Foton Series Light Bus. Instruction — 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
·107·
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
1
Diagnosis request
9
N/A
2
N/A
10
N/A
3
N/A
11
N/A
4
Grounding
12
N/A
5
Grounding
13
N/A
6
N/A
14
N/A
7
Communication
15
N/A
8
N/A
16
+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
·109·
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
·111·
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
·113·
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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OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS
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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
·115·
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
·117·
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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OPERATION AND MAINTENANCE MANUAL FOR FOTON VIEW SERIES LIGHT BUS
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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
·119·
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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