it is short out, short out, connected to ground)

(a) Unplug the round connector on the CVT

transmission.
(b) Unplug the TCU connector
(c) Measure the resistance between wire
harness terminals.
Normal resistance

358
 Measuring Wire Normal
terminals Color resistance
B Greater than
A35-3-car body
10kΩ
R/Y Greater than
A35-1-car body
10kΩ
\ Greater than
A35-3-A33-1
10kΩ
A35-3- A33-90 B Less than 1Ω
A35-1- A33-5 R/Y Less than 1Ω

Repair or replace the wire

NG
harness
OK

3 Replace the hydraulic control block

P0960 EDS1driving cone wheel pressure sensor broken circuit

1 Check driving cone wheel pressure sensor

(a) Unplug the round connector on the CVT

transmission.
(b) Measuring resistance at terminals.
Normal resistance

Measuring Wire Normal

terminals Color resistance
2-1 \ 5.05Ω±6%

NG Replace the driving cone wheel

pressure sensor

OK

2 Check the wire harness

359
 (a) Unplug the round connector on the CVT
transmission.
(b) Unplug the TCU connector
(c) Measure the resistance between wire
harness terminals.
Normal resistance

Measuring Wire Normal

terminals Color resistance
A35-2-A33-90 B Less than 1Ω
A35-1-A33-5 R/Y Less than 1Ω

NG Repair or replace the wire

harness

OK

3 Replace hydraulic control block

P0966 EDS2 driven cone wheel pressure regulator Connected to ground

1 Check driven cone wheel pressure regulator

(a) Unplug the round connector on the CVT

transmission.
(b) Measuring resistance at terminals.
Normal resistance
Measuring Wire Normal
terminals Color resistance
3-1 \ 5.05Ω±6%

NG Replace driving cone wheel

pressure sensor

OK

2 Check the wire harness (broken circuit)

(a) Unplug the round connector on the CVT

transmission.
(b) Measure the resistance between wire
harness terminals.
Normal resistance

Measuring Wire Color Normal

terminals resistance
R/Y Greater than
3-car body
10kΩ

360
 L Greater than
1-car body
10kΩ

NG Repair or replace the wire

harness

OK

3 Replace the hydraulic control block

P0967 EDS2 driven cone wheel Pressure regulator short out

1 Check driven cone wheel pressure regulator

(a) Unplug the round connector on the CVT

transmission.
(b) Measuring resistance at terminals.
Normal resistance

Measuring Wire Normal

terminals Color resistance
2-1 \ 5.05Ω±6%

NG Replace driving cone wheel

pressure sensor

OK

2 Check the wire harness

(a) Unplug the round connector on the CVT

transmission.
(b) Unplug the TCU connector
(c) Measure the resistance between wire
harness terminals.
Normal resistance

361
 Measuring Wire Color Normal
terminals resistance
L Greater
2-car body
than 10kΩ
R/Y Greater
1-car body
than 10kΩ
\ Greater
2-1
than 10kΩ
R/Y Less than
A35-1-A33-5
1Ω
L Less than
A35-2-A33-91
1Ω

NG Repair or replace the wire

harness

OK

3 Replace the hydraulic control block

P0964 EDS2 driven cone wheel pressure regulator broken circuit

1 Check driven cone wheel pressure regulator

(a) Unplug the round connector on the CVT

transmission.
(b) Measuring resistance at terminals.
Normal resistance
Measuring Wire Normal
terminals Color resistance
2-1 \ 5.05Ω±6%

NG Replace the driving cone wheel

pressure sensor

OK

2 Check the wire harness

362
 (a) Unplug the round connector on the CVT
transmission.
(b) Unplug the TCU connector
(c) Measure the resistance between wire
harness terminals.
Normal resistance
Measuring Wire Normal
terminals Color resistance
A35-2-A33-91 L Less than 1Ω
A35-1-A33-5 R/Y Less than 1Ω

NG Repair or replace the wire

harness

OK

3 Replace the hydraulic control block

P0902 EDS3 clutch pressure regulator Connected to ground

1 Check the clutch pressure regulator

(a) Unplug the round connector on the CVT

transmission.
(b) Measuring resistance at terminals.
Normal resistance
Measuring Wire Color Normal
terminals resistance
4-1 \ 5.05Ω±6%

NG Replace the driving cone wheel

pressure sensor

OK

2 Check the wire harness

363
 (a) Unplug the round connector on the CVT
transmission.
(b) Measure the resistance between wire
harness terminals.
Normal resistance
Measuring Wire Color Normal
terminals resistance
A35-4-car Y/W Greater
body than 10kΩ
A35-1-car R/Y Greater
body than 10kΩ

NG Repair or replace the wire

harness

OK

3 Replace the hydraulic control block

P0903 EDS3 clutch Pressure regulator short out

1 Check the clutch pressure regulator

(a) Unplug the round connector on the CVT

transmission.
(b) Measuring resistance at terminals.
Normal resistance
Measuring Wire Color Normal
terminals resistance
4-1 \ 5.05Ω±6%

NG Replace the driving cone wheel

pressure sensor

OK

2 Check the wire harness

364
 (a) Unplug the round connector on the CVT
transmission.
(b) Unplug the TCU connector
(c) Measure the resistance between wire
harness terminals.
Normal resistance

Measuring Wire Normal

terminals Color resistance
A35-4-car Y/W Greater than
body 10kΩ
A35-1-car R/Y Greater than
body 10kΩ
\ Greater than
4-1
10kΩ
A35-4-A33-89 Y/W Less than 1Ω
A35-1-A33-5 R/Y Less than 1Ω

NG Repair or replace the wire

harness

OK

3 Replace the hydraulic control block

P0900 EDS3 clutch pressure regulator broken circuit

1 Check the clutch pressure regulator

(a) Unplug the round connector on the CVT

transmission.
(b) Measuring resistance at terminals.
Normal resistance
Measuring Wire Color Normal
terminals resistance
4-1 \ 5.05Ω±6%

NG Replace the driving cone wheel

pressure sensor

OK

2 Check the wire harness

365
 (a) Unplug the round connector on the CVT
transmission.
(b) Measure the resistance between wire
harness terminals.
Normal resistance
Measuring Wire Color Normal
terminals resistance
Y/W Less than
A35-4-A33-89
1Ω
R/Y Less than
A35-1-A33-5
1Ω

NG Repair or replace the wire

harness

OK

3 Replace the hydraulic control block

P0868 Pressure pre-tightened regulator fails

1 Check the oil level and oil products

NG Replace the transmission oil

OK

2 Check the oil pump

(a) Replace an oil pump temporarily.

(b) Check if the faults occur again.
OK: Faults solved

OK Replace the oil pump with

faults

NG

3 Check the hydraulic control block

(a) Replace a hydraulic control block

temporarily.
(b) Check if the faults occur again.
OK: Faults solved

366
 OK Replace the hydraulic control
block

NG

4 Replace the transmission

P0811 Clutch (forward or backward) slips

1 Measure with measuring apparatus

(a) Measure the clutch pressure and speed of

engine and driving cone wheel with detecting
apparatus.
(b) Check if the measuring value is within the
appropriate range.
OK: the statistics is normal.

OK Clear the DTC and check again

NG

2 Check the oil level and oil products

NG ADD or replace the

transmission oil

OK

3 Check the hydraulic control block

(a) Replace a hydraulic control block

temporarily.
(b) Check if the faults occur again.
OK: Faults solved

OK Replace the hydraulic control

block
NG

4 Replace the transmission

P0730 Transmission ratio control fails

367
 1 Check with measuring apparatus
(a) Check the signal sent by the speed
sensor with tester and check the input current
and feedback current of driving cone wheel
pressure sensor.
(b) Check if the measuring value is within
appropriate range.
OK: the statistics is normal.

NG Replace the speed sensor or

pressure sensor

OK

2 Check the oil level and oil products

NG Add or replace the

transmission oil

OK

3 Check the oil pump

(a) Replace an oil pump temporarily.

(b) Check if the faults occur again.
OK: Faults solved

OK Replace the oil pump with

faults

NG

4 Check the hydraulic control block

(a) Replace a hydraulic control block
temporarily.
(b) Check if the faults occur again.
OK: Faults solved

OK Replace the hydraulic control

block

NG

5 Replace the transmission

P1765 Driven cone wheel pressure is too low

368
1 Check the oil level and oil model

NG Check or replace the pressure

regulator

OK

2 Check the dynamic driving circumstances

(a) Unplug the round connector on the CVT

transmission.
(b) Start engine
(c) Manual gear shifting
(d) Measure the terminal signal with
oscilloscope.
Normal resistance
Measuring Wire Color Normal
terminals resistance
3-car body B About 5.05Ω

NG Check or replace the pressure

regulator

OK

4 Check the hydraulic control block

(a) Replace a hydraulic control block

temporarily.
(b) Check if the faults occur again.
OK: Faults solved

OK Replace the hydraulic control

block

NG

5 Check the oil pump

(a) Replace an oil pump temporarily.
(b) Check if the faults occur again.
OK: Faults solved

OK Replace oil pump

NG

6 Replace the transmission

369
 P1766 Driven cone wheel pressure is too high

1 Check oil level and oil model

NG Check or replace the pressure

regulator

OK

2 Check the dynamic driving conditions

(a) Unplug the round connector on the CVT

transmission.
(b) Start engine
(c) Manual shifting gear
(d) Check the output waveform with
oscilloscope.
Normal resistance
Measuring Wire Color Normal
terminals resistance
3-car body B About 5.05Ω

NG Check or replace the pressure

regulator
OK

4 Check the hydraulic control block

(a) Replace a hydraulic control block
temporarily.
(b) Check if the faults occur again.
OK: Faults solved

OK Replace the hydraulic control

block

NG

5 Check the oil pump

(a) Replace an oil pump temporarily.

(b) Check if the faults occur again.
OK: Faults solved

OK Replace oil pump

NG

370
6 Replace the transmission

P0218 Transmission oil temperature is too high

1 Check the oil cooler

NG Check or replace the pressure

regulator

OK

2 Detect the driving conditions

(a) Check the oil temperature under normal

driving circumstances.
OK: oil temperature less than 120℃

NG Apply measures of heat

dissipation
OK

3 Consult users about the driving conditions

P1767 Transmission oil temperature exceeds range

1 Check the oil cooler

NG Check or replace the pressure

regulator

OK

2 Detect the oil level

(a) Check if the oil level is within appropriate

range.

NG Add transmission oil

OK

3 Check the transmission oil temperature

371
 (a) Check the transmission oil temperature.
OK: Oil temperature is less than 140℃

NG Apply measures of heat

dissipation

OK

4 Consult users about the driving conditions

P0219 Driving system speed exceeds range

1 Check the engine speed

(a) Check the engine speed limit is within

6000rpm.

NG Limit the engine speed

OK

2 The system is normal, clear DTC and read again.

P2766 The speed of driving cone wheel is inconformity with the actual speed

1 Detect other speed

(a) Detect other speed with detecting

apparatus.
(b) Check if the speed is normal.
OK: other speed is normal.

NG Solve other problems of speed

first

OK

2 Detect the signal of driving cone wheel

(a) Measure the driving cone wheel speed

when the clutch is connected to the engine.
(b) The whole detection from low speed to
high speed.
(c) Check if the RPM difference is within
200rpm
OK: normal

372
 NG Check next step

OK

3 Check the sensor

(a) Check the position and angle of sensor.

(b) Check the fragment at the front of sensor.
OK: the position of sensor is normal

NG Check or replace the sensor

OK

4 Replace the TCU

(a) Replace a TCU temporarily.

(b) Check if the faults occur again.
OK: Faults solved

NG Replace the transmission

OK

5 Replace the TCU with faults

P0721 The speed of driven cone wheel is inconformity with the actual speed

1 Detect other speed

(a) Detect other speed with detector.

(b) Check if the speed is normal.
OK: Other speed is normal.

NG Solve the problems of other

speed first

OK

3 Check the sensor

(a) Check the position and angle of sensor.

(b) Check the fragment at the front of sensor.
OK: the position of sensor is normal.

373
 NG Check or replace the sensor

OK

4 Replace the TCU

(a) Replace a TCU temporarily.

(b) Check if the faults occur again.
OK: Faults solved

NG Replace the transmission

OK

5 Replace the TCU with faults

P0944 Insufficient clamping force

1 Check the oil level

(a) Read other module DTC with diagnostic

apparatus.
(b) Check if there are faults with CAN bus.
OK: other module has faults with BUS

OK Repair CAN BUS

NG

2 Replace the transmission

P1762 The current value is fixed and can not be changed

1 Detect other DTCs

(a) Check and repair the following DTCs:

P0962 P0963 P0960 P0966 P0967 P0964
P0902 P0903 P0900 P1763 P1764.
(b) Check if the speed is normal.
OK: Other speed is normal.

NG Solve other problems of speed

first

374
 OK

2 Replace the TCU

(a) Replace a TCU temporarily.

(b) Check if the faults occur again.
OK: Faults solved

NG Replace the transmission

OK

3 Replace the TCU with faults

P0882 Voltage of battery or high end is too low

1 Detect the battery record

(a) Check the battery voltage record when

with faults; confirm it is the problems of
storage battery or high end voltage.

Voltage record Go to
Problems of storage battery A
A
Problems of high end voltage B

2 Replace the battery

(a) Replace a battery temporarily.

(b) Check if the faults occur again.
OK: Faults solved

OK Replace the battery with faults

NG

3 Go to TCU power supply circuit

4 Go to transmission and TCU circuit

375
 NG Repair the circuit

OK

5 Replace the TCU

(a) Replace a TCU temporarily.

(b) Check if the faults occur again.
OK: Faults solved

NG Replace the transmission

OK

6 Replace the TCU with faults

P0883 The voltage of battery or high end is too high

1 Detect the battery record

(a) Check the battery voltage record when

with faults; confirm it is the problems of
storage battery or high end voltage.

Voltage record Go to
Problems of storage battery A
Problems of high end voltage B
A

2 Replace the battery

(a) Replace a battery temporarily.

(b) Check if the faults occur again.
OK: Faults solved

OK Replace the battery with faults

NG

3 Go to TCU power supply circuit

376
 B

4 Go to transmission and TCU circuit

NG Repair the circuit

OK

5 Replace the TCU

(a) Replace a TCU temporarily.
(b) Check if the faults occur again.
OK: Faults solved

NG Replace the transmission

OK

6 Replace the TCU with faults

P2787 Clutch temperature is too high

1 Check with detector

(a) Check the current of every pressure

regulator with detector
OK: the current is normal

NG Replace the pressure regulator

OK

2 Check the hydraulic control block

(a) Replace a hydraulic control block
temporarily.
(b) Check if the faults occur again.
OK: Faults solved
OK Replace the hydraulic control
block

NG

3 Replace the transmission

377
 The rigid line engine speed signal transmission from ECU to TCU is inconformity with
P0727
the actual speed

1 Check the engine

(a) Check the engine examing report.

OK: there are engine fault reports.

OK Repair the engine

NG

2 Check the TCU input signal

(a) Start engine

(b) Check the output waveform with
oscilloscope.

Engine Speed Signal

Frequency
900rmp 30Hz
3000rmp 100Hz

OK Replace the TCU

NG

3 Replace the transmission

P1761 pressure regulator current fails

1 Check the engine

(a) Check the engine examing report.

OK: there are engine fault reports.

OK Repair the engine

NG

2 Check the TCU input signal

(a) Start engine

(b) Check the output waveform with
oscilloscope.

378
 Engine Speed Signal
Frequency
900rmp 30Hz
3000rmp 100Hz

OK Replace the TCU

NG

3 Replace the transmission

U0301 Vehicle configuration fails

1 Check the TCU software and hardware

(a) Check if the combination of software and

hardware is correct.

2 End

P0706 Driving mode sensor signal line fails

1 Check the wire harness

379
 (a) Unplug the connector of TCU and
transmission.

Measuring Wire Normal

terminals Color resistance
A35-1-A33-5 R/Y Less than 1Ω
A35-2-A33-91 L Less than 1Ω
A35-3-A33-90 B Less than 1Ω
A35-4-A33-89 Y/W Less than 1Ω
A35-5-A33-38 O Less than 1Ω
A35-6-A33-33 B/Y Less than 1Ω
A35-7-A33-41 B/O Less than 1Ω
A35-7-A33-64 B/O Less than 1Ω
A35-7-A33-86 B/O Less than 1Ω
A35-8-A33-32 R/Y Less than 1Ω
A35-8-A33-74 R/Y Less than 1Ω
A35-9-A33-30 R/B Less than 1Ω
A35-9- A33-77 R/B Less than 1Ω
OA35-9- A33-78 R/B Less than 1Ω
K
A35-10-A33-75 B/L Less than 1Ω
:
A35-11-A33-63 L/Y Less than 1Ω
A35-12-A33-61
t L/B Less than 1Ω
h
A35-13-A33-57 L/W Less than 1Ω
e
A35-14-A33-58 W/G Less than 1Ω
r W/L Less than 1Ω
A35-15-A33-79
e
A35-15-A33-35 G/B Less than 1Ω
are engine fault reports.

NG Repair or replace the wire

harness

NG
2 Check the TCU
(a) Replace a TCU temporarily.
(b) Check if the faults occur again.
OK: Faults solved
OK Replace the TCU

NG

3 Replace driving mode sensor

P0705 Driving mode sensor multi-line fails

380
1 Check the wire harness

(a) Unplug the connector of TCU and

transmission.

Measuring Wire Normal

terminals Color resistance
A35-1-A33-5 R/Y Less than 1Ω
A35-2-A33-91 L Less than 1Ω
A35-3-A33-90 B Less than 1Ω
A35-4-A33-89 Y/W Less than 1Ω
A35-5-A33-38 O Less than 1Ω
A35-6-A33-33 B/Y Less than 1Ω
A35-7-A33-41 B/O Less than 1Ω
A35-7-A33-64 B/O Less than 1Ω
A35-7-A33-86 B/O Less than 1Ω
A35-8-A33-32 R/Y Less than 1Ω
A35-8-A33-74 R/Y Less than 1Ω
A35-9-A33-30 R/B Less than 1Ω
A35-9- A33-77 R/B Less than 1Ω
OA35-9- A33-78 R/B Less than 1Ω
O
A35-10-A33-75 B/L Less than 1Ω
K
A35-11-A33-63 L/Y Less than 1Ω
:
A35-12-A33-61 L/B Less than 1Ω
A35-13-A33-57
t L/W Less than 1Ω
h
A35-14-A33-58 W/G Less than 1Ω
e W/L Less than 1Ω
A35-15-A33-79
r
A35-15-A33-35
e G/B Less than 1Ω
OOK: there are engine fault reports.

NG Repair or replace the wire

harness

NG

2 Check the TCU

(a) Replace a TCU temporarily.

(b) Check if the faults occur again.
OK: Faults solved

OK Replace the TCU

NG

3 Replace driving mode sensor

381
 P0955 Manual shift up and down signal fails

1 Check the gearshift at TCU circuit (Refer to TCU circuit)

NG Repair the TCU the circuit

OK

2 Check the TCU

(a) Replace a TCU temporarily.

(b) Check if the faults occur again.
OK: Faults solved

OK Replace the TCU

NG

3 Replace the gearshift

U0001 CAN BUS fails

1 Check if CAN BUS of other module fails as well

(a) Read other module DTC with diagnostic

apparatus.
(b) Check if there are CAN BUS faults.
OK: CAN BUS of other module fails as well

OK Repair the CAN BUS

NG

2 Check the TCU

(a) Replace a normal TCU temporarily.

(b) Check if the faults occur again.
OK: Faults solved

NG Go to next checking procedure

OK

382
3 Replace the TCU with faults

U0100 ECU CAN communication fails

1 Check the ECU CAN communication port

(a) Read other module DTC with diagnostic

apparatus.
(b) Check if there are CAN BUS faults
OK: CAN BUS of other module fails as well

OK Repair the CAN BUS

NG

2 Check the TCU

(a) Replace a normal TCU temporarily.

(b) Check if the faults occur again.
OK: Faults solved

NG Go to next checking procedure

OK

3 Replace the TCU with faults

U1012 Engine speed signal on the CAN BUS fails

1 Check the MCU

(a) Replace a MCU temporarily.

(b) Clear the DTCs.
(c) Re-read the DTCs and see if the DTCs
occur again.
OK: DTCs solved.

NG Go to next checking procedure

OK

2 Replace MCU with faults

383
 U1013 Acceleration pedal on the CAN BUS fails

1 Check the EMS

(a) Replace an EMS temporarily.

(b) Clear the DTCs.
(c) Re-read the DTCs and see if the DTCs
occur again.
OK: DTCs solved.

NG Go to next checking procedure

OK

2 Replace EMS with faults

U1014 Engine torque signal on the CAN BUS fails

1 Check the EMS

(a) Replace an EMS temporarily.

(b) Clear the DTCs.
(c) Re-read the DTCs and see if the DTCs
occur again.
OK: DTCs solved.

NG Go to next checking procedure

OK

2 Replace the EMS with faults

384
Section 6 Preparing Tools
Work glove One pair
Wrench/sleeve 10#

Section 7 Disassembly and Assembly

1. TCU
1.) Disassembly
(1) Turn the power supply OFF
(2) Disconnect the negative pole of battery
(3) Open the hood
(4) Unplug the TCU connector
(5) Remove the 3 fixing bolts with wrench and take out the TCU and bracket assembly.

2. Assembly
The sequence of assembly is the same with that of the disassembly

3. CVT assembly
See the chassis for the assembly and disassembly of CVT

385