BYD G3. Service Manual — part 9

BYD G3 AUTO Owner’s Manual

126

Engine Compartment Appearance

1. Distribution box assembly

2. Engine oil level dipstick

3. Overflow tank of engine coolant

4. Fuel flap of engine oil

5. Battery

6. Radiator

7. Electric cooling fan

8. Condenser

9. Windscreen cleanser container

BYD G3 AUTO Owner’s Manual

127

Fuse Location

Please refer to section 8 ―Fuse and
Relay‖ for the name of electric appliance
protected by each fuse.

Notes of Self-maintenance

In case of self maintenance, you must
follow the correct procedures in this
section.

You must pay attention to that incorrect
or incomplete maintenance operations
may cause operating problems.

This section only makes explanations on
maintenance operations which can be
easily done by yourself. As said in
section 6, some items must still be
maintained by qualified technicians with
special tools.

During operation, you must pay special
attention to avoiding accidental injuries.
You are required to follow the special
preventive measures below.

BYD G3 AUTO Owner’s Manual

128

Tips

● When the engine is running,

you must keep your hands,
clothes and tools away from
the running fans and drive belt
of engine.(It is best to take
down such things as finger
ring, watch and necktie.)

● After

you

drive

the

car,

the

temperature of such things as
its engine, radiator, exhaust
pipe, hold-up vessel of power
steering fluid and spark plug
cover must be very high in the
engine compartment.

Thus, you must be careful and
do

not

touch

them.

The

temperature of engine oil, fluid
and spark plug must be very
high, too.
● If the engine is very hot, do not

take down the radiator cover or
screw off the drain plug to
avoid burning.

● Do not leave any flammable

material

in

the

engine

compartment such as paper or
cloth.

● If you work near electric

cooling fan or radiator grill, you
must confirm that the ignition
switch has been turned off.

When turning on the ignition
switch, if the temperature of
engine coolant rises and/or
turning on the air conditioner,
the electric cooling fan of
engine

will

start

running

automatically.

● Nearby the fuel tank or battery,

do

not

smoke,

to

avoid

generating spark and naked
flame, as it may cause fire.

● Handle the storage battery

with special care, as it contains
poisonous gas and corrosive
sulfuric acid.

● The car shall only be lifted by a

jack. Do not crawl under the
car; lift it with car lifting jack or
other firm braces.

● Now matter operating on the

top or bottom of the car, you
must use eyes protector, to
avoid

dropping

or

falling

objects and splashing fluid.

● Used engine oil contains

potential pollutants, which may
cause skin diseases such as
skin inflammation and skin
cancer. Thus, you must pay
attention to avoiding long or
frequent touch of these engine
oils. You can wash the used

engine oil on your skin with
soap and fresh water.

● Do not put the used engine oil

in the place within the reach of
children.

● Dispose of the used engine oil

and filter by some safe and
satisfied means and do not
throw them together with the
household garbage, in the
sewer or on the ground. Refer
to BYD service station for
recycling

or

disposing

methods.

● Since brake fluid may damage

the eyes as well as the paint
finish, you must be very careful
in filling brake fluid; if it
splashes into the eyes, wash
with fresh water immediately; if
your

eyes

still

feel

uncomfortable, you must go to
see a doctor.

BYD G3 AUTO Owner’s Manual

129

Notes

◆ Remember, storage battery

and ignition coil bears high
current or high voltage. Pay
attention to short circuit caused
by accidents.

◆ If the coolant overflows, you

must wash it with water, to
avoid

damaging

the

components or paint finish.

◆ Do not drop any dirt or any

other things into the spark plug
hole.

◆ Do not lever up the external

electrode of spark plug at the
side of central electrode.

◆ You can only use the specified

spark plug. Using other spark
plug may damage the engine or
generate radio interference.

◆ Do not fill too much power

steering fluid, or the power
steering gear may be damaged.

◆ If the brake fluid overflows, you

must wash it with water, to
avoid

damaging

the

components or paint finish.

◆ Do not drive with the air filter

taken down, otherwise it may
cause excessive wear of engine
and meanwhile backfire will

cause

fire

in

the

engine

compartment.

◆ Notes: do not scratch the glass

by the wiper bracket.

◆ In closing the engine cover,

check if any tools or cloths are
left in the engine compartment.

Location of Jack

Front

Back

BYD G3 AUTO Owner’s Manual

130

When lifting a car with jack, place it in
proper position as shown in the
figure.

Tips

In lifting, you must follow the
regulations below to reduce the
possibility of human injuries:
● Avoid breathing the gas

exhausted by the engine. The
exhaust gas contains carbon
monoxide,

colorless

and

odorless.

It

may

cause

consciousness loss, and even
death.

● Do not place any part of your

body under the car lifted by a
jack. Otherwise, it may cause
human injuries.

● In lifting a car with a jack, do not

start or run the engine.

● Stop the car on the flat ground,

make sure the parking brake is
applied and block the wheels
opposite the lifting point, when
necessary.

● Make sure the jack is placed in

the correct lifting point. Lifting
the car in incorrect lifting point
will damage the car or the car
may drop from the jack to cause
human injuries.

● When the car is only lifted by a

jack, do not crawl under the car;
a car supporting bracket is
required.

● Do not lift the car if any people

in it.

● In lifting the car, do not put any

thing on the top or bottom of the
jack.

Notes

Make sure the jack is stored
properly, or it may damage the
car.

BYD G3 AUTO Owner’s Manual

131

Chapter 7

Section 2

Self-maintenance

Engine and Chassis

Check Engine Oil Level. . . . . . . . . . . . . . . . . . . . . 132
Check Fluid Level in Gearbox . . . . . . . . . . . . . . . . . . . 134
Check Cooling Fluid Level in Engine . . . . . . . . . . . . . . . .. 135
Check Radiator and Condenser . . . . . . . . . . . . . . . . . .. 135
Check Tire Pressure . . . . . . . . . . . . . . . . . . . . . . 135
Check and Replace Tire . . . . . . . . . . . . . . . . . . . . .. 136
Tires Rotation . . . . . . . . . . . . . . . . . . . . . . . . ... 138
Precautions on Aluminum Wheel . . . . . . . . . . . . . . . . . 139

BYD G3 AUTO Owner’s Manual

132

Check Engine Oil Level

Shut down engine at operating
temperature, and check engine oil
level with dipstick.
1. To get accurate reading, you shall

pack the car on flat ground. Shut
down the engine and wait for a few
minutes so that engine oil is collected
at the bottom of the engine.

2. Pull out the dipstick, place a piece of

fabric at its end and wipe it clean.

3. Insert the dipstick again. You shall

insert it to the bottommost position for
accurate reading.

4. Pull out the dipstick, place a piece of

fabric at its end and check the engine
oil level.

Note

Do not drop engine oil on parts of
the car.

If the oil level is near the low oil line,
you shall add additional engine oil of
the same type in the engine.

Remove the engine oil fill cap, add a
small amount of engine oil and then
check

the

dipstick.

You

are

recommended to use funnel when
adding engine oil.
After adding engine oil, the oil level shall
be located between the low oil line and
high oil line on the dipstick as shown in
the figure above.
When the oil level is proper, install the fill
cap and tighten it manually.

Note

◆ Do not splash engine oil on

parts of the car.

◆ Do not add too much oil, or

engine may be damaged.

◆ Check the oil level with

dipstick after you finish adding
engine oil.

Engine Oil Specification

Only use lubricating oil approved by
BYD-authorized service stations or
equivalents in compliance with the
following grade and viscosity.

Engine Oil Grade for Gasoline Engine:

SAE 5W

—30 above -30℃

SAE 15W

—40 above -15℃

API Grade SG or above
Amount: 3L (liter)

Low level

High level

Oil filling

Correct

Overfull

BYD G3 AUTO Owner’s Manual

133

Recommended viscosity (SAE):

In extremely cold weather, SAE 10W -
30 oil or oil with higher viscosity may
cause difficulty to start the engine, so
SAE

5W-30

engine

oil

is

recommended.

API Classification Label

ILSAC Certification Label

Engine Oil Identification Label

One or two API registration label is
available on some engine tank for
reference when choosing oil.

API classification label is somewhere on
the outside of the tank.
Engine oil quality is indicated on the
label top according to API (American
Petroleum Institute) standard, such as
SL. SAE viscosity is indicated at the
middle of the label, such as 10W-30.
―Energy-Conserving‖ symbol at the
bottom of the label indicates that it can
save engine oil.
Certification of ILSAC (International
Lubricant Standardization and Approval
Committee) is at the front side of the oil
tank.

Predicted temperature range prior
to next oil change

BYD G3 AUTO Owner’s Manual

134

Check Fluid Level in Gearbox

Manual Gearbox (Description about
CVT gearbox is added)

Check the fluid level in gearbox when
transmission is at the normal operating
temperature of 80℃ with the car parking
on flat ground. Remove the bolt of fluid
filler opening of the transmission, and
touch the fluid level within the bolt hole
with a finger carefully. The fluid level
shall reach the edge of the bolt hole. If
not, please add original MTF (manual
transmission fluid) from BYD until the
fluid overflow from the filler opening. At
last, install back and tighten the bolt of
the fluid filler opening.

Clean up overflowing fluid immediately
as it may damage parts in the engine
compartment.

If original MTF is not available, you can
use API certified gear oil as substitute.
For specific specifications, please refer
to Maintenance Manual or contact BYD
service station.

Transmission fluid shall be replaced by
mileage or interval as specified in
Periodic

Maintenance

Table.

The

existing transmission fluid shall be
drained completely before filling new
transmission fluid.

Please contact BYD service station if
you have any doubt about checking fluid
level or filling fluid in gearbox.

Oil filling plug

Position of oil filling plug

Transmission

fluid

Level of gear fluid

Drain plug

Position of drain plug

Note: no water can be contained in the
gear fluid so as to avoid rusting the
components in the transmission.

BYD G3 AUTO Owner’s Manual

135

Check Cooling Fluid Level in Engine

Check the transparent overflow tank
of the cooling fluid when the engine
is cold. If the cooling fluid level is
located between “FULL” and “LOW”
line on the tank, it is in compliance
with the requirement. If the fluid level
is low, additional cooling fluid shall
be added. (Refer to section “Choose
Cooling Fluid

” below for information

on usable type of cooling fluid.)
The cooling fluid level in the overflow
tank varies with the temperature of the
engine. But if the fluid level is under
―LOW‖ line, more fluid shall be added
until fluid level reaches ―FULL‖ line.
After adding cooling fluid, if the fluid
level drops in short period, there may be
leakage in the system. You shall
conduct visual check to radiator, hose,
radiator cap, drain cock and pump.
If visual check can not find out leakage,
please contact BYD service station to
check cap pressure and whether there is
leakage in cooling system.

Tips

To avoid scorching, do not
remove radiator cap when engine
is hot.

Choose Cooling Fluid
Only use cooling fluid authorized by
BYD service station. Choose and add
suitable type of cooling fluid into cooling
system

according

to

environment

temperature.
Improper cooling fluid may damage
engine cooling system.

Note

Do not over use water, which may
damage engine cooling system in
winter.

For more detailed information, please
contact BYD service station.

Check Radiator and Condenser
If radiator or condenser becomes very
dirty or you can not determine their
status, please send the car to BYD
service station.

Tips

To avoid scorching, do not touch
radiator

or

condenser when

engine is hot.

Note

Do not

service

radiator

or

condenser by yourself to avoid
damage.

Check Tire Pressure

Maintain proper pressure in tires.
For information on recommended cold
tire pressure and tire dimension, please
refer to Chapter 8.
You shall check the tire pressure every
two weeks, or, at least, every month.
Spare tire pressure shall also be
checked.
Improper tire pressure may increase gas
consumption, reduce driving comfort,
tire service life, and pose danger to road
safety.
If the tire need air filling frequently,
please contact BYD service station for a
check.

BYD G3 AUTO Owner’s Manual

136

Tips

Maintain proper pressure in tires.
Improper pressure may cause the
following conditions, and even
severe injury.
Low tire pressure (insufficient air
filling)
● Excessive wear
● Abnormal wear
● Difficulty in operation
● Air leakage due to overheat of

tires

● Deteriorated sealability at the

edge of tire.

● Deformation of wheel and/or

detachment of tire and wheel

High Tire Pressure (excessive air
filling)
● Difficulty in operation
● Excessive wear of center of tire

tread

● Increased possibility that hard

road may do damage to tire

Follow the instructions below when
checking tire pressure:

● Check tire pressure only when the

tire is cold. After driving over 1.5 km,
the car shall be parked for over 3
hours before checking tire pressure.
You can check pressure directly after
a driving no more than 1.5 km.

● Tire pressure gauge must be used.

Experiential judgment of tire pressure
may have severe error. In addition,
several pounds' difference in tire
pressure

may

reduce

driving

operability and comfort.

● Do not release air in tire or reduce

tire pressure after driving. It is
normal that tire pressure is higher
after travel.

● Make sure valve cock is installed

on tire. It blocks dust, damp from
entering tire and prevent air leakage.
Install a new one if the valve cock gets
missing.

Check and Replace Tire

Check Tire

Check tread wear according to tire wear
indicator If the wear indicator is visible,
the tire shall be replaced.

Tire wear indicator is embedded in the
tire of BYD G3 to indicate when to
replace it. When wear depth reaches
1.6mm or less, the wear indicator will be
exposed. If two or more wear indicators
in continuous tread grooves are visible,
the tire shall be replaced. The thinner
tread, the greater danger of tire skid.

Tire wear indicator

BYD G3 AUTO Owner’s Manual

137

When the tire tread is worn to less than
4mm in depth, the snow tire function is
lost.

In case of cutting, rupture, crack
exposing cord fabric or abnormal tire
inflation, it means there is internal
damage in the tire and the tire shall be
replaced.

In case of frequent air leakage or
unrepairable cutting or other damage
due to the severity or position, the tire
shall be replaced. When you are not
sure about tire conditions, please
contact BYD service station.
If air leakage occurs on the road, stop
driving immediately. Even a small travel
after air leakage may cause permanent
damage to the tire.

After 6 years’ use, the tire, even if it
has no obvious damage, shall be
inspected by qualified technician.

The tire may deteriorate due to aging
even it has not been used heavily.
This rule also applies to spare tires and
tires in storage.

Replace Tires

Only use a tire with the same dimension
and structure, and the same or higher
load capacity to replace the tire installed
on the car.
Any difference in dimensions and
structure may have serious effect on
operability,

passenger

comfort,

calibration

of

speedometer

and

odometer,

ground

clearance

and

clearance between car body and tire or
tire chain.

Tips

Please follow the instructions
below. Or it may result in severe
injury.
● Never use a combination of

radial ply tire, bias belted tire
and diagonal-ply tire on the
same car, or it may lose
operability in driving, leaving
the driver in great danger.

● Only use tires with dimensions

recommended

by

the

manufacturer. Or the car may
lose control in driving.

Never replace the tire on BYD G3 with
a used tire.
Tires from unknown origin may pose
great danger.
You are recommended to replace
four tires at one time, or at least, you
shall replace two front/rear tires at
the same time.
For steps of replacing tire, please refer

to ―When Tire Has Air Leakage‖ in
Chapter 4.
Keep the wheels in balance after
replacing tires.
Unbalanced tire may pose adverse
effect on auto operability and tire service
life. The tire may lose balance during
normal use. As a result, irregular check
is required to keep the tire in good
balance.

BYD G3 AUTO Owner’s Manual

138

Tires Rotation

To equalize tire wear and extend its
service life, you are recommended to
rotate tire positions every 10, OOO km.
But the optimum time to rotate tires
depends on driving habit and road
conditions.

Before tire rotation, check for uneven
wear or damage. Improper tire pressure
and wheel alignment, unbalanced wheel
and frequent braking may lead to
abnormal tire wear.

Choose Tire Chain

Use tire chain with proper dimension.
The rule to choose tire chain varies with
locations and road conditions. Please
refer to local rule before choosing tire
chain.

Install Tire Chain
When possible, tire chain shall be
installed on front wheels. Do not install
tire chain on rear wheels. Tighten tire
chain again after driving for 0.5-1.0 km.

Follow strictly the instruction from the
manufacturer when installing tire chain.
If wheel housing is installed on the car,
remove it before installing tire chain,
otherwise it may be damaged by tire
chain.

Tips

● When tire chain is installed, the

driving speed shall not exceed
50km/h or the speed limit
specified by the manufacturer,
whichever is lower.

● Drive carefully when tire chain

is

installed

and

avoid

protrusion, holes and sharp
turn on the road, which may
cause jolt of the car.

● When tire chain is installed,

avoid sharp turn or braking
with wheels locked, which may
pose adverse effect to car
operability.

● When tire chain is installed,

slow down the car before
turning

to

prevent

losing

control of the car, which may
cause accident.

BYD G3 AUTO Owner’s Manual

139

Replace Wheels

When to Replace Wheels
When the wheel has damage such as
bending, crack or severe corrosion, it
shall be replaced.
If damaged wheel is not replaced timely,
the tire may detach from the wheel or
the car may lose control.

Choose Wheels

Only replace the wheel installed on
the car with a wheel with the same
load capacity, diameter, rim width
and offset.

BYD service station can replace wheels
correctly.
Wheels with different dimensions and
structure may have serious effect on
operability, service life of wheels and
bearings, cooling of brake, calibration of
speedometer and odometer, brake
performance,

headlight

alignment,

bumper height, ground clearance and
clearance between car body/chassis
and tire /tire chain.

Do not replace the wheel on BYD G3
with a used wheel, which may have
undergone treatment or long travel
mileage, getting the car into trouble
without prior warning. Do not use a
wheel which is repaired after bending,
as it may have structural damage. Do
not use inner tube intended for tubeless
tire on an air-leaking wheel.

Tips

Do not use

a wheel with

specifications other than that
recommended

by

the

manufacturer, or the car may lose
control in driving, which may
result in severe injury or death.

Precautions on Aluminum Wheel

● For a car with aluminum wheels, the

nuts on the wheels shall be check
after the first 1,600 km travel to make
sure they remains tight.

● After tires are rotated, repaired or

replaced, the nuts on the wheels shall
be check after the first 1,600 km travel
to make sure they remains tight.

● Do not damage the wheels when

using tire chain.

● Only use BYD nuts and wrench

intended for aluminum wheels.

● When adjusting wheel balance using

tire chain, only use BYD counter
balance, plastic hammer or rubber
hammer.

● As with all autos, aluminum wheels on

BYD G3 shall be checked regularly,
and replaced if any damage.

BYD G3 AUTO Owner’s Manual

140

Chapter 7

Section 3

Self-maintenance

Electric Appliance

Check Battery Status . . . . . . . . . . . . . . . . . . . . . ... 141
Check and Replace Fuses . . . . . . . . . . . . . . . . . . . .. 143
Add Cleanser . . . . . . . . . . . . . . . . . . . . . . . . . 144
Replace Bulb . . . . . . . . . . . . . . . . . . . . . . . . . 145

BYD G3 AUTO Owner’s Manual

141

Check Battery Status

Precautions

Tips

Precautions on Battery
Battery produces flammable and
explosive hydrogen.
● When using tools, prevent the

battery from generating spark.

● Do not smoke or use matches

near battery.

Electrolyte contains toxic and
corrosive sulphuric acid.

●

Prevent

electrolyte

from

touching eye, skin or clothing.

● Do not drink electrolyte by

mistake.

● Wear eye protector when

working near battery.

● Keep children away from

battery.

Emergency Treatment

● When electrolyte enters eyes,

immediately

wash eyes with

running clean water and then go
to hospital. If possible, clean the
affected area with sponge or cloth
soaked in water on the way to the
hospital.

● When electrolyte touches skin,

immediately wash the affected
area thoroughly with clean water.
If you feel burning or pain, go to
hospital immediately.

● When electrolyte is splashed on

your clothes, it may penetrate and
touch the skin. Please take off the
clothes

with

electrolyte

immediately, if necessary, treat it
as per the previous method.

● If you drink battery electrolyte by
mistake, you shall drink a lot of
water or milk immediately. Milk
containing magnesia, uncooked egg
and plant oils are recommended to
be eaten immediately. You shall go
the hospital for emergency medical
treatment.

Check Battery Appearance

Check whether battery and its
terminal is corroded, loose, cracked
or has loose fixture.

a. If battery is corroded, clean it with

mixture liquid of soda and warm
water. Apply grease lubricant on the
outer surface of terminals to prevent
further corrosion.

b. If terminal is loose, tighten the nuts of

clamps; but do not tighten them too
much.

c. Tighten the fixture properly to allow

the battery fixed on proper place.
Tighten the fixture too much may
damage the battery box.

Terminal

Grounding
cable

Tightening
clamp