Index Foton Foton Series Light Bus. Service Manual

Content .. 6 7 8 9 ..

Foton Series Light Bus. Service Manual - part 8

OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

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via fuel return pipeline.

4.2.10 Ignition Coil

The ignition coil assembly integrates the ignition module and two ignition coils (shown in Figure 4-18).

Primary coil is controlled by ECM through ignition module; each secondary of ignition coil is connected with

spark plug in series inside two cylinders to form a loop.

Figure 4-17 Working Principle of Fuel Pressure Regulator

1-Pressure regulating diaphragm; 2-Pressure regulating spring; 3-Manifold pressure collection hole

The primary coil resistance: 0.5 Ω±0.05Ω

Figure 4-18 Ignition coil

The secondary coil resistance: 5200Ω±400Ω

Wiring: A-2, 3 cylinders ignition driving, B-1, 4 cylinders ignition driving,

C-Grounding, D-+12V

Pressure fuel

Intake manifold

Return fuel

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Chapter 4 BJ491EQ1 Gasoline Engine Fuel Injection System

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4.2.11 High Voltage Cable and Spark Plug

Because electronic fuel injection system adopts high energy and high voltage ignition, the high voltage cable

must be endurable with high voltage, and also can restrain the radio interference occurred during ignition

4.2.11.1 Check Spark Plug

Use the steel brush to clean the spark plug. Visual check plug electrode for burnt-out, damaged thread and

insulator. Replace if plug is damanged.

Type of

spark plugs: F6RTC or F5RTC; thread specification: M14×1.25. Bend the side electrode carefully

and adjust the electrode clearance to its correct position: 1.1 mm ± 0. 1mm (see Figure 4-19).

Figure 4-19 Check Spark Plug

Installation torque of spark plug: 25 ~ 30 N.m.

Replace the spark plug at every 10,000km normally.

4.2.11.2 Check High Voltage Cable

● Caution: Do not pull or bend the high voltage cable, otherwise its inside conductor may be damaged (see

Figure 4-20).

High voltage cable is of damp type. Replace the high voltage cable if the resistance between its two ends is

larger than 25 KΩ.

Figure 4-20 Check High Voltage cable

4.2.11.3 Check flashover in each cylinder

Dismantle at the same time the spark plugs in two cylinders, and connect them with corresponding high

Incorrect

Correct

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voltage cable. Make sure plugs’ screw thread ground to cylinder block. Start up the gasoline engine to observe the

flashover.

● Caution: To observe the flashover, the injector in concerning cylinder should be unplugged. Otherwise

unburned gasoline would burn near the three-way catalytic converter to damange injector immediately. Two spark

plugs in a same group should be dismantled at the same time. Otherwise the ignition system may be damaged.

4.2.12 Throttle Valve Body

The throttle valve body is installed at the front end of intake manifold. It controls air intake flow. It is

composed by throttle body, valve, accelerating mechanism, throttle position sensor and idle speed air control valve

(See Figure 4-21).

4.2.12.1 Throttle Position Sensor

The throttle position sensor monitors the throttle opening angle, and sends the signal to the ECM. The signal

is the basis for engine’s various normal woking conditions especially at idle and transition. The sensor is installed

on the throttle assembly, and has the same axis with acclerating lever and throttle. It is a lineral variable resistance

type, and its sliding terminal driven by throttle shaft.

Connection: A-+5V; B-Grounding signal; C-Throttle position signal.

Resistance between A and B: 3kΩ~12kΩ

Figure 4-21 Throttle Valve Body Assembly

1-Idle speed air control valve; 2-Throttle position sensor;

3-Throttle valve body; 4- Accelerator cable plate

● Note: Never adjust TP screw.

4.2.12.2 Idle Speed Air Control Valve

By changing throttle bypass air, idle air control valve enables proper air intake at engine startup, warm-up

and idle. The valve consists of a cone pintle and pintle carrier, fixed on throttle valve body. It is controlled by

ECM output signal. It could maintain engine Rpm at preset value during warm-up and idle running through

feedback control.

Connection: A-Coil B-; B-Coil B+; C-Coil A-; D-Coil A+

Resistance of idle speed air control valve coil: 53Ω±5.3Ω

4.1.13 Canister Purge Control Solenoid

The canister purge solenoid is installed between the canister and intake manifold (figure 4-22). ECM controls

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Chapter 4 BJ491EQ1 Gasoline Engine Fuel Injection System

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the fuel vapor volume through it. When the solenoid is not connected, it will keep in off position to avoid fuel

vapor enriching air-fule mixture. The solenoid keeps “off” during engine startup and warmup processes. When

engine has reached its operation temperature, ECM unit controls solenoid open/close by its paulse squre wave

output so as to control fuel vapor amount entering intake manifold.

Canister purge control solenoid connection terminal: A-ECM; B-+12V.

Resistance of canister purge control solenoid: 19-22Ω
● Note: The pipe marked with “CAN” will be connected to the canister. It is not allowed to connect it in a

wrong way.

Figure 4-22 Canister Purge Control Solenoid

4.2.14 Three Way Catalytic Converter

Three-way catalytic converter is installed between the exhaust manifold and the muffler, behind oxygen

sensor. It is cellular structured inside. In its cellular pipe wall are precious metal coatings (platinum, rhodium and

palladium) that are used to be catalytic media. While the air-fuel ratio is 14.5～14.7, and the working temperature

is 375～800℃, the harmful exhaust gas from cylinder will be reacted into unhuamful gas via conveter.

The optimal working temperature of three way catalytic converter is 375~800℃, and the maximum

endurable temperature for short time period is 920℃.

● Note: There are model and installation arrowhead marked on the surface of three way catalytic converter,

and it is not allowed to be installed on the contrary direction.

Structure of the three-way catalytic converter is shown in Figure 4-23.

Figure 4-23 Three-Way Catalytic Converter

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4.2.15 Communication and maulfunction diagonistic plug

The communication and malfunction diagnostic plug is a communication interface between electric fuel

injection system and peripherals. It draws out from system harness. The emergency malfunction judgment can

also be made by short circuiting “Diagnosis request” and “Grounding” to flash malfunction indicator, or retrival

fault codes with radom code reader..

Table 4-3 The definitions of the malfunction diagnostic plug interface.

Table 4-3 Pins in16-Pin Diagnostic Connector

Diagnosis request

N/A

Grounding

N/A

Grounding

N/A

Communication

N/A

+12V

Table 4-4 Fault code and its definition.

Table 4-4 Fault Code of Code Reader

Fault code

Fault description

0105

Air intake absolute pressure sensor circuit failure

0110

Air intake temperature sensor circuit failure

0115

Coolant temperature sensor circuit failure

0120

Throttle valve position sensor circuit failure

0130

Oxygen sensor circuit failure

0170

Reading of oxygen sensor is abnormal

0200

Injector circuit failure

0230

Fuel pump circuit failure

0335

Crankshaft position sensor circuit failure

0351

Ignition coil of 1-4 cylinder circuit failure

0352

Ignition coil of 2-3 cylinder circuit failure

0443

Canister solenoid circuit failure

0505

Idle speed control valve circuit failure

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Chapter 4 BJ491EQ1 Gasoline Engine Fuel Injection System

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Fault code

Fault description

0560

System voltage too high

1530

AC clutch circuit failure

1604

1605

1640

ECM failure

Explanation of table 4-4:

(1) The code reader can read the unerased historical fault codes in ECM. Correct fault codes can be

retrivaled only when malfunction indicator flashed.

(2) If code reader indicates “---”, it means electronic fuel injection system is ok. If it indicates “E”, it means

ignition switch is off.

(3) It is suggest to approach service station to clear up fault code after each troubleshooting.

4.2.16 Harness

The harness transmits digital signal. The signals from various sensors go to ECM through harness. After the

computation and judgment, ECN sends control signals via harness to the injection system and direct ignition

system. One end of harness is ECM plug, and sensor / ignition system plug on the other. ECM unit, the sensor,

fuel supply system and ignition system all have its special socket. Watch carefully to avoid mistake.

4.2.16.1 Figure 4-24 shows multi point electronic injection gasoline engine system harness diagram for

BJ491EQ1 Foton View Sea Lion light bus.

4.2.16.2 Figure 4-25 shows multi point electronic injection gasoline engine system harness diagram for

BJ491EQ1 pick-up and SUV.

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OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

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Figure 4-24 MPI Gasoline Engine Harness Diagram for BJ491EQ1 Foton View Sea Lion Light Bus

Canister

control

valve

Grounding

No.4

injector

Air intake

pressure

sensor

Coolant

temperature

sensor

No.1

injector

No.2

injector

No.3

injector

Observation of H1 inserter wiring

connect in end

Grounding

Ignition

coil

Idle speed

control

valve

Air intake

temperature

sensor

Crankshaft

position

sensor

Throttle valve

position

sensor

Ignition power

supply

Observation of H2 inserter wiring

connect in end

Ignition power

supply

Ignition power

supply

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Chapter 4 BJ491EQ1 Gasoline Engine Fuel Injection System

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Figure 4-25 MPI Gasoline Engine System Harness Diagram for BJ491EQ1 Pick-Up and SUV

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OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS

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Chapter 5 Application of BJ491EQ1

Gasoline Engine

5.1 Regulations for Safe Operating

5.1.1

The operator should know the structure of an engine and master the skills for its use and maintenance.

Those who don’t know the operation techniques are not allowed to start up an engine.

5.1.2

The operator should wear working clothes that meet the safety and work protection requirements. Women

operators should wear safety helmet to avoid personal injuries.

5.1.3

Smoking is not allowed while filling fuel tank with gasoline.

5.1.4

When an engine is running, don’t stand in rotation range of a fan. Don’t put hand near pulley, belt or fan.

Don’t wear loose clothes.

5.1.5

When an engine is running, the operator is not allowed to approach any of its rotating parts. It is strictly

prohibited to dismantle parts while diesel engine is running. It needs special care during the necessary check and

adjustment..

5.1.6

Avoid being scalded while filling coolant, draining oil /coolant or approaching high-temperature locations

on engine. Keep away from exhaust pipe / muffler hot surface while service or repair is in progress to avoid

scalding.

5.1.7

Never remove radiator cap while the engine is hot, or hot coolant may spray out.

5.1.8

Keep away from the hot surface of exhaust pipe and muffler to avoid scalding.

5.1.9

Try to avoid contacting petrol-oil products while managing fuel/oil to prevent skin from irritated or

getting poisoned. Never suck fuel with mouth.

5.1.10

Electrolyte of battery is corrosive. Never let it splash into eyes, on skin or cloth. Wash it imme

-diately with clean water if that happens.

5.1.11

Make sure to keep transmission lever in “neutral” position.

5.1.12 Operator should never try to go on working when he feels bad, tired or sluggish.

5.2 Fuel, Oil and Cooling fluids

5.2.1 Gasoline

Oxygen sensor and three-way catalytic converter are adopted in the multi point electronic control fuel

injection system of BJ491EQ. In order to let 3-way catalytic converter work effectively without being poisoned by

lead, sulfur, and phosphorus, quality non-leaded gasoline above 93# that is in conformity with governmental

standard GB 17930-1999 is required.

In order to avoid fault and prolong diesel engine’s service life, engine must use clean fuel. It is required to fill

clean gasoline that meets national standards in qualified gas station. For self-filling, always keep sealing during

filling fuel. Precautions should be taken during fuel transportation, filling and use to avoid contamination.

High RVP gasoline must be used in cold regions to ensure engine’s cold startup performance.

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Chapter 5 Application of BJ491EQ1 Gasoline Engine

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Figure 5-1 Fill clean and ratified gasoline

l Caution:

(1) Catalyst in converter will get intoxicated if inferior lead free gasoline or leaded gasoline and gasoline

with high contaminants are used. These fuels will restrain its functions of oxygenation and deoxidization to CO,

HC and NOx, that makes engine exhausting more harmful gas to atmosphere.

(2) For a vehicle that has applied fuel additives, these symptoms are normal such as unstable idling speed,

high emission and hot-startup difficulty within short time (usually happens within first 5 tanks after additive

application). As additives is cleaning the fuel pipeline during the period.

(3) Clean fuel tank and fuel pipeline. Change to use ceramic fuel filter when a vehicle uses 10% ethanol

gasoline. It is normal for a vehicle using ethanol gasoline to show poor accelerating performance.

5.2.2 Lubricants (engine oil)

DJ491EQ1 Engine should use ratified SF rate (or up) oil. Choose oil according to ambient temperature as

indicated in figure 2 – 2.
l Cautions:

(1) Use oil according to specification, don't use unspecified or inferior oil to avoid damages such as

cylinder score or bearing grabbing.

Figure 5-2 Oil application and temperature

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(2) Engine oil that is to be filled shall not contain contaminants and moisture.

(3) Never mix to use oils of different rates or different manufactures. Never mix to use new and used oil

during technical maintenance.

5.2.3 Lubricating Grease

Alternator, starter bearing, water pump shaft and cooling fan grease cup should use specified general auto

lithium-base grease.
l Note: Clean grease cup before applying grease. Apply grease with grease gun.

5.2.4 Coolant

Coolant to be used in gasoline engine must has the properties such as anti-frozen, corrosion proof,

anti-fouling and with higher boiling point.

Caution: Coolant is poisonous and must be stored in its original container.

If an engine uses hard water (containing more minerals), high temperature will facilitate minerals to separate

out, forming scale in pipeline and high temperature parts. Scale blocks pipeline and restrains heat radiation, which

could overheat engine and lead to faults.

5.3 Preparations before Startup

Caution: Before starting up an engine, operator should carefully read this manual and operate strictly according

to instructions.
l Check following parts before starting the gasoline engine:

5.3.1

Carefully check each part of diesel engine for their connecting, fastening and operation.

5.3.2

Check coolant level in the radiator, and check fastening of coolant pipe connectors and fan belt

tension.

Note:

(1) Correct coolant level is very important to efficient operation of engine cooling system.

(2) Check coolant level only when engine has been shut off.

5.3.3

Use dipstick to check if oil amount meets requirements. And check if oil has been aged or deteriorated.

Change oil timely in following events: oil is deteriorated; its color has been turned; it becomes thinner has

moisture inside.
l Caution: Lower hole in dipstick is the alarming level, not operation level. Add oil timely as per specification

to avoid severe accident.

5.3.4

Open fuel tank switch to check fuel amount inside tank, and check if pipe connectors in fuel supply

system are fastened tightly. Remove any leaks and bleed the pipelines.

5.3.5

Check electrolyte level in battery.

5.3.6

Check the fastening of electrical connectors on components as battery, alternator, starter, spark plug and

ignition coils, ECM and other electrical devices.

5.4 Startup Procedures

l Caution: Never crank an engine without proper pre-starting preparations. Before starting-up, check if there

are any objects around that hamper engine operation.

(1) Set transmission to N gear.

(2) Depress clutch pedal to reduce load on engine during cranking.

(3) Electronic control fuel ejection system will provide suitable air fuel ratio under any working condition.

Do not depress accelerator pedal no matter it is a hot or could startup, as ECM keeps monitoring the working

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Chapter 5 Application of BJ491EQ1 Gasoline Engine

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condition of gasoline engine based on the throttle position. Once accelerator pedal is stepped down to open the

throttle, ECM will be unable to determine whether gasoline engine is starting or not, thus cannot feed fuel

correctly.

(4) Turn igniton key to START to start up the gasoline engine.

(5) It may take longer time for first starting (for new vehicle or the vehicle whose fuel supply systems has

just been serviced). This is because oil passage requires time to reach proper oil supplying pressure.
l Caution:

(1) Each cranking should not last more than 5 seconds. This is to protect starter and battery. There should

be at least 15 seconds interval between a fail start-up to second cranking. If 3 attempts cannot start up engine, one

has to turn to find the cause before next cranking.

(2) Oil warning indicator turns on during cranking.

Immediately release the ignition key after engine has started up. The ignition key will automatically reset to

ON position. At this point gasoline engine is running at fast idle speed condition if it is a cold starting. Engine will

automatically return to normal idle speed operation gradually.
l Note: The oil warning indicator turns out once gasoline engine runs correctly.

5.5 Idle Speed & Warm-up

After start-up, the gasoline engine needs warm-up for several minutes at idle speed. It will warm up at a

higher rotation speed under the control of ECM when the engine is cold, and the idle speed will slow down to

normal along with the increase of coolant temperature.

When ambient temperature is lower than -10℃, gasoline engine should be warmed up for 5 minutes before

driving.

Idle speed for gasoline engine will increase by about 150 r/min while A/C is on.

5.6 Check during Running

5.6.1

Check for knocking, loosening or other abnormal sound (especially after fuel filling and service).

5.6.2

Check electrical parts for burnt smell due to over heating.

5.6.3

Check fuel, cooling and lubricating systems for leakages.

5.6.4

Check meters of oil pressure, coolant temperature, current and oil level for correct readings.

Warning: The operator must not stand within the rotation range of fan when engine is running. Never dismantle

parts while engine is running. Use special care when performing check and adjustments.

Caution: Listen to any abnormal sound that may come out from a running engine. Check regularly fuel and

coolant passages for leakage. Remove any leakage immediately to avoid major accident.

5.7 Shutdown

If the engine needs to be shut down under heavy load running, operator should first lower its Rpm gradually

for 2~3min and then turn off ignition key. This is to cool diesel engine gradually and evenly to avoid parts

distortion due to sharp cooling.

5.8 Component Protection

ECM, sensors and acuator must be protected from water, static electricity and strong electromagnet

disturbance. Be careful not to drop them to ground or impact them during service.

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5.9 Limp in

If the EFI system parts are failure, EMS could turn into safety mode which could let vehicle manage to drive

to service station.

5.10 Important Points during Operation

5.10.1

According to these use and maintenance procedures in this manual to operate a gasoline engine.

5.10.2

A new or overhauled engine should have run-in period. It is not allowed to run it at high speed or under

heavy load in the first place.

5.10.3

Normal coolant temperature during engine operation is 80~95℃. The normal pressure of engine oil at

medium speed should be 245~392kPa, and the oil pressure warning indicator should be off (the indicator is on

during engine cranking).

5.10.4

Keep constant power supply to ECM. ECM will loss all data inside its memory once its power supply is

cut off. Initialization operation must be performed prior to normal starting for a newly assembled vehicles or a

vehicle whose ECM had been disassembled.

5.10.4.1 Connect battery’s postive and negative terminals.
5.10.4.2 Initialize the electronic control fuel injection system:

——Turn the ignition key to ON position;
——Turn off ignition key in about 3s;
——Turn ignition key again to ON position in about 5s;
——Control system initialization is finished.

5.10.4.3 “Check Engine” indicator lamp in instrument panel should lit automatically.
5.10.4.4 Initialization of electronic control fuel injection system:

——Turn the ignition key to ON;
——After several seconds, gasoline engine tends to start up or starts up completely;
——Turn off ignition key;
——Fuel supplying system initialization is finished.

5.10.4.5 Re-start the gasoline engine in about 5 seconds.

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Chapter 6 Technical Maintenance of BJ491EQ1 Gasoline Engine

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Chapter 6 Technical Maintenance of BJ491EQ1

Gasoline Engine

There are many reasons that could worsen gasoline engine technical conditions such as parts wear, loosen

fasteners, clearance changes and fuel/ oil deterioration. They will lead to many maulfunctions including hard

start-up, higher fuel/oil consumption, even a dead engine. It is very important to clean, check, lubricate the engine

or adjust and replace its parts/components at a fixed time period according to its the technical conditions and

operation time/mileage.

●Note: Strictly adhere to the maintenance requirements will keep the engine at a good technical condition

thus prolong its service life.

6.1 Technical maintenance interval

Technical maintenance is divided into 4 levels according to wear speed of engine’s various parts:

6.1.1

Rountine technical maintenance: normally carried out after each driving shift (about 8-10 hours.)

6.1.2

1000km technical maintenance

6.1.3

3000km technical maintenance

6.1.4

6000km technical maintenance

6.2 Content of technical maintenance

Perform following maintenance procedures to keep engine running properly

6.2.1 Rountine technical maintenance

(1) Check the levels of fuel, coolant and oil, and refill if necessary.
●Note: Check fluid levels only after the gasoline engine has cooled down and parked on flat ground.

Use #93 or above high quality lead free gasoline (GB17930-1999).
●Caution:

Do not refill the fuel when the engine is running. Do not fill up fuel tank under higher ambient

temperature as fuel might spill out due to expansion. Wipe out spilled fuel right away.

(2) Clean dirt and electrolyte away from the battery. Battery does not need maintenamce normally, but

regular fluid level check is needed when a battery works in higher temperature environment. Its fluid level should

be between MIN and MAX lines on battery case side. Add distilled water when electrolyte is not enough.

●Caution: Never add electrolyte or unclean water into battery. To do this will cause undercharging which

influences battery performance. Send the battery to the service station if the fluid drops too fast.

●Warning: The battery electrolyte is caustic and do not spill it into eyes, on skin or clothing. Wash them

right away with clean water if these happen.

(3) Check for fuel, oil, air or electricity leakages. Remove leakages immediately

(4) Check if high voltage cables are loose.

(5) Check if the gasoline engine works properly after it has started, and check instrument panel indicators.

6.2.2 Technical maintenance at 1000km

(1) Perform above rountine technical maintenance.

(2) Check the battery electrolyte concentration and battery voltage;

(3) Check for connection on alternator, ignition coil, spark plug, high voltage damping cable or connectors;

(4) Clean the air filter;

(5) Check if fastners are firmly secured.

6.2.3 Technical maintenance at 3000km

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(1) Perform above 1000km maintenance procedures.

(2) Clean spark plug electrodes and adjust the clearance between electrodes. Adjust clearance: F6 RTC or F5

RTC is 1.1mm±0.1mm.

(3) Clean or replace air filter paper element.
●Caution: To avoid dirty air entering cylinder to damage the related parts, do not start the gasoline engine

after air filter has been removed.

6.2.4 Technical maintenance after each 6000km

(1) Perform above 3000km maintenance procedures.

(2) Wash the fuel tank, check the fuel pipe and replace the fuel filter.

(3) Check if there is any crack or electric leaking on the battery.

(4) Check if the alternator works properly.

(5) Change the oil inside oil pan.
●Note: Must use oil that is above SF 10W/30 (or 15W/40). Use 5W/30 engine oil in winter. Do not use

other oil or inferior oil; do not mix to use oil of different brands and rates.

Change oil more frequently when vehicle runs in dirty environment or under ambient temperature that is

lower than -20℃.

(6) Replace oil / air filter elements (could be early or later according to actual conditions).

(7) Wash and clear gasoline engine PCV valve and its ventilation pipe, and make sure it works properly.

6.2.5 Seasonal technical maintenance

(1) Recommend to change the antifreeze and antirust coolant once a year.

(2) Change to use winter lubricant in time when the winter comes.

(3) Adjust battery electrolyte concentration according season.

6.3 Technical maintenance for lubrication system

Choose correct lubricant for gasoline engine lubricating system according to working temperature.

Normally, it is suggested to use above SF 10W/30 or 15W/40 engine oil (GD 11121); for cold winter region,

it is suggested to use SF 5W/30 engine oil.

●Caution: Do not mix to use oil of different brands and rates.

Measure the oil level: park the vehicle on flat ground and draw out the dipstick after the oil level has been

stable. Wipe the oil on dipstick with a clean cloth, and insert the dipstick back into the tube (all the way down).

Draw out dipstick to observe oil level. There are two lines on the dipstick, right oil level should be higher than the

middle section between these two lines.

●Note: Check the oil level before driving the vehicle, and keep watching oil pressure during running.

Change with new engine oil: Drain oil after each 6000 km and change to use new oil.

Oil changing procedures:

(1) Park the vehicle on flat ground;

(2) Run the gasoline engine to heat oil temperature up to 80℃.

(3) Stop the engine, put an oil tray below gasoline engine. Unscrew the drain plug and discharge oil.
●Warning: Avoid being scaled, dispose drained oil properly to protect environment.

(4) Put on a new washer, fasten drain plug with specified torque.

(5) Fill new oil and check oil level.

If there are heavy deposites in oil pa, wash the lubricating system with lightweight spindle oil but not

gasoline or kerosene

Run the gasoline engine without load for a while each time after oil changing to facilitate oil to reach every

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Chapter 6 Technical Maintenance of BJ491EQ1 Gasoline Engine

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lubricating position.

Clean the oil filling port to prevent impurity from entering into the oil during oil filling. Check the oil level 5

minutes after the filling. Fasten the cap after oil filling.

Replace the oil filter or air filter elements at the same time of oil changing.

6.4 Technical maintenance for cooling system

When the gasoline engine is running, there must be enough coolant inside cooling system to keep the engine

working properly. Check the cooling system every time before starting the vehicle, and replenish coolant in time.

Change coolant

Drain used coolant, wash cooling system with clean water. Fill coolant to a specified level in radiator. Start

the gasoline engine and run it 5 minutes to flood the cooling system. Stop the engine and check the level again.

Add coolant if necessary.

●Caution:

(1) Using tap water, mineral water and other un-treated hard is strictly prohibited. Use coolant with high

quality.

(2) Using inferior coolant or mix to use coolant of different brands is strictly prohibited. Otherwise parts

and components may get damaged.

(3) Abnormal high coolant consumption indicates leaking inside cooling system. Send it to service station

for help.

Check the fan belt tension. Under 98N pressure, the deflection of a new belt is 5~7mm, old belt is 7~8mm.

6.5 Technical maintenance for fuel system

6.5.1 Fuel pipe

The fuel pressure inside fuel pipe is higher for an electronic fuel injection gasoline engine, so the parts on

fuel supply / return pipes must be secured firmly without any leaking. Check the tightening of fuel return pipe

regularly, and remove the leaking in time.

●Warning:

(1) During fuel pipe checking, never start the gasoline engine after fuel injector, oil rail components and fuel

pipe on engine have been removed. Sparying fuel into air may cause fire.

(2) Wrap the fuel pipe joint by plastic clothing during fuel pipe maintenance to prevent fuel spilling out; do

not smoke or have lighted fire around to avoid fire accident.

6.5.2 Fuel filter

Replace the fuel filter after each 6000km.
●Caution: There is an arrowhead on fuel filter case that indicates the gasoline flow direction. It is absolutely

not allowed to assemble the fuel filter in a wrong direction. Replace fuel filter if it is assemble in wrong way.

6.5.3 Fuel injector

For a vehicle that has been laid for long, start the gasoline engine and hold for 5 to 10 minutes once in every

one or two months to avoid fuel injector clogging.

During regular service, clean the fuel injector with ultrasonic after each 20000km. Make sure that there is no

media which will damage the oxygen sensor and three way catalytic converter. No need to diassemble injector

during this procedure.

6.5.4 Throttle body

Clean the throttle body at each 20,000 km or every year.

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