CHANGHE FREEDOM SERVICE MANUAL TABLE OF CONTENTS

TABLE OF CONTENTS
THE FIRST PART GENERAL INFORMATION
SECTION 1 GENERAL INFORMATION ............................................................................. 1
SECTION 2 SCHEDULED MAINTENANCE..................................................................... 22
THE SECOND PART ENGINE
SECTION 3 ENGINE ................................................................................................................. 40
SECTION 4 ENGINE MECHANICAL....................................................................................51
SECTION 5 ENGINE COOLING SYSTEM ........................................................................88
SECTION 6 ENGINE LUBRICATE SYSTEM .................................................................102
SECTION 7 ENGINE MANAGE SYSTEM ...................................................................110
THE THIRD PART CLUTCH TRANSMISSION DIFFERENTIAL
SECTION 8 CLUTCH ...............................................................................................................115
SECTION 9 TRANSMISSION ...............................................................................................124
SECTION 10 GEAR SHIFTING CONTROL ....................................................................161
SECTION 11 PROPELLER SHAFT ...................................................................................171
SECTION 12 DIFFERENTIAL ..............................................................................................177
THE FOURTH PART SUSPENSION STEERING BRAKE
SECTION 13 SUSPENSION ...................................................................................................191
SECTION 14 MANUAL RACK AND PINION ..................................................................214
SECTION 15 BRAKES .............................................................................................................225
THE FIFTH PART BODY AND ELECTRICAL SERVICE
SECTION 16 ELECTRICAL SYSTEM ................................................................................266
SECTION 17 BODY ELECTRICAL SYSTEM. ................................................................282
SECTION 18 BODY SERVICE ..............................................................................................310
THE SIXTH PART HEATER AND AIR CONDITIONING
SECTION 19 HEATER AND COOLING ............................................................................319
SECTION 20 SEAT BELT AND AIR BAG SYSTEM....................................................330
CHANGHE FREEDOM SERVICE MANUAL GENERAL INFORMATION

METRIC FASTENERS STANDARD TIGHTENING TORQUE

Each fastener should be tightened to the torque specified in each section of this manual.
If no description or specification is provided, refer to the following tightening torque chart for the
applicable torque for each fastener. When a fastener of greater strength than the original one is used,
however, use the torque specified for the original fastener.
NOTE:
z For the flanged bolt, flanged nut and self-lock nut of 4T and 7T strength, add 10% to the
tightening torque given in the following chart.
z The following chart is applicable only where the fastened parts are made of steel light
alloy.

Tightening Torque Table

THREAD
DIAMETER(mm)
4 5 6 8 10 12 14 16 18
STRENGTH

N·m 1.5 3.0 5.5 13 29 45 65 105 160

kg·m 0.15 0.30 0.55 1.3 2.9 4.5 6.5 10.5 16

lb·ft 1.0 2.5 4.0 9.5 21.0 32.5 47.0 76.0 116.0

N·m 2.4 4.7 8.4 20 42 80 125 193 280

kg·m 0.24 0.47 0.84 2.0 4.2 8.0 12.5 19.3 28

lb·ft 2.0 3.5 6.0 14.5 30.5 58.0 90.5 139.5 202.5

N·m 2.4 4.9 8.8 21 44 84 133 203 298

kg·m 0.24 0.49 0.88 2.1 4.4 8.4 13.3 20.3 29.8

lb·ft 2.0 3.5 6.5 15.5 32.0 61.0 96.5 147.0 215.5

N·m 2.3 4.5 10 23 50 85 135 210 240

kg·m 0.23 0.45 1.0 2.3 5.0 8.5 13.5 21 24

lb·ft 2.0 3.5 7.5 17.0 36.5 61.5 98.0 152.0 174.0

N·m 3.1 6.3 11 27 56 105 168 258 373

kg·m 0.31 0.63 1.1 2.7 5.6 10.5 16.8 25.8 37.3

lb·ft 2.5 4.5 8.0 19.5 40.5 76.0 121.5 187.0 270.0

N·m 3.2 6.5 12 29 59 113 175 270 395

kg·m 0.32 0.65 1.2 2.9 5.9 11.3 17.5 27 39.5

lb·ft 2.5 5.0 9.0 21.0 43.0 82.0 126.5 195.5 286.0

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CHANGHE FREEDOM SERVICE MANUAL GENERAL INFORMATION

Super grease（E） z Apply the steering case（rack and

（99000-25050） pinion） interior parts。
5

Gear oil z Transmission case

4speed ： 1.0l[2.1/1.8
Gear oil standard SAE （American/British）pint]
Transmission oil 75W-85 GL-4 5speed ： 1.3l[2.7/2.3
rank （American/British）pint]
Differential oil rank 75W-85 GL-5 z Transmission gear and bearing.
z Differential gear case(hyperbola
6 gear oil）
1.3l[2.7/2.3（American/British）pint]

Temperature
Silicon grease z Steel plate spring bush
（99000-25190）
7

4 Stroke engine oil z Engine oil pan：

Recommend to use SE，SF，SG or SH engine oil。 （ Be used in the period of
replacing engine oil ）
z Crankshaft neck and pulley
Condign engine oil viscosity chart z connecting rod big end and little
end bearing
z Camshaft neck
z Valve rocker shaft
z Oil pump gear
8 z Piston and piston ring
z Engine oil seal
z Valve rod
z Accelerate pedal，brake and clutch
pedal axes
z Door lock and hinge
z Shunt gear

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CHANGHE FREEDOM SERVICE MANUAL SCHEDULED MAINTENANCE

Engine idle speed inspection

Check the rotate speed of idle speed adjust as
necessary. A bout the steps of engine idle speed
inspection and adjustment, refer to engine service.

Engine Type DA465QE/2F DA471Q K14

idle speed 850±50r/min 900r/min

Fuel Evaporative Emission Control System

Inspection
Crankcase PCV Valve Inspection
Ventilation hose and connector
Check crankcase ventilation hose and PCV
hose for leaks, cracks or clog. If there is any bad
situation, then fix or replace. Check hose and make
1.PCV hose 2. PCV valve sure it is close and firm.

PCV Valve Inspection

1) Disconnect PCV valve hose from 3-way joint.
2) Run engine at idle. Place your finger over
end of PCV valve to check for vacuum. If there is no
vacuum, check for clogged valve. Replace as
necessary.
3) Stop engine and connect PCV valve hose to
3-way joint.
4)PCV Valve replacement：For validly
protecting the vehicle exhaust system, use the PCV
valve type and factory which is appointed by my
company.

Fuel Evaporative Emission Control System

1) Visually inspect hoses for cracks, damage, or
excessive bends. Inspect all clamps for damage and
proper position.
2) If malfunction is found, repair or replace.
3) Check EVAP canister for operation and clog,
refer to “in Section 3 ”.

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CHANGHE FREEDOM SERVICE MANUAL ENGINE

Condition Possible Correction

Erratic Ignition system
1． Improper ignition timing. Adjust
2． Defective spark plug，or improper gap. Replace or adjust
3． High tension cord bad insulation. Replace
Electricity injection system
1． Step motor Check circuit or replace
2． Throttle position sensor Check circuit or replace
3． ECU Replace
4． Intake temperature pressure sensor Check circuit or replace
Others
1． Air filter dirty and clogged Clean
2． Intake system leak Adjust
3． Exhaust manifold have carbon deposit Clean or replace
4． Clearance of valve improperly adjusted Adjust
5． Valves not seating tight Repair
6． Cylinder gasket break Replace
Abnormity Ignition system
slap 1． Spark plug overheating Replace
（knocking、 2． Improper ignition timing Adjust
advanced Fuel system
sparking 、 1. Fuel quality is not good Replace
combustion Electricity injection system
lag） 1． knock meter（or have）. Replace
2． Intake temperature pressure sensor Replace
Others
1． Carbon deposit on piston head or cylinder Clean
head
2． Abnormity cylinder cushion Replace
3． Improper valve clearance Adjust
4． Valve lock Repair or replace
5． Weakened valve spring Replace
Ignition system
1． Improper ignition timing Adjust
2． Spark plug calorie value ineptitude Replace
Exhaust system
1． Clogged exhaust pipe Clean
Cooling system
Overheating
1． No enough coolant Refill and check circle
2． Loose or broken water pump belt Adjust or replace
3． Erratically working thermostat Replace
4． Poor water pump performance Replace
5． Leaky radiator Repair or replace

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CHANGHE FREEDOM SERVICE MANUAL ENGINE MECHANICAL

Fig. 3-082
Install cylinder head onto cylinder block. Tighten cylinder head bolts gradually with torque wrench to
specified torque.

Fig. 3-083

Camshaft
Apply engine oil to cams and journals on camshaft, and oil seal on cylinder head. Then install it to
cylinder head from transmission case side.
Be careful not to leave out the thrust plate when installing the camshaft. After setting this shaft in
place, with its thrust plate properly fitted, turn the shaft by hand to be sure it rotates smoothly.

Fig. 3-084

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CHANGHE FREEDOM SERVICE MANUAL ENGINE LUBRICATE SYSTEM

二、The Work Flow Of Lubricate System (chart 5－1)

3# camshaft
bearing journal

Piston and cylinder

block wall Rocker arm shaft

Rocker arm
Connecting rod small end
5# camshaft
bearing journal
1、2、4# camshaft
Connecting rod big end
bearing journal
Distributor gear shaft
Crankshaft journal

Camshaft center hole

Cylinder block oil hole

Oil filter Bypass valve

Cylinder block wall

Oil pump Relief valve

Oil strainer

Oil pan

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CHANGHE FREEDOM SERVICE MANUAL TRANSMISSION

Separating Upper Case from Lower Case

1) Remove clutch release bearing from
transmission input shaft．

Fig．13-4-1

2) Remove input shaft bearing retainer bolts

and pull out retainer by using 3 conventional 6 mm
bolts．

Fig.．13-4-2

3) Remove gear shift lever case and speed

meter driven gear case．
4) Remove bolts securing extension case to
transmission case and take off extension case．

Fig.．13-4-3

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CHANGHE FREEDOM SERVICE MANUAL GEAR SHIFTING CONTROL

图1 Gear shift and select cables

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CHANGHE FREEDOM SERVICE MANUAL DIFFERENTIAL

Bevel pinion bearing preload adjustment

The bevel pinion, as installed in the normal
manner in the carrier, is required to offer a certain
torque resistance when checked with the use of a
prescribed torquing pulley (special tool ○ A ) as
shown in the following figure. This resistance is a
"preload," which is due to the tightness of the two
tapered roller bearings by which the pinion is held
in the carrier. And this tightness is determined
primarily by the thickness of the adjusting collar
plus a shim. Check the preload and, if the preload
measurement is off the specified range indicated
below, increase or decrease shim thickness. The
method is as follows:
1) Tentatively install pinion in carrier, using
adjusting collar and a 1 mm thick shim, and
tighten the nut to secure splined yoke. Torque the
nut to the following specification.
2) Put on torquing pulley (special tool) and
give a pull, as left shown, and read spring balance
indication just when the pulley begins to turn. The
reading is a starting torque, and is required to be
within the specified torque range.
3) Increasing shim thickness decreases this
preload, and vice versa. Four size shim stock
available for "mounting distance" adjustment,
mentioned above, is meant to be used in
producing a proper shim thickness in this preload
adjustment, too.

NOTICE:
● When tentatively installing pinion in
carrier, be sure to oil bearings lightly with
gear oil, and to leave out the oil seal.
● Make a note of the starting torque.
Pinion bearing 5.0—13.0kg—cm
preload （4.3—11.2 1b—in）
Starting torque 1.0—2.6kg
（with pulley） （2.2—5.7 1b）

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CHANGHE FREEDOM SERVICE MANUAL SUSPENSION

.
condition when tightening them to specified
torque（68±7N.M）.
6） Check toe-in setting, adjust as required

Knuckle
Removal
1） Hoist vehicle and remove wheel.
2） Remove wheel hub.
3） Disconnect tie-rod end from knuckle with
remover.
4） Remove ball stub bolt from knuckle, then
remove strut bracket bolts from strut bracket.
5） Remove knuckle.

Installation
1) Install knuckle to ball stud on suspension
arm and strut bracket. Align knuckle bolt hole with
ball stud groove as shown and install ball stud bolt.
Tighten each bolt and nuts to specified torque.
Torque： 55±5.5N.M
95±10N.M

2) Connect tie-rod end to knuckle and tighten

tie-rod end castle nut to specified torque（50±
5N.M）.

NOTE：
As tight tie-rod end nut，push the tie-rod
up with garage jack to prevent ball stub from
rotation.

5） Have vehicle off hoist and in non-loaded

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CHANGHE FREEDOM SERVICE MANUAL MANUAL RACK AND PINION

INSTALLATION
1) Be sure that front wheels and steering
wheel are in straight forward state and insert
lower joint into steering pinion shafts
2) Tighten steering shaft lower joint bolts to
specified torque.
3) Apply grease to steering shaft seal “A”，
and install steering shaft seal to dash panel, as
shown in left figure .
4) Align flat part “B” of lower joint shaft with
bolt hole “C” of steering column joint as shown，
then insert lower joint shaft into steering column
joint .
5) Tighten steering column mounting bolts
to specified torque.
6) Install combination switch.
7) Connect harness of combination switch
and ignition switch with connector.
8) Install combination switch upper and
lower cover.
9) Install steering wheel, if necessary.
10) Connect the negative cable with the
battery.

CAUTION：
Once the steering column is removed
from the vehicle, the column is extremely
susceptible to damage. Dropping the
column assembly on its end could collapse
the steering shaft or loosen the plastic
shear pins which maintain column length.
Leaning on the column assembly could
cause it to bend or deform. Any of the above
damage could impair the column's
NOTE:
collapsible design.
When servicing steering column or any
Steering column mounting nuts should
column-mounted component, remove
not be loosened with steering shaft joint
steering wheel. But when removing steering
upper side bolt tightened as this could
column simply to gain access to instrument
cause damage to shaft joint bearing.
panel components, leave steering wheel
installed on steering column.

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CHANGHE FREEDOM SERVICE MANUAL BRAKES

Tightening torque

Fastening parts kg.m

1. Disc bolt 4.0-6.0
2. Steering knuckle castle
15.0-25.0
nut
3. Flexible hose bolt 2.0-2.5
4. Caliper bolt 7.0-10.0
5. Caliper pin bolt 3.0-3.8
6. Caliper pin 5.0-6.0
7. Wheel nut 5.0-8.0

Front Brake Flexible Hose

Connect flexible hose to caliper as show
below and tighten hose bolt to specification.

NOTICE:
After completing installation, fill reservoir
with brake fluid and bleed brake system.
Perform brake test and check each installed
part for oil leakage.

Inspection for After Installing Front Brake

Mount tires and make certain that they rotate
smoothly, with a force of less than 3.3 kg (7.3 lb).

NOTICE:
For the above check, the following must
be observed.
1) Jack up front wheels, both right and left,
off the ground.
2) The below figure shows outer periphery
of tire.
3) Be careful not to depress brake pedal
when checking tire for rotation.

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CHANGHE FREEDOM SERVICE MANUAL BRAKES

6) When bubbles stop, depress and hold

brake pedal and tighten bleeder plug.
7) Then attach bleeder plug cap.

8) After completing bleeding operation, apply

fluid pressure to pipe line and check for leakage.

9) Replenish fluid into reservoir up to

specified level.
10) Check brake pedal for “sponginess”. If
found spongy, repeat entire procedure of
bleeding.

INSPECT BOOSTER OPERATION

There are two ways to perform this inspection,
with and without a tester. Ordinarily, it is possible
to roughly determine its condition without using a
tester.

NOTE:
For this check, make sure that no air is in
hydraulic line.

[INSPECTION WITHOUT TESTER]

Check Air Tightness
1） Start engine.
2） Stop engine after running for 1 to 2
minutes.
3） Depress brake pedal several times with the
same load as in ordinary braking and observe
pedal travel. If pedal goes down deep the first time
but its travel decreases as it is depressed the
second and more times, air tightness is obtained.
4） If pedal travel doesn't change, air
tightness isn't obtained.
NOTE：
If defective, inspect vacuum lines and sealing
parts, and replace any faulty part.
When this has been done, repeat the entire
test.

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CHANGHE FREEDOM SERVICE MANUAL ELECTRICAL SYSTEM

RADIO 、CIGAR LIGHTER AND ELECTRONIC LOCK

281