Engine

Edition：January 2015
Volume 1
Printing：January 2015 Volume 2
Pulication NO：FXSW-201501 Engine Control System(LJ465) 11A
Engine Control System(4W12) 11B
Engine Control System(4W10) 11C
Fuel(LJ465) 12A
Fuel(4W10/4W12) 12B
Emission Control(LJ465) 13A
Emission Control(4W10/4W12) 13B
Intake(LJ465) 14A
Intake(4W10/4W12) 14B
Engine Mechanism System(LJ465) 15A
Engine Mechanism System(4W10/4W12) 15B
Exhaust(LJ465) 16A
Exhaust(4W10/4W12) 16B
Cooling(LJ465) 17A
Cooling(4W10/4W12) 17B
Lubrication System(LJ465) 18A
Lubrication System(4W10/4W12) 18B
Ignition System(LJ465) 19A
Ignition System(4W10/4W12) 19B
Starting and Charging(LJ465) 20A
Starting and Charging(4W10/4W12) 20B
Volume 3
2015 Beiqi Foton Motor Co.,Ltd
All right reserved.No part of this service manual may

be reproduced or stored in a retrieval system,or
transmitted in any form,or by any
means,electronic,mechanical,photo-copying,recording
or otherwise,without the proir written permission of
Foton.
11A
Engine Control System(LJ465)
Engine Control System....................11A-1 Operating Principles.....................11A-38
Precautions....................................11A-1 Onboard Check............................11A-39
System Overview............................11A-2 Overhaul.......................................11A-41
System Function Introductions.......11A-6 Knock Sensor.................................11A-43
Basic Principles..............................11A-8 Operating Principles.....................11A-43
Main Components........................11A-15 Onboard Check............................11A-44
System Component Description....11A-16 Overhaul.......................................11A-45
Engine Control Module (ECM).......11A-17 Crankshaft position sensor...........11A-47
Operating Principles.....................11A-17 Operating Principles.....................11A-47
Replacement................................11A-18 Overhaul.......................................11A-48
Coolant Temperature Sensor.........11A-20 Front oxygen sensor......................11A-50
Operating Principles.....................11A-20 Operating Principles.....................11A-50
Overhaul.......................................11A-21 Onboard Check............................11A-51
Throttle valve body.........................11A-23 Overhaul.......................................11A-52
Cleaning of throttle body..............11A-23 Rear oxygen sensor.......................11A-53
Adjustment of fixed idling adjusting screw Operating Principles.....................11A-53
(SAS)............................................11A-24 Onboard Check............................11A-54
Adjustment of the basic idling.......11A-25 Overhaul.......................................11A-55
Overhaul.......................................11A-26 Canister solenoid valve.................11A-56
Idle stepper motor..........................11A-29 Operating Principles.....................11A-56
Operating Principles.....................11A-29 Onboard Check............................11A-57
Onboard Check............................11A-30 Overhaul.......................................11A-58
Overhaul.......................................11A-32 Vehicle speed sensor.....................11A-61
Throttle position sensor................11A-34 Operating Principles.....................11A-61
Operating Principles.....................11A-34 Onboard Check............................11A-62
Onboard Check............................11A-35 Overhaul.......................................11A-63
Overhaul.......................................11A-36 Ignition Module...............................11A-64
Air Intake Manifold Pressure/Temperature Operating Principles.....................11A-64
Sensor.............................................11A-38 Overhaul.......................................11A-65
11A
Engine Control System(LJ465) - Engine Control System 11A-1
11A
Engine Control System
Precautions
1. Cutting off the Power Supply
• In order to prevent damage to people or vehicle, before removing or installing
any electrical equipment, and when tools or equipments tend to come into
contact with exposed electrical terminals, you must disconnect the negative
battery cable first, and connect the negative battery cable in the end.
• If not otherwise specified, you must turn off the ignition switch.
Danger
Before connecting or disconnecting the negative battery cable, be sure to turn off the
ignition switch and light switches. (Failure to do so may damage the semiconductor
element)
2. During maintenance, you should carry out adjustment, disassembly and testing
according to provisions described in this manual.
3. EFI system components are characterized by high reliability, when the vehicle
or engine is abnormal, first check the condition of related mechanical
components, connectors and wiring harness systems, grounding wire,
high-voltage spark plug connectors and pressure regulator vacuum line, etc.
4. Remove the debris on the mounting surface with a sealant scraper or a wire
brush before installation, make sure the sealing surface is flat, smooth and free
of oil. Do not forget to remove the sealant on mounting holes, threaded holes
and threads.
5. When installing sensors and actuators and other components, fixing bolts should
be tightened to the specified value.
6. Unless otherwise specified in the testing process, you should not test the ECM
and the sensors with a pointer type multimeter, but with a high impedance digital
multimeter.
7. You must handle with care when installing and carrying a sensor to ensure it is
free from damage, as any shock, drop may cause great harm to its performance.
8. Do not start the engine for a long time when the battery voltage is low or the
starter is faulty, so as to avoid damaging the catalytic converter.
9. You should not check the wiring harness electrical system by puncturing the
harness with a fine needle.
10 . When removing and replacing the oxygen sensor, the sensor must not come
into contact with water or other liquids.
11 . The fuel pump can neither operate for a long time without gasoline, nor operate
with gasoline in the air.
12 . The vast majority of EFI parts are irreparable, they are generally to be replaced
after confirming being damaged.
13 . The system should use anti-interference type of spark plugs and high-voltage
lines, as non-impedance type of spark plugs and high-voltage lines will not only
release the interference wave, but also adversely affect the ignition coil driver
module within the ECM.
14 . You must not open the ECM lid.
11A-2 Engine Control System(LJ465) - Engine Control System
11A
System Overview
1. General Introduction
465QR1E1 is an electronically controlled multi-point fuel injection (MPI) engine control system.
It uses Delphi MT22.1.1engine control module (ECM) as the control center, and measures
a variety of work parameters of the engine by utilizing a variety of sensors mounted on
different parts of the engine, and precisely controls the fuel injection with a fuel injector
according to a preset control program in the computer, thus allows the engine to obtain the
optimum concentration of gas mixture under a variety of conditions. In addition, the electronic
control fuel injection system can also achieve starting enrichment, warm-up enrichment,
acceleration enrichment, full load enrichment, deceleration dilution, forced idling fuel-cut,
automatic idling speed control and other functions through the control program in the ECM,
thus meets the requirements on gas mixture placed by the special conditions of the engine,
not only allows the engine to obtain good fuel economy and emissions, but also improves
the vehicle performance. In addition, ECM also boasts several fault diagnosis modes allowing
you to simplify the fault finding.
2. Engine Control System functions include:
• Knock control
• Mileage memory
• Overvoltage protection
• Fuel pump control
• Canister solenoid valve control
• Idling stepper motor control
Engine Control System functions include • Vehicle main power relay control
• Closed-loop control multi-point sequential
fuel injection [including intake manifold
pressure (MAP) sensor pressure cylinder
identification]
• Speed-Density-Air Measurement (intake
manifold pressure temperature sensor)
• System self-diagnostics function
3. ECM Control Structural Diagram

11A
Engine control module (ECM) Function
System 5V Sensor reference voltage

12V Battery power supply power
System power supply control

supply
control Main power relay control
12V Ignition power supply
12V Power ground
Ignition system control

5V Sensor reference supply ground Ignition coil (1/4 cylinder)
Ignition module driver ground Ignition coil (2/3 cylinder)
Fuel injector A
Fuel injector control

Air inlet pressure sensor (MAP) Fuel injector B
Fuel injector C
Throttle position sensor (TPS)
Fuel injector D
Analog signal input
Coolant temperature (WTS) Sensor

Engine control module (ECM) Idle stepper motor coil
Idle valve control

Front oxygen sensor
Idle stepper motor coil
Rear oxygen sensor
Oil lever sensor
Acceleration sensor (G)
Fuel pump relay

System components
power control
Front oxygen sensor heating

Frequency signal input
Rear oxygen sensor heating

58X Engine speed sensor and crankshaft position sensor
Canister solenoid valve
Knock sensor
Vehicle speed sensor

Accessory power control
Radiator low-speed fan relay
Radiator high-speed fan relay

Accessory control signal input
Engine speed
A/C request signal
Instrument signal
Coolant temperature
Oil level signal
System fault indicator
Other system fault indicator

Communication
Diagnosis Diagnosis K line

Fault diagnosis request signal
Signal
fpwx11A0199
11A 4. Engine Control System Diagram
8 7 3 2 1
10
11
12 13 14 15 16 5 6
fpwx11A0200
1 Air inlet 9 Fuel pressure adjuster

2 Air filter 10 Fuel injector
3 Idle stepper motor 11 Positive crankcase ventilation valve
4 Throttle position sensor (TPS) (PCV)
5 Canister solenoid valve 12 Crankshaft position sensor
6 Carbon Canister 13 Front oxygen sensor
7 Air Intake Pressure/Temperature 14 Three-way catalytic converter
Sensor 15 Rear oxygen sensor
8 Fuel Rail 16 Knock sensor
5. Distribution Diagram of Engine Control System Main Components:

11A
3 4 5 6 7 8 9 10
11
12
fpwx11A0201
1 Air Intake Pressure/Temperature 7 Fuel injector 1

Sensor 8 Fuel injector 2
2 Vehicle speed sensor 9 Fuel injector 3
3 Rear oxygen sensor 10 Fuel injector 4
4 Three-way catalytic converter 11 Water temperature sensor
5 Starter 12 Engine
6 Ignition coil
11A
System Function Introductions
1. Idle Close-loop Control
The idling condition control of gasoline engine at normal operating temperature is a
closed loop control. The EFI system fully closes the throttle in idling conditions and
controls the air intake during gasoline engine idling with a throttle body attached to
the idling speed regulator. In the mean time, gasoline engine ECU monitors the gasoline
engine RPM in real-time and compares it with the system default idling value, and
adjusts the idling control valve and the ignition advance angle in time according to the
fluctuations in gasoline engine speed to ensure the smooth running of the gasoline
engine.
2. Ignition Timing Control System
EFI systems equipped by 465QR1E1 engine are direct ignition control systems which
feature functions such as automatic control of ECU ignition timing and charging time
setting control. The ignition system utilizes the advanced non-distributor direct ignition
technology which is provided to the built-in ignition drive circuit by the engine electronic
control module. It sends ignition signal to the primary winding of the double ignition
coil, respectively provides ignition signal current for 1,4 and 2,3 cylinder groupings,
simultaneously ignites the two spark plugs respectively connected to coil 1, 4 or 2,3
groupings. Besides the timely replacement of the spark plug, no other components of
the ignition system require any maintenance during normal operation.
During the operation of a gasoline engine, the electronic controller determines the
ignition advance angle set value based on the load information and RPM signal and
corrects it according to the coolant temperature and other signals, thus derives the
exact ignition advance angle to determine the ignition timing.
3. Multipoint Fuel Injection System
The gasoline engine control system is a closed-loop control system equipped with
heated oxygen sensor. The oxygen sensor sends the oxygen concentration signal of
the exhaust gas to the ECU, based on which ECU adjusts the amount of fuel injection
system, thus allows the gasoline engine to operate at the theoretical air-fuel ratio
(14.7:1 ) state to ensure the optimum conversion efficiency of the catalytic converter.
4. Close-loop control
The system adopts close-loop control on the engine fuel supply and idling; The benefit
of close-loop control is that the system control is able to eliminate the differences
between the system and related mechanical parts caused by manufacturing as well
as wear and tear, and thus improves the consistency and integration of the entire
vehicle and reduces the emission.
5. Evaporation/emission pollution control
The gasoline engine control system controls the rate of the charcoal canister purge
and cleaning timing based on the gasoline engine operating conditions to control the
vehicle canister cleaning.
6. Troubleshooting
Gasoline engine control system boasts the self-diagnostic function, i.e. when system 11A
components fails, ECU will start the fault indicator to alert the driver to the vehicle
maintenance. At this point, the system will ensure that the customer drives the vehicle
to the service station for repairs under the premise of protecting the gasoline engine.
(a) Self-diagnostic of system failure is an essential function of en engine control system;
When one or several system components work abnormally, the system will remind the
user of the necessary inspection and maintenance through lighting the fault indicator
in a timely manner; When a fault occurs, the system can also control the engine
operation by deploying a temporary emergency program to ensure that the user can
drive the vehicle for repair.
(b) When a sensor and an actuator are detected to be abnormal, the engine fault check
light will turn on to alert the driver.
(c) When a sensor and an actuator are detected to be abnormal, a fault code corresponding
to the fault condition will be outputted.
(d) ECMdata in the ECM associated with the sensors and actuators can be read through
a fault diagnostic unit. Furthermore, the actuator can be driven by force in a specific
case.
7. Overvoltage Protection
In case of any fault in the charging system, leading to overvoltage, the system will
enter the protective mode and limit engine RPM, in order to protect the ECM from
damage.
8. Three-way catalytic converter
Also known as catalytic cleaner. Installed in the exhaust system of a vehicle, the device
is used to reduce the most emissions and pollutants discharged by an engine. The
three-way catalytic converter, consists of a metal housing, a network chassis and a
catalyst layer (containing platinum, rhodium and other precious metals), can remove
90% of the three major pollutants, i.e. HC (hydrocarbons), CO (carbon monoxide) and
NOx (nitrogen oxides) (the so-called three-way refers to a chemical reaction for
removing these three compounds). When the exhaust gas flows through the purifier,
the platinum catalyst will bring about the oxidation of HC and CO producing water
vapor and carbon dioxide; Rhodium catalyst will lead to the reduction of NOx to nitrogen
and oxygen. The oxidation and reduction reactions only occur when the temperature
reaches 250 ℃. The improper selection and use of gasoline or lubricant additive, i.e.
using the leaded fuel additives or engine oil additive with excessive levels of sulfur,
phosphorus, zinc, will lead to phosphorus, lead substance covering the surface of the
catalyst layer of the three-way catalytic converter, thus prevents the harmful ingredients
in the exhaust gas from contacting with the surface and loses the catalytic action, the
process of which is commonly known as of three-way catalytic converter "poisoning".
11A
Basic Principles
1. Starting control principle.
(a) After turning on the ignition switch, the fuel pump will stop following 1.5 seconds of
operation.
(b) Engine begins to rotate, ECM detects two valid 58X signal, then the fuel pump begins
to run.
(c) The fuel pump stops 0.8 seconds after the disappearing of RPM signal (analog signal
susceptible to interference).
(d) Pre-spray: Pre-spray only sprays once in the normal starting process (if fuel is absorbed
by carbon deposit, the mixture gas is diluted, start will not be easy).
(e) Initial stage of start: intake manifold internal pressure appears as ambient atmospheric
pressure. Throttle is closed, ECM is specified as a fixed parameter based on the start
temperature.
(f) In the starting process: the fuel injection amount varies according to the change of
engine coolant temperature, and the ignition angle is also constantly adjusted and
varies according to the engine coolant temperature, intake air temperature and the
engine speed.
(g) Starting process ends: engine speed exceeds 600rpm, starting condition ends.
2. Control principle of fuel injection.
(a) ECM controls the injector drive time and injection timing, allows the engine to obtain
the optimum air-fuel ratio of mixture gas in a variety of conditions.
(b) Each cylinder's intake ports are equipped with a fuel injector, the fuel pump inside the
fuel tank fuel pumps out the fuel and conveys it into the high pressure fuel rail. The
fuel pressure regulator allows the injection pressure to be stable, the fuel injector injects
the fuel directly into the air path of each cylinder. Each cylinder injects once (injection
order is 1-3-4-2) in every working cycle of the engine (twice revolutions of a crankshaft),
this spray method is called sequential injection.
(c) When the engine is operating in cold or in high load condition, ECM carries out
open-loop control and provides richer mixture in order to maintain good performance;
when the engine is in normal operating condition (small to medium load), ECM carries
out closed-loop control through the oxygen sensor feedback signal to get the best
air-fuel ratio, and allows the three-way catalytic converter to achieve the best cleaning
efficiency.
(d) Fuel injection pulse width control.
Signal Input ECM Control Output

• Air-fuel ratio correction
• Closed-loop feedback correction
Calcula-
• Intake manifold pressure tion of
Fuel injection
fuel in-
• Inflation temperature pulse width
jection
• Inflation efficiency quantity
• Self-learning correction
11A
• Supply voltage correction
• Exhaust gas recirculation
• Acceleration Enrichment
• Reduction Dilution
• Reduction Fuel Stoppage
• Feul Injector Parameters
Control Signal Description:
Correction Items Content

• Starting air-fuel ratio
• Air-fuel ratio when the engine is operating
• Air-fuel ratio of engine low coolant temperature
Air-fuel ratio Includes • Air-fuel ratio of engine normal coolant temperature
• Theocratic air-fuel ratio
• Enriched air-fuel ratio
• Overheating protection air-fuel ratio
Closed-loop feedback • The actual air-fuel ratio controlled by the feedback signal
correction of the oxygen sensor is around the theoretical ratio
Intake manifold pres- • Read directly by a MAP mounted on the intake manifold
sure
• Correct the slow internal change of engine induced by long
Self-learning time operation
• When the battery voltage changes, voltage correction can
Power supply voltage ensure the correct amount of fuel injection
• When the ECM detects the intake manifold pressure, a
substantial increase in the value of the throttle opening,
Acceleration Enrich- engine mixture in order to avoid an instant thinning, and
ment increase the fuel injection quantity. to improve the power
performance
substantial decrease in the value of the throttle opening,
Reduction Dilution engine mixture in order to avoid an instant thickening, and
decrease the fuel injection quantity. To improve emissions
and driveability
• Control the fuel cut when the system detects a vehicle
Reduction Fuel Stop-
enters the deceleration state. To reduce emissions and
page
fuel consumption
11A
• When the engine speed is higher than the set value, fuel
will be cut off
• When the ignition system is faulty, fuel will be cut off
• Provide relationship between engine and fuel injection
Injection parameters quantity
(e) Correction of engine mixture gas

• At normal operating temperature, engine's partial load control is a closed loop
fuel control. At this point, the system performs real-time correction of injection
quantity based on the voltage signal feedback of oxygen sensor to adjust the
concentration of the mixture to approach theoretical air-fuel ratio, so that to
ensure the best conversion efficiency of catalytic converters in converting harmful
gas in the exhaust gas, and in the same time guarantee better fuel economy.
• When the engine is in its normal operating temperature range, open-loop fuel
control will be adopted at full load operation. At this point, in order to ensure
optimal engine power output, the system will control fuel injection with a richer
air-fuel ratio, and modestly increases the ignition advance angle based on the
premise that the engine knock does not occur. The system will also use the
exhaust gas temperature mathematical model established during calibration to
control exhaust temperature in order to protect the engine and the three-way
catalytic converter.
• The determination made by the system on engine full load condition is based
on the signal provided by the throttle position sensor. The system usually
considers the engine being in a full load condition when the throttle opening
reaches 80% to 90%. When the driver depresses the accelerator pedal to
accelerate the vehicle, the system will be appropriately increases the fuel
injection quantity to guarantee the power required by the engine during
acceleration. The increased fuel injection amount is proportional to the change
rate of throttle opening. When accelerating, ECM will appropriately postpone
the ignition advance angle and then gradually recover it in order to prevent the
excessive increases of torque engendered during hard acceleration of the engine
from shocking the drivetrain.
• When acceleration conditions are close to the full load of an engine, the system
will temporarily disconnect automotive air conditioning systems automatically
to ensure the power output of the engine during acceleration. Whatever the
case, the system will cut off the fuel supply when the engine speed exceeds
the maximum speed set by the system to suppress the unlimited increase of
RPM so to protect the engine and prevent the "Galloping"; the system will
immediately restore oil when the RPM drops back below the specified maximum
RPM of the system.
3. Ignition Control Principle.
(a) Start: when an engine starts, a fixed ignition advance angle will be used, so that the
gas inside the cylinder will be ignited and provide positive torque. When the engine
RPM is increased to a certain speed, ECM will calculate the ignition advance angle
according to the input signals.
(b) Ignition advance angle control. 11A
Correction signal ECM Output Control

• Coolant Temperature
Correction
• Intake air temperature
correction
• Altitude correction
• Idle Correction
• Main ignition angle Calculate the ignition advance
Ignition advance angle
angle
• Speed Reduction Fuel
Stoppage Correction
• Acceleration Correction
• Power Enrichment
Correction
• Air conditioning correction
(c) Main ignition advance angle: when the engine temperature reaches the normal value,
the main ignition angle at throttle opening is usually the minimum ignition angle at the
optimum torque point. When the throttle is closed, the ignition angle should be reduced
in order to get the idle stability.
(d) Ignition advance angle correction:
• Acceleration correction: When the vehicle accelerates, ECM detects a knock
signal, corrects the ignition angle until the knock does not occur. And is used
to reduce engine speed fluctuations caused by the contortion and vibration of
drive system.
• Power Enrichment Correction: near external characteristic point, enrich air-fuel
ratio to the most optimum torque and most dilute air-fuel ratio value in order to
get better power and torque.
• Correction of deceleration fuel-cut: perform ignition advance angle correction
when exiting deceleration fuel-cut to make the transition smooth.
• Air conditioning control correction: when engine is idling, turn off the A/C and
correct the ignition advance angle, so that the RPM is steadily transmitted.
4. Idle Control Principle.
(a) Idle Control
• Control the amount of throttle valve bypass air according to the idling state and
the change of engine load when idling, so that the idle speed is maintained at
an optimum RPM. ECM drives the idle stepper motor according to the engine
coolant temperature and air conditioner load, so that the engine can run with
the default target idle speed. In addition, when the engine is idling, by turning
on or off the air conditioning switch the idle stepper motor will adjust the bypass
air amount based on the load condition of the engine to avoid idle instability.
11A (b) Calculate Target Idle.

Input ECM Output Control
• Basic Target Idle
• Voltage Compensation
• Speed Compensation
• Fan Compensation
Calculate Target Idle Target Idle
• Headlight Compensation
• Air Conditioning
Compensation
• Deceleration Adjustment
• Voltage Compensation: when the voltage is less than 12V, the system will
automatically increase the target idle to increase generating capacity of the
generator.
• Air Conditioning Compensation: when the A/C is on during idling, to compensate
for the dynamic consumption of the compressor, the target idle increases by
150 r/min.
• Headlight Compensation: after turning on the dim beam, the target idle increases
50rpm to compensate for their electricity consumption.
• Fan Compensation: when the coolant temperature rises, fan operates, to
compensate for the power consumption of fan operation, the target idle increases
by 50 r/min.
(c) Idle Control Parameters:
• Idle Air Volume Control.
• Fuel Injection Amount Control.
• Ignition timing Control.
(d) Idle Design Control Timing:
• Idle Stability Calibration.
• Acceleration Condition Calibration.
• Deceleration Condition Calibration.
• Deceleration Fuel-cut.
• Engine Transient State Transition Condition Fuel Supply Calibration.
• Constant Speed Calibration.
• Mechanical and Electrical Load/Deload Calibration.
(e) Target Idle Determinants:
• When engine water temperature is low, system provides a higher target idle to
accelerate the vehicle warming.
• When applied Load (e.g. headlights, air conditioning, cooling fans and other
appliances load) is turned on, the system will increase idling speed to
compensate for the increased load in order to maintain the stability of idling 11A
speed.
5. Knock Control Principle.
(a) Introduction of Knock Sensor:
• Knock sensor is a piezoelectric ceramic solid sound microphone. Mounted on
the engine block, usually installed between 2,3 cylinders, to make for the engine
knock balance, it picks up a solid sound and converts it into a voltage signal.
ECM makes use of the vibration frequency signal exported by the sensor and
by going through ECM internal filter to determine the occurrence of engine
knock. When knock signal is detected, ECM corrects the ignition angle until the
knock does not occur.
(b) Knock Control Conditions:
• Vehicle is equipped with knock sensors.
• Engine speed is greater than 800rpm.
• MAP is greater than 40kpa.
(c) Knock Control Mode:
• Steady State Control: During normal engine operation, ECM collects and
analyzes the sound during engine combustion through knock sensor to detect
the knock by means of filtering. Once the knock intensity exceeds the limit, the
system will quickly delay the cylinder advance angle that gives rise to knock to
eliminate knock.
• Transient State Control: Rapid acceleration or abrupt changes in engine speed
may easily give rise to knock. When the likelihood of knock occurrence is
predicted, system will automatically delay the ignition timing to avoid the
occurrence of overranging (strong) knock.
• Quickly delays the ignition angle: Once knock is detected, the system quickly
delays the ignition advance angle, depending on engine RPM, and returns back
to normal within the next 2-3 seconds.
• Adaptive ignition angle: difference or change will occur to the engine due to
manufacturing errors and wear after prolonged use (belts, toothed pulleys, cams
affect the phase angle relationship). During the initial work of the system and
the engine or re-energizing of the ECM the engine may produce knock which
will be recorded by the system. After a period of running-in, the system will
automatically generate an adaptive ignition adjustment correction value
(self-learning value). When the engine is running in the same operating
conditions, the system will automatically perform adaptive adjustment to the
ignition advance angle.The occurrence of strong knock shall be avoided. System
adaptive learning is constantly updated during engine operation.
6. Canister solenoid valve control principle.
(a) The flow used to control canister purge air flow. The canister solenoid valve is controlled
by the ECM according to the duration and the frequency (i.e. duty cycle) of electrical
pulse emitted through comprehensive calculations performed according to a series of
signals, such as the engine load, engine coolant temperature and so on. Excess
accumulation of gasoline vapor in charcoal canister will lead to gasoline leakage,
causing environmental pollution, so the role of the canister solenoid valve is to open
11A at the right time, allowing excess gasoline vapors entering the intake pipe and fully
mixing with air to take part in combustion.
(b) The canister will not participate in the work in the following situations:
• From the period of time after engine old start until engine coolant temperature
rises.
• Engine idling phases.
• Engine heavy load phase.
• Important system sensor is faulty.
11A
Main Components
3 4 5 6 7 8 9 10
11
12
fpwx11A0201
1 Air Intake Pressure/Temperature 7 Fuel injector 1

Sensor 8 Fuel injector 2
2 Vehicle speed sensor 9 Fuel injector 3
4 Three-way catalytic converter 11 Water temperature sensor
5 Starter 12 Engine
6 Ignition coil
11A
System Component Description
GUI widget Overview Amount Function
• ECM optimizes the control sys-
tem based on the signal provid-
ECM 16-bit CPU 1 ed by the sensor, making it suit-
able for the engine operating
conditions
• Detect the oxygen concentration
Front oxygen sensor Heater type 1 in the exhaust gas
• ECM compares the signals from
the front and rear oxygen sen-
Rear oxygen sensor Heater type 1 sors to determine the condition
of three-way catalytic converter
• Detect the intake air and deter-
Intake manifold pres- mine the compression top dead
Piezoelectric type 1
sure sensor center
Crankshaft position Magneto-electricity in- • Detect the position and speed

1 of crankshaft rotation
sensor duction coil type
Knock sensor Frequent-response type 1 • Detect the engine for knock
• Inject fuel according to the sig-
Fuel injector 4-hole type 4 nal from the ECM
Electromagnetic coil • Control the intake air
Idle stepper motor 1
type
• Control the emission according
Canister solenoid to the digital pulse square wave
Electromagnetic type 1
valve of ECM
Throttle position sen- 3 wire carbon film resis- • Detect throttle opening
1
sor tors sliding pointer type
Negative temperature • Detect the engine coolant tem-
Coolant Temperature
coefficient (NTC) ther- 1 perature
Sensor
mistor type
Thermal sensitivity of Negative temperature • Detect engine intake air temper-
air inlet temperature coefficient (NTC) ther- 1 ature
sensor mistor type
Vehicle speed sen- • Detect the vehicle speed
Hall-effect type 1
sor
Electromagnetic coil • Ignite the gas mixture
Ignition coil 1
type
Turbo type single-stage • Provide the system with fuel of
Gasoline pump 1 sufficient pressure
motor pump
Engine Control System(LJ465) - Engine Control Module (ECM) 11A-17
11A
Engine Control Module (ECM)
Operating Principles
1. ECM is an electronically controlled engine control center consists of a sensor
signal input interface, an actuator drive circuit and a microprocessor as core
component. It receives and processes engine status signals inputted by all
sensors to allow the engine operating in accordance with a predetermined
program and in the best condition, thereby ensures good performance, fuel
economy and emissions.
2. Normal operating voltage: 9 - 16V,
operating temperature: -40 ℃ - 105 ℃.
3. Overvoltage protection: -14V - 24V.
4. The ECM features a self-protection
function which may lead to start failure
during service, but everything will be
normal after replacing the ECM. It is
possible that ECM is faulty, but the ECM
fpwx11A0001
is not damaged, only the ECM has entered
the self-protection mode, and the ECM will
return to normal after a period of time.
11A-18 Engine Control System(LJ465) - Engine Control Module (ECM)
11A
Replacement
1. Turn off the ignition switch.
2. Disconnect the battery negative cable.
Note
When disconnecting and reconnecting the negative battery cable, turn off the ignition
switch and light switches first. Completely loosen the fixing nuts of the battery negative
terminals. Do not pry the cable terminals when perform these operations.
3. Remove the ECM.

(a) Slide the front passenger seat backward.
(b) Turn over the seat.
fpwx11A0002
(c) Disconnect the ECM connector, push down

the plug and unplug the ECM connector.
fpwx11A0003
(d) Remove the ECM connector.

Note
After removing the connector, ensure that the
connection part of the connector does not come
into contact with dirt, water and other impurities.
fpwx11A0004
(e) Remove 4 fixing bolts of the ECM.

Tool: 10mm sleeve
fpwx11A0005
Engine Control System(LJ465) - Engine Control Module (ECM) 11A-19
(f) Remove the ECM module. 11A
Note
• Make sure to remove the battery negative

cable for more than 1 minute before
removing the ECM.
• Be careful when removing the ECM and
avoid collisions.
fpwx11A0006
• Be careful of water after removing the
ECM.
• Attention should be paid to the protection
of the plug pins.
4. Install the ECM module.

(a) Install 4 fixing bolts of the ECM.
(10±1N·m)
Tool: 10mm sleeve
Torque: 10±1N•m
Note
Note electrostatic protection during installation.
fpwx11A0007
(b) Install the ECM connector.

Note
Gently pull it down with a hand to confirm the
ECM connector is installed in place.
fpwx11A0008
(c) Put the seat in its original position.

5. Connect the battery negative cable.
11A-20 Engine Control System(LJ465) - Coolant Temperature Sensor
11A
Coolant Temperature Sensor
1. Coolant temperature sensor is used to
detect the operating temperature of an
engine. ECM provides the optimal control
scheme for an engine depending on the
temperature.
2. This coolant temperature sensor is a
two-wires type. A single-wire sensor is
generally used to provide coolant
fpwx11A0009
temperature signals for a meter.
Engine Control System(LJ465) - Coolant Temperature Sensor 11A-21
11A
Overhaul
2. Open the engine cap, slowly unscrew the
expansion tank pressure cap.
Note
Do not open the pressure cap when the engine
is heat. Do not open the radiator cover until the
engine cools down below 50°C. Otherwise, hot
coolant or steam may lead to personal injury.
fpwx11A0010 (See
17A Cooling(LJ465) - Cooling System,
Precautions
)
3. Lift the vehicle, unscrew the drain bolt on

the lower part of the tank to discharge the
coolant.
Note
When discharge the coolant, collect the residual
coolant with a special container. If not continue
to use, dispose it according to regulations.
fpwx11A0011
4. Dismount the engine coolant temperature

(ECT) sensor.
(a) Disconnect the engine coolant temperature
(ECT) sensor connector.
(b) Dismount the ECT sensor.
Tool: 19mm wrench
fpwx11A0012
Note
• Clean the mounting surface after the

removal.
• Clean the mounting hole threads after the
removal.
• Clean the sensor mounting threads after
the removal.
11A-22 Engine Control System(LJ465) - Coolant Temperature Sensor
11A 5. Check the ECT sensor.

(a) Immerse the temperature sensing part of the
ECT sensor in hot water, and measure the
resistance between the terminals of the ECT
sensor with a multimeter.
(b) If the measurement results do not meet the
standard, replace the ECT sensor.
fpwx11A0013 Working voltage: 5 VDC
Working temperature: -40℃～135℃
Limit temperature: 140℃ (only
accumulated 1 hour)
Sealing pressure: 145 kPa
At room temperature 20℃, the resistance
value is 3511Ω ± 2.6%
Note
If you check the ECT sensor in water, do not

allow water entering the terminal. Wipe dry the
sensor after checking.
6. Install the ECT sensor.

(a) Install the ECT sensor.
Note
Apply sealant on the threaded portion.
fpwx11A0014
(b) Install the coolant temperature sensor and

tighten it, connect ECT sensor connector.
Tool: 19mm wrench
Torque: 24 ± 2N•m
(24±2N·m)
fpwx11A0015
7. Add engine coolant. (See17A Cooling(LJ465) - Coolant, Replacement)

8. Start the engine and check for coolant leaks.
Engine Control System(LJ465) - Throttle valve body 11A-23
11A
Throttle valve body
Cleaning of throttle body
1. Start the engine and preheat it until the coolant temperature exceeds 80℃, then
stop the engine.
2. Remove the intake hose from the throttle body.
3. Block the bypass gas passage inlet of the throttle body with a plug.
Note
Do not allow the cleaning agent entering the bypass gas passage.
4. Inject the cleaning agent into the valve

through throttle body inlet port and hold
for 5 minutes.
5. Start the engine and idle for about 1
minute after several times of acceleration
operation, if the idling is unstable due to
the clogging of bypass gas passage (or
engine flameout), you may slightly open
fpwx11A0016
the throttle to keep the engine running.
6. If the deposit inside the throttle is not
cleared, then repeat step (4) and (5).
7. Pull out the plug of the bypass gas
passage.
8. Connect the intake hose.

9. Clear up the fault diagnosis code with a fault diagnostic unit (DTC).
10 . Adjust the basic idling.
Note
If there are irregular vibrations during engine idling after the adjustment of the basic
idling, you should disconnect the negative battery cable for more than 10 seconds,
then reconnect it and idle the engine for about 10 minutes.
11A-24 Engine Control System(LJ465) - Throttle valve body
11A
Adjustment of fixed idling adjusting screw (SAS)
1. Do not adjust the "fixed SAS" unless necessary, because the fixed SAS was
precisely adjusted before delivery, thus has been fixed.
2. If the fixed SAS has been arbitrarily rotated, re-adjust it according to the following
steps:
(a) Fully relax the throttle cable.
(b) Loosen the SAS locknut.
(c) Counterclockwise exit the SAS, completely
switch on and off the throttle.
(d) Clockwise rotate the "fixed SAS" until it
reaches the position point of contacting with
the throttle lever (i.e., the point position where
the throttle starts to open).
fpwx11A0017
(e) Lock the locknut while securing the "fixed
SAS".
(f) Adjust the throttle cable tension.
(g) Adjust the basic idling.
11A
Adjustment of the basic idling
1. Standard idling is adjusted at the factory by the manufacturer with a idling
adjustment screw (SAS), so usually you do not have to re-adjust.
2. If the SAS was incorrectly adjusted, it will cause too high or too low idling during
engine load change. When this occurs, adjust in the following manner.
Note
If you need to adjust the basic idling, you must first confirm that the spark plugs, fuel
injectors, idle stepper motor, cylinder compression pressure are in the normal state
before the adjustment.
(a) Before checking and adjustment, set the vehicle in the pre-delivery check status.
(b) Turn off the ignition switch.
(c) Connect the fault diagnostic unit to the fault diagnosis connector.
(d) Start the engine and keep it at idling.
(e) Check the idling.
Standard value: 750 ± 50rpm
Note
• When driving a new car within 500Km, the engine speed may be lower than the
standard value of 20 - 100rpm, but it does not need to be adjusted.
• If the engine shuts down or the engine speed is still lower than the standard
value when the vehicle has traveled for more than 500Km, it may be caused by
the dirty throttle, so you must clean the throttle.
(f) If the idling speed is not within the standard

values, adjust the idling adjustment screw
(SAS).
Note
If the SAS has been fully turned to the end but
is still higher than the standard value of idling,
check if the "fixed SAS" has been turned. If the
fpwx11A0018 "fixed SAS" has been turned, then readjust the
"fixed SAS".
• Turn off the ignition switch.
• Remove the fault diagnostic unit.
• Start the engine and idle for 10 minutes to
confirm whether the idling condition is OK.
11A
Overhaul
2. Lift the vehicle, drain the coolant.
Note

fpwx11A0019
3. Turn over the front passenger seat.

4. Dismount the air intake piping. (See14A Intake(LJ465) - Air Inlet Pipe,
Replacement )
5. Remove the throttle valve body.
(a) Disconnect the idle stepper motor connector.
fpwx11A0020
(b) Disconnect the TPS connector.
fpwx11A0021
(c) Loosen the throttle cable adjustment bolt on

the throttle and remove the throttle cable.
Tool: 13mm wrench
fpwx11A0022
(d) Dismount 2 warm-water pipes and 1 vacuum 11A

hose from the throttle body.
fpwx11A0023
(e) Remove 4 fixing bolts of the throttle body.

Tool: 10mm sleeve
fpwx11A0024
(f) Remove the throttle valve body.

Note
Check the throttle body and intake manifold
gasket for damage and replace if necessary.
fpwx11A0025
6. Install the throttle valve body.

(a) Install 4 fixing bolts of the throttle body.
Tool: 10mm sleeve
Torque: 10±1N•m
(10±1N·m) fpwx11A0026
(b) Install 2 warm-water pipes and 1 vacuum

hose on the throttle body.
fpwx11A0027
11A (c) Connect the TPS connector.
fpwx11A0028
(d) Connect the idle stepper motor connector.
fpwx11A0029
(e) Install the throttle cable and adjust cable

tightness, lock the nuts.
Tool: 10mm wrench
Torque: 5±1N•m
(5±1N·m)
fpwx11A0030
7. Install intake pipings. (See14A Intake(LJ465) - Air Inlet Pipe, Replacement )

8. Turn down the front passenger seat, lock the fixing buckle of passenger seat.
9. Add engine coolant. (See 17A Cooling(LJ465) - Coolant, Replacement)
Engine Control System(LJ465) - Idle stepper motor 11A-29
11A
Idle stepper motor
Idle stepper motor is essentially a miniature motor.
As the motor will rotate in different directions when
applying current of different directions to the motor
coil; The axis of rotation of the motor drives the
screw movement, therefore indirectly controls the
valve opening; The digital square wave signal
released by the ECM controls the motor's positive
fpwx11A0031 and negative rotations, and thus controls the stepper
motor travel.
11A-30 Engine Control System(LJ465) - Idle stepper motor
11A
Onboard Check
1. Check the operation sound.
(a) Confirm that the engine coolant temperature (ECT) is below 20℃.
Note
If ECT is higher than 20℃, remove the harness connector of the WTS and connect
another WTS which is lower than 20℃ to it.
(b) When the ignition switch is turned ON (do not start the engine), check the stepper
motor for operation sound.
(c) If you can not hear the sound of the stepper motor operation, check the control harness
of the idle stepper motor. If the control harness is OK, then the stepper motor or the
ECM may be faulty.
2. Check the RPM.
(a) Start the engine and operate it to normal operating temperature.
(c) Connect the diagnostic unit to the troubleshooting connectors (16-pin) on the bottom
of the front passenger seat.
(d) Turn on the ignition switch and turn on diagnostic unit - use the latest version of
software.
(e) Perform idle stepper motor test.
(f) When the diagnostic unit controls the stretch and rotation of an idle stepper motor, the
engine speed can simultaneously have high or low changes (you can feel the vibration
by touching the idle stepper motor with a hand).
(g) If the engine speed does not simultaneously have high or low changes, you should
check the idle stepper motor control harness. If the control harness is OK, then the
stepper motor or the ECM may be faulty.
3. Check the number of steps.
software.
(e) Select the following menu items:
Diagnostic unit
Check the conditions (range) Normal conditions
display items
• Engine coolant Increase 10 - 70
A/C switch: OFF→ON
temperature: 80 - steps
95℃
• Light and all
Idle stepper motor
accessories: OFF
• Transmission: A/C switch: OFF 2 - 25 steps
Neutral
• Engine: idling
11A
• When A/C switch is
ON, A/C
compressor should
work
(f) If the result does not meet the requirements, check the idle stepper motor, harness or
ECM.
11A-32 Engine Control System(LJ465) - Idle stepper motor
11A
Overhaul
fpwx11A0032
3. Dismount the idle speed stepper motor.

fpwx11A0033
(b) Dismount 2 cross clamping screws of the idle

stepper motor.
fpwx11A0037
(c) Remove the idle stepper motor.

Note

removal.
• Clean the bypass air ducts after the
removal.
fpwx11A0035
4. Check the resistance of the stepper motor 11A

coil.
1 2 3 4
(a) Connect special tools (wiring for test).
(b) Measure the resistance value between the
terminal 1 and terminal 2 of the idle speed
stepper motor connectors.
(c) Measure the resistance value between the
fpwx11A0036
(d) Replace the idle stepper motor if the result
does not meet the requirements.
5. Install the idle stepper motor.

(a) Install 2 retaining screws of the idle stepper
motor.
fpwx11A0037
(b) Connect the harness connectors of the idle

stepper motor.
Note
• Do not apply any kind of force in the axial

direction to push or pull the shaft.
• Before loading the idle stepper motor into
the throttle body, its shaft must be in fully
fpwx11A0038
retracted position.
• After dismounting the battery or ECM,
attention should be paid in time on the
stepper motor self-learning.
6. Self-learning methods of idle stepper motor: turn on the ignition switch, wait for
5 seconds, and then start the engine.
7. Turn down the main engine cover and lock the fixing buckle of driver seat.
11A-34 Engine Control System(LJ465) - Throttle position sensor
11A
Throttle position sensor
1. Throttle Position Sensor (TPS) is used to
provide the ECM with throttle angle, corner
speed and the engine idle position
information. Based on this information,
ECM can obtain engine load information,
condition information (such as starting,
idling, reverse towing, partial load, full
load) as well as acceleration and
fpwx11A0039
deceleration information. It is a three-wire
type sensor, ECM detects the throttle
opening by monitoring the voltage
changes.
2. Throttle position sensor consists of a
carbon resister and a sliding pointer.
3. The sensor sliding pointer is connected
to the throttle shaft and is operated with
the shaft. When the throttle opening is
changed with the accelerator pedal, the
position of the sliding pointer on carbon
film resistors will also change, the
resistance value output at the moment will
also change, which indirectly reflects the
throttle opening.
Engine Control System(LJ465) - Throttle position sensor 11A-35
11A
Onboard Check
1. Start the engine and operate it to normal operating temperature.
3. Connect the diagnostic unit to the troubleshooting connectors (16-pin) on the
bottom of the front passenger seat.
4. Turn on the ignition switch and turn on diagnostic unit - use the latest version
of software.
Diagnostic unit
display items
Idle position 300 - 1000mV (0%)
• Ignition Switch: ON The throttle gradually Increase in direct

Throttle Position proportion to the
• Engine is not open
Sensor (TPS) throttle opening angle
running
4500 - 5500mV
Full open
(100%)
5. If the result does not meet the requirements, check the throttle position sensor,
harness or ECM.
11A-36 Engine Control System(LJ465) - Throttle position sensor
11A
Overhaul
2. Loosen the seat buckle, flip the front
passenger seat.
fpwx11A0040
3. Dismount the TPS.

(a) Disconnect the connectors of the throttle
position sensor (TPS).
fpwx11A0041
(b) Remove 2 fixing screws of TPS.
fpwx11A0042
(c) Remove the TPS.

Note
Clean the mounting surface after the removal.
fpwx11A0043
Engine Control System(LJ465) - Throttle position sensor 11A-37
4. Check the TPS resistance. 11A

(a) Measure the resistance value between
1 2
terminal 1 and the terminal 2 of TPS side
connector.
3
(b) Measure the resistance value between
connector.
fpwx11A0044
(c) If the resistance is outside the standard range
or does not change smoothly, replace the
throttle position sensor.
5. Install TPS.
(a) Intall 2 fixing screws of TPS.
fpwx11A0045
(b) Connect the TPS connector.
fpwx11A0046
6. Turn down the front passenger seat, lock the fixing buckle of the front passenger
seat.
11A-38 Engine Control System(LJ465) - Air Intake Manifold Pressure/Temperature Sensor
11A
Air Intake Manifold Pressure/Temperature Sensor
1. The system uses the speed-density-air
metering method to detect the amount of
air entering the engine, thereby controls
fuel injection pulse width and precisely
controls the engine power output; At the
same time, the system uses the MAP
sensor cylinder identification technology,
with MAP sensor installed near the air
fpwx11A0047
intake port of the four-cylinder intake
manifold, there is a instant drop at the
sensor for about 1Kpa in the moment of
intake valve opening; ECM detects this
instant pressure drop and determines the
compression top dead center signal
through software analysis and processing
after receiving this signal.
2. The sensing element of intake air
temperature is a negative temperature
coefficient (NTC) resistor, the resistance
value falls with the rise of intake air
temperature, the engine ECU detects
changes in intake air temperature through
an internal comparison circuit.
Engine Control System(LJ465) - Air Intake Manifold Pressure/Temperature Sensor 11A-39
11A
Onboard Check
of software.
5. Select the following menu items:
Diagnostic unit
Check the conditions (range) Normal value
display items
Intake temperature:
-20℃
-20℃
Intake temperature:
0℃
0℃
• Ignition Switch: ON
Air inlet temperature Intake temperature:
• or engine is 20℃
sensor 20℃
operating
Intake temperature:
40℃
40℃
Intake temperature:
80℃
80℃
6. Set the digital multimeter in DC voltage

4 3 2 1 profile, connect the black pen to ground
and the red pen to MAP sensor 3rd and
4th terminals respectively.
(a) When in idling state, the 3rd terminal should
have a reference voltage of 5V , the 4th
terminal voltage is about 1.3V.
(b) When slowly open the throttle in no-load state,
fpwx11A0048
the 4th pin terminal voltage will have little
change.
(c) When quickly open the throttle, the 4th
terminal voltage can instantly reach 4V, then
drops to about 1.5V.
(d) Set the digital multimeter in DC voltage profile,
connect the black pen to ground and the red
pen to the intake temperature sensor 2nd
terminal. Measure the intake temperature
signal.
11A
Diagnostic unit
Condition Check Normal value
display items
Intake temperature:
3.2 - 3.8V
0℃
Intake temperature:
2.3 - 2.9V
Air inlet temperature 20℃
Ignition Switch: ON
sensor Intake temperature:
1.5 - 2.1V
40℃
Intake temperature:
0.4 - 1.0V
80℃
(e) If the result is not as specified, check the

intake manifold pressure / temperature
sensor, harness or ECM.
Engine Control System(LJ465) - Air Intake Manifold Pressure/Temperature Sensor 11A-41
11A
Overhaul
fpwx11A0049
3. Dismount the intake manifold

pressure/temperature sensor.
(a) Disconnect the connectors of intake manifold
(b) Dismount 1 retaining bolt of the intake
manifold pressure sensor.
Tool: 10mm sleeve
fpwx11A0050
(c) Dismount the intake manifold pressure

sensor.
Note
fpwx11A0051
4. Check the resistance of intake temperature

4 3 2 1 sensor.
(a) Set the digital multimeter in ohm profile, then
connect two pens to the 2nd and the 3rd
terminal of the sensor respectively. Simulation
method can also be used for the
measurement, i.e. blow the sensor with a hair
dryer (be careful not to get too close) and
fpwx11A0052
observe changes in sensor resistance, which
should decline at this point.
(b) Replace the intake manifold pressure/
temperature sensor if the result does not meet
the requirements.
11A
Diagnostic unit
Condition check Inspection items Normal value
display items
Air inlet temperature Extreme pressure 655kPa
Ignition switch: ON
sensor Operating voltage 5V±0.1V
Operating current 10mA (maximum)
5. Install the intake manifold

(a) Install the intake manifold
pressure/temperature sensor and connectors.
(b) Install the intake manifold
pressure/temperature sensor with fixing bolts.
(5±1N·m) Tool: 10mm sleeve
fpwx11A0053 Torque: 5±1N.m
Note
Proceed the installation with the press-in
method, knocking the sensor into the mounting
hole with any impact tools (e.g. a hammer, etc.)
is not allowed.
Engine Control System(LJ465) - Knock Sensor 11A-43
11A
Knock Sensor
The knock sensor is a vibration acceleration sensor
mounted on the engine block, usually mounted
between the cylinder 2 and 3; It makes for the
balance of engine knock; ECM determines the
occurrence of engine knock by utilizing the vibration
frequency signal outputted by the sensor and by
going through ECM internal filter; When a signal is
fpwx11A0054 detected ECM will gradually reduce until the
knocking does not occur, then gradually restore to
the knocking edge, and so forth.
11A-44 Engine Control System(LJ465) - Knock Sensor
11A
Onboard Check
3. Connect the diagnostic tester.
4. Switch the digital multimeter to millivolt profile to measure the signal voltage
on the 1st and the 2nd terminals.
5. Tap around the knock sensor with a hammer, then there should be a voltage
output.
6. Detect the sensor signal with an oscilloscope.
7. Tap around the knock sensor with a hammer, then there should be a wave form
output.
8. Replace the knock sensor if the result is abnormal.
Engine Control System(LJ465) - Knock Sensor 11A-45
11A
Overhaul
2. Lift the vehicle.
3. Remove the knock sensor.
(a) Disconnect the knock sensor connector.
fpwx11A0055
(b) Dismount the fixing bolt of knock sensor.

Tool: 12mm sleeve
fpwx11A0056
(c) Remove the knock sensor.

Note

removal.
• Contact with various liquids (such as: oil,
coolant, brake fluid, etc) is not allowed
after the removal. Prolonged exposure to
fpwx11A0057
these liquid will cause sensor corrosion.
4. Check the knock sensor.

1 2
(a) Set the digital multimeter in ohm profile to
measure the resistance between the
terminals.
Sensor resistance: > 1MΩ (25 ± 5℃)
(b) Replace the knock sensor if the result does
not meet the requirements.
fpwx11A0058
11A-46 Engine Control System(LJ465) - Knock Sensor
11A 5. Install the knock sensor.

(a) Install the knock sensor with fixing bolts.
Tool: 12mm sleeve
(15~25N·m) Torque: 15 - 25N•m
Note
fpwx11A0059
• Make sure the knock sensor is in the right
direction.
• Proceed the installation with the press-in
method, knocking the sensor into the
mounting hole with any impact tools (e.g.
a hammer, etc.) is not allowed.
• The sensor must be tightly attached to the
cylinder block with its metal surface, no
gaskets of any type is allowed for the
installation.
• When wiring the sensor signal cable, be
careful of signal cable resonance to avoid
break.
(b) Connect the knock sensor connector.
fpwx11A0060
Engine Control System(LJ465) - Crankshaft position sensor 11A-47
11A
Crankshaft position sensor
The system is furnished with s a magnetic induction
coil type rotational speed sensor which generates
alternating current and voltage signals through
rotating the cutting magnetic field lines. By utilizing
the alternating signal and through shaping the ECM
converts the signal into a digital signal recognizable
by the engine ECM for controlling the engine system.
fpwx11A0061 The flywheel ring gear and signal wheel are mounted
together, the signal wheel features a 58X-tooth form
for providing RPM, rotation angle and TDC for ECM.
The continuous gap is the TDC of a cylinder.
11A-48 Engine Control System(LJ465) - Crankshaft position sensor
11A
Overhaul
2. Lift the passenger seat.
3. Remove the CKP Sensor.
(a) Disconnect the crankshaft position sensor
connector.
fpwx11A0062
(b) Dismount 1 crankshaft position sensor fixing

bolt on a flywheel housing.
Tool: 10mm sleeve
fpwx11A0063
(c) Remove the crankshaft position sensor.

Note
Clean up the mounting surface after the removal
to make sure there is no oil.
fpwx11A0064
4. Check the crankshaft position sensor.

(a) Working temperature: -40℃～150℃
3 2 1 Air gap: 0.5mm - 1.5mm
Coil resistance: 1000±100Ω
Coil inductance: 290±30kHz
(b) If the resistance value is not as specified,
fpwx11A0065 replace the sensor.
5. Install the crankshaft position sensor.

Note
• Apply a thin layer of engine oil on the O-ring of the crankshaft position sensor.
• Proceed the installation with the press-in method, knocking the sensor into the
mounting hole with any impact tools (e.g. a hammer, etc.) is not allowed.
Engine Control System(LJ465) - Crankshaft position sensor 11A-49
(a) Screw the crankshaft position sensor into the 11A

mounting hole.
fpwx11A0066
(b) Tighten 1 fixing bolt.

(10±1N·m)
Tool: 10mm sleeve
Torque: 10±1N•m
fpwx11A0067
(c) Connect the crankshaft position sensor

connector.
fpwx11A0068
11A-50 Engine Control System(LJ465) - Front oxygen sensor
11A
Front oxygen sensor
The front oxygen sensor is used to detect oxygen
content in the vehicle emissions, thereby determining
whether the engine gas mixture is concentrated or
dilute, and then sends the generated signal to the
engine control unit, allowing the engine control unit
to change the fuel injection timing based on the
signal. The ultimate aim is to better control
fpwx11A0069 emissions, making emissions up to the standard as
well as saving the fuel.
Engine Control System(LJ465) - Front oxygen sensor 11A-51
11A
Onboard Check
of software.
Diagnostic unit
display items
When suddenly
• Engine: warming up
decelerate the engine ≤200mV
state
from 4000rpm
• Air-fuel ratio: diluted
during deceleration When suddenly 600 - 1000mV
accelerate the engine
Front oxygen sensor • Engine: warming up 100 - 900mV
state (periodically changing
When engine is idling
• Check the air-fuel 5-8 times within 10
ratio with oxygen seconds)
sensor signal,
check the control At 2500 rpm 600 - 1000mV
condition with ECM
6. If the voltage is not as specified, check the sensor, wiring harness and ECM.
11A-52 Engine Control System(LJ465) - Front oxygen sensor
11A
Overhaul
3. Dismount the front oxygen sensor.
(a) Disconnect the front oxygen sensor
connector.
(b) Unscrew the front oxygen sensor with a
wrench.
Tool: 22mm wrench
fpwx11A0070
Danger
As a high-temperature part exhaust pipe should

only be operated after complete cooling.
4. Check the front oxygen sensor.

(a) Ignition temperature of sensing element is
4 3 2 1 approximately: 400℃
Sensor's optimal operating temperature
range: 650℃ - 800℃
The maximum superheat temperature: 1000℃
fpwx11A0071 Standard resistance: 2.5 - 4.5Ω(20℃)
replace the sensor.
5. Install the front oxygen sensor.

Note
A layer of anti-rust oil should be applied at the

threads before installation to prevent the removal
difficulty after rust.
(40~60N·m)
(a) Place the oxygen sensor in the installation
fpwx11A0072 position and tighten the front oxygen sensor.
Tool: 22mm wrench
Torque: 40 - 60 N•m
(b) Install the front oxygen sensor connector.
6. Lower the vehicle.

Engine Control System(LJ465) - Rear oxygen sensor 11A-53
11A
Rear oxygen sensor
1. The rear oxygen sensor is used to detect
the oxygen content of the exhaust gas
after the three-way catalytic conversion;
The sensor converts this signal into an
electrical signal and sends it to the ECM;
The ECM compares the signals of the front
and the rear oxygen sensors to the judge
whether the three-way catalytic conversion
fpwx11A0073
is working well.
2. The rear oxygen sensor features the same
construction as the front oxygen sensor.
11A-54 Engine Control System(LJ465) - Rear oxygen sensor
11A
Onboard Check
of software.
Diagnostic unit display items Check the conditions (range) Normal value
state
• Check the air-fuel ratio When the en- Approximately
Rear oxygen sensor
with oxygen sensor sig- gine is running 100mV
nal, check the control
condition with ECM
Engine Control System(LJ465) - Rear oxygen sensor 11A-55
11A
Overhaul
3. Dismount the rear oxygen sensor.
(a) Disconnect the rear oxygen sensor connector.
(b) Unscrew the rear oxygen sensor with a
wrench.
Tool: 22mm wrench
Danger
fpwx11A0074
4. Check the rear oxygen sensor.

4 3 2 1 connect two pens to the 3rd and the 4th
terminal of the sensor respectively to measure
the resistance between the terminals.
Standard resistance: 2.5 - 4.5Ω(20℃)
fpwx11A0075 replace the sensor.
5. Install the rear oxygen sensor.

Note

(a) Install and tighten the rear oxygen sensor.

(40~60N·m) fpwx11A0076
Tool: 22mm wrench
Torque: 40 - 60 N•m
(b) Install the rear oxygen sensor connector.

11A-56 Engine Control System(LJ465) - Canister solenoid valve
11A
When the engine starts in cold, the solenoid valve
installed between the charcoal canister and the
intake manifold opens, allowing the gasoline vapor
in the charcoal canister to be carried into the cylinder
for combustion by the clean air under the influence
of the vacuum degree of the intake manifold. This
not only reduces the emissions, but also reduces
fpwx11A0077 fuel consumption.
Engine Control System(LJ465) - Canister solenoid valve 11A-57
11A
Onboard Check
of software.
5. Check the action of canister solenoid valve.
(a) Use the "Action Test" function of the diagnostic unit.
• Touch the canister solenoid valve of the fuel evaporative emission control system
(EVAP) with a hand.
• Use the "Action Test" function of a diagnostic unit to perform canister solenoid
valve action test.
• The canister solenoid valve should vibrate slightly. If the canister solenoid valve
does not vibrate slightly, check the solenoid valve, wiring harness and ECM.
(b) Vacuum method.
• Unplug the vacuum hose on the charcoal canister and check the vacuum hoses
for vacuum suction. When the engine is idling, if the solenoid valve is working
properly, the canister solenoid valve should be closed and there should be no
vacuum suction in the vacuum hose.
• If there is vacuum suction in the vacuum hose at this point, then dismount the
solenoid valve connector, and check the No. 1 and 2 terminals of the canister
solenoid valve connector with a multimeter for voltage. The presence of voltage
indicates that the ECM is faulty; the absence of voltage indicates that canister
solenoid valve is blocked up in open position.
• Press down accelerator pedal, allowing the engine speed exceeding 2000r/min;
Check the vacuum hose for vacuum suction, the presence of vacuum suction
indicates that canister solenoid valve is working properly; If there is no vacuum
suction in vacuum hose and supply voltage of canister solenoid valve is normal,
it indicate that the canister solenoid valve is faulty; If the voltage is abnormal, it
indicates that the ECM or harness is faulty.
11A
Overhaul
fpwx11A0078
3. Remove the intake pipe. (See14A Intake(LJ465) - Air Inlet Pipe, Replacement )
4. Disassemble the canister solenoid valve.
(a) Disconnect canister solenoid valve connector.
fpwx11A0079
(b) Loosen the clip of canister solenoid valve

intake port and disconnect the hose
connection (connecting to canister).
Note
For vehicle with a long mileage, you should first
twist the hose when disconnecting it, and do not
disconnect the hose before making sure it is
fpwx11A0080 loosened.
(c) Loosen the clip of canister solenoid valve

connection (connecting to a canister).
(d) Pry up the fixing buckle with a flat screwdriver
and upward pull out the solenoid valve.
fpwx11A0081
Engine Control System(LJ465) - Canister solenoid valve 11A-59
5. Check the canister solenoid valve. 11A

(a) Connect the canister solenoid valve to the
battery power supply, there should have
ticking sound when turning on/off the solenoid
valve, blow into the intake port (connecting to
a canister) at the moment:
• If there is air flowing out of the outlet
fpwx11A0082
port (connecting to the intake manifold),
it indicates that the canister solenoid
valve is working properly Otherwise,
replace the solenoid valve.
• If the solenoid valve is not energized,
the solenoid valve should remain
closed and the air can not pass.
(b) Check the resistance of the canister solenoid

2 1
valve
Impedance: 19 - 22Ω
fpwx11A0083
6. Install the canister solenoid valve.

(a) Engage the canister solenoid valve into a slot.
(b) Connect the clip of canister solenoid valve
outlet port (connecting to the lower intake
manifold under the throttle body).
fpwx11A0084
(c) Connect the clip of canister solenoid valve

intake port (connecting to canister).
fpwx11A0085
11A (d) Connect the canister solenoid valve

connector.
fpwx11A0086
7. Install the intake pipe. (See14A Intake(LJ465) - Air Inlet Pipe, Replacement )
8. Turn down the front passenger seat, lock the fixing buckle of front passenger
seat.
Engine Control System(LJ465) - Vehicle speed sensor 11A-61
11A
The vehicle speed sensor is a Hall-effect sensor. It
works together with a signal wheel on the
transmission output shaft. ECM receives a voltage
signal through this sensor to determine the current
speed of the vehicle.
fpwx11A0087
11A-62 Engine Control System(LJ465) - Vehicle speed sensor
11A
Onboard Check
of software.
5. Drive the vehicle and read the diagnostic data flow: vehicle speed.
6. Vehicle speed: the display value is consistent with the actual vehicle speed.
7. If the display value is inconsistent with the actual vehicle speed, check the speed
sensor, wiring harness and ECM.
9. Turn on the ignition switch without starting engine. Check as specified below:
(a) Set the digital multimeter in voltage profile,
then connect the 1st and the 2nd terminal of
1 2 3
the sensor with two pens respectively, it
should have 12V reference voltage. If not OK,
check the wiring harness.
(b) Start the engine and engage the gear, check
the 3rd terminal of the sensor with an
oscilloscope for wave form of the output
fpwx11A0088
signal. If not OK, check the wiring harness
and sensors.
Engine Control System(LJ465) - Vehicle speed sensor 11A-63
11A
Overhaul
3. Dismount the vehicle speed sensor.
(a) Disconnect the connectors of the vehicle
speed sensor.
(b) Dismount the fixing bolts of vehicle speed
sensor.
Tool: 10mm sleeve
fpwx11A0089
(c) Rotate and remove the vehicle speed sensor.

Note
fpwx11A0090
4. Install the vehicle speed sensor.

(a) Install the vehicle speed sensor and tighten
1 fixing bolt.
Torque: 10±1N•m
Note
fpwx11A0091 Proceed the installation with the press-in
is not allowed.
(b) Connect the connectors of the vehicle speed
sensor.
5. Lay down the vehicle.

6. Check the vehicle after the installation.
(a) Start the vehicle and check whether there is oil leak at the speed sensor and further
check whether the speedometer combination meter is working properly.
11A-64 Engine Control System(LJ465) - Ignition Module
11A
Ignition Module
By deploying the grouping ignition technology and
utilizing the principle of electromagnetic coil
inductance to produce high-energy, the ECM
controls the power-on and power-off time of the
primary coil, and breaks down the spark plug gap
with the high-voltage generated in the secondary
coil to produce a strong spark and ignite the mixed
fpwx11A0092 gas. Since air ionization is strong and resistance is
low during engine exhaust stroke, the spark plug
gap could be broken down with very low voltage,
therefore, the system uses a grouping ignition
technology to avoid wasting energy.
Engine Control System(LJ465) - Ignition Module 11A-65
11A
Overhaul
2. Lift the main engine cover.
3. Dismount the air intake piping. (See14A Intake(LJ465) - Air Inlet Pipe,
Replacement )
4. Dismount the ignition module.
(a) Disconnect the ignition module connectors.
(b) Unplug the high-voltage lines.
Note
Mark the order of the high-voltage lines of each
cylinder to facilitate the installation.
fpwx11A0093
(d) Dismount the fixing bolts of the ignition

module.
Tool: 8mm sleeve
(e) Remove the ignition module.
fpwx11A0094
5. Install the ignition module.

(a) Install 2 fixing bolts of the ignition module.
Tool: 8mm sleeve
Torque: 10±1N•m
(10±1N·m)
fpwx11A0095
(b) Connect high-voltage lines in the correct

order.
(c) Connect the ignition module connectors.
fpwx11A0096
6. Install intake pipings. (See14A Intake(LJ465) - Air Inlet Pipe, Replacement )

seat.
11A-66 Engine Control System(LJ465) - Ignition Module
11A
Engine Control System(4W12)
11B
Engine Control System....................11B-1 Onboard Check............................11B-37
Precautions....................................11B-1 Overhaul.......................................11B-39
System Overview............................11B-2 Operating Principles.....................11B-41
Introduction to System Functions....11B-6 Overhaul.......................................11B-42
Basic Principles..............................11B-8 Knock Sensor.................................11B-43
Main Components........................11B-15 Operating Principles.....................11B-43
System Component Description....11B-16 Onboard Check............................11B-44
Engine Control Module (ECM).......11B-17 Overhaul.......................................11B-45
Operating Principles.....................11B-17 Crankshaft position sensor...........11B-47
Replacement................................11B-18 Operating Principles.....................11B-47
Coolant Temperature Sensor.........11B-20 Overhaul.......................................11B-48
Operating Principles.....................11B-20 Front oxygen sensor......................11B-50
Overhaul.......................................11B-21 Operating Principles.....................11B-50
Throttle valve body.........................11B-23 Onboard Check............................11B-51
Cleaning of throttle body..............11B-23 Overhaul.......................................11B-52
Adjustment of fixed idling adjusting screw Rear oxygen sensor.......................11B-53
(SAS)............................................11B-24 Operating Principles.....................11B-53
Adjustment of the basic idling.......11B-25 Onboard Check............................11B-54
Overhaul.......................................11B-26 Overhaul.......................................11B-55
Idle stepper motor..........................11B-28 Canister solenoid valve.................11B-56
Operating Principles.....................11B-28 Operating Principles.....................11B-56
Onboard Check............................11B-29 Onboard Check............................11B-57
Throttle position sensor................11B-33 Vehicle speed sensor.....................11B-60
Operating Principles.....................11B-33 Operating Principles.....................11B-60
Onboard Check............................11B-34 Onboard Check............................11B-61
Air Intake Manifold Pressure/Temperature Ignition Module...............................11B-63
Sensor.............................................11B-36 Operating Principles.....................11B-63
Operating Principles.....................11B-36 Overhaul.......................................11B-64
11B
Engine Control System(4W12) - Engine Control System 11B-1
Engine Control System

Precautions 11B
1. Cutting off the Power Supply
• In order to prevent damage to people or vehicle, before removing or installing
any electrical equipment, and when tools or equipments tend to come into
contact with exposed electrical terminals, you must disconnect the negative
battery cable first, and connect the negative battery cable in the end.
• If not otherwise specified, you must turn off the ignition switch.
Danger
Before connecting or disconnecting the negative battery cable, be sure to turn off the
ignition switch and light switches. (Failure to do so may damage the semiconductor
element)
2. During maintenance, you should carry out adjustment, disassembly and testing
according to provisions described in this manual.
3. EFI system components are characterized by high reliability, when the vehicle
or engine is abnormal, first check the condition of related mechanical
components, connectors and wiring harness systems, grounding wire,
high-voltage spark plug connectors and pressure regulator vacuum line, etc.
4. Remove the debris on the mounting surface with a sealant scraper or a wire
brush before installation, make sure the sealing surface is flat, smooth and free
of oil. Do not forget to remove the sealant on mounting holes, threaded holes
and threads.
5. When installing sensors and actuators and other components, fixing bolts should
be tightened to the specified value.
6. Unless otherwise specified in the testing process, you should not test the ECM
and the sensors with a pointer type multimeter, but with a high impedance digital
multimeter.
7. You must handle with care when installing and carrying a sensor to ensure it is
free from damage, as any shock, drop may cause great harm to its performance.
8. Do not start the engine for a long time when the battery voltage is low or the
starter is faulty, so as to avoid damaging the catalytic converter.
9. You should not check the wiring harness electrical system by puncturing the
harness with a fine needle.
10 . When removing and replacing the oxygen sensor, the sensor must not come
into contact with water or other liquids.
11 . The fuel pump can neither operate for a long time without gasoline, nor operate
with gasoline in the air.
12 . The vast majority of EFI parts are irreparable, they are generally to be replaced
after confirming being damaged.
13 . The system should use anti-interference type of spark plugs and high-voltage
lines, as non-impedance type of spark plugs and high-voltage lines will not only
release the interference wave, but also adversely affect the ignition coil driver
module within the ECM.
14 . You must not open the ECM lid.
11B-2 Engine Control System(4W12) - Engine Control System
System Overview
11B 1. General Introduction
4W12 is an electronically controlled multi-point fuel injection (MPI) engine control system. It
uses Delphi MT22.1engine control module (ECM) as the control center, and measures a
variety of work parameters of the engine by utilizing a variety of sensors mounted on different
parts of the engine, and precisely controls the fuel injection with a fuel injector according to
a preset control program in the computer, thus allows the engine to obtain the optimum
concentration of gas mixture under a variety of conditions. In addition, the electronic control
fuel injection system can also achieve starting enrichment, warm-up enrichment, acceleration
enrichment, full load enrichment, deceleration dilution, forced idling fuel-cut, automatic idling
speed control and other functions through the control program in the ECM, thus meets the
requirements on gas mixture placed by the special conditions of the engine, not only allows
the engine to obtain good fuel economy and emissions, but also improves the vehicle
performance. In addition, ECM also boasts several fault diagnosis modes allowing you to
simplify the fault finding.
2. Engine Control System functions include:
• Knock control
• Mileage memory
Engine Control System functions include • Vehicle main power relay control
identification]

Engine control module (ECM) Function 11B
System 5V Sensor reference voltage


supply
12V Power ground

Fuel injector A

Air inlet pressure sensor (MAP) Fuel injector B
Fuel injector C
Air inlet temperature sensor (IAT)
Fuel injector D
Analog signal input

Engine control module (ECM) Idle stepper motor coil
Idle valve control

Coolant temperature (WTS) Sensor Idle stepper motor coil
Front oxygen sensor Idle stepper motor coil
Rear oxygen sensor Idle stepper motor coil
Oil lever sensor
Fuel pump relay

System components
power control


Knock sensor


Engine speed
A/C request signal
Instrument signal
Coolant temperature
Oil level signal

Communication
Diagnosis CAN BUS communication Diagnosis K line

Signal
fpwx11b0199
4. Engine Control System Diagram
11B
9 8 4 3 2 1
10
12 11
13 14 15 16 17 6 7
fpwx11B0200
1 Air inlet 10 Fuel Rail

3 Air inlet temperature sensor 12 Positive crankcase ventilation valve
4 Idle stepper motor (PCV)
5 Throttle position sensor (TPS) 13 Crankshaft position (CKP) sensor
6 Canister solenoid valve 14 Front oxygen sensor
7 Carbon Canister 15 Three-way catalytic converter
8 Air inlet pressure sensor 16 Rear oxygen sensor
9 Connects the fuel filter 17 Knock sensor

11B
4 5 6
7 8 9 10
11
2 1
fpwx11B0201
1 Variable control solenoid valve of 7 Fuel injector 1

intake passage 8 Fuel injector 2
2 Starter 9 Fuel injector 3
4 Three-way catalytic converter 11 Engine
5 Front oxygen sensor
6 Exhaust gas recirculation solenoid
valve
Introduction to System Functions

11B 1. Idle Close-loop Control
The idling condition control of gasoline engine at normal operating temperature is a
closed loop control. The EFI system fully closes the throttle in idling conditions and
controls the air intake during gasoline engine idling with a throttle body attached to
the idling speed regulator. In the mean time, gasoline engine ECU monitors the gasoline
engine RPM in real-time and compares it with the system default idling value, and
adjusts the idling control valve and the ignition advance angle in time according to the
fluctuations in gasoline engine speed to ensure the smooth running of the gasoline
engine.
2. Ignition Timing Control System
EFI systems equipped by 4W12 engine are direct ignition control systems which feature
functions such as automatic control of ECU ignition timing and charging time setting
control. The ignition system utilizes the advanced non-distributor direct ignition
technology which is provided to the built-in ignition drive circuit by the engine electronic
control module. It sends ignition signal to the primary winding of the double ignition
coil, respectively provides ignition signal current for 1,4 and 2,3 cylinder groupings,
simultaneously ignites the two spark plugs respectively connected to coil 1, 4 or 2,3
groupings. Besides the timely replacement of the spark plug, no other components of
the ignition system require any maintenance during normal operation.
During the operation of a gasoline engine, the electronic controller determines the
ignition advance angle set value based on the load information and RPM signal and
corrects it according to the coolant temperature and other signals, thus derives the
exact ignition advance angle to determine the ignition timing.
3. Multipoint Fuel Injection System
The gasoline engine control system is a closed-loop control system equipped with
heated oxygen sensor. The oxygen sensor sends the oxygen concentration signal of
the exhaust gas to the ECU, based on which ECU adjusts the amount of fuel injection
system, thus allows the gasoline engine to operate at the theoretical air-fuel ratio (14.7:
1 ) state to ensure the optimum conversion efficiency of the catalytic converter.
4. Close-loop control
The system adopts close-loop control on the engine fuel supply and idling; The benefit
of close-loop control is that the system control is able to eliminate the differences
between the system and related mechanical parts caused by manufacturing as well
as wear and tear, and thus improves the consistency and integration of the entire
vehicle and reduces the emission.
5. Evaporation/emission pollution control
The gasoline engine control system controls the rate of the charcoal canister purge
and cleaning timing based on the gasoline engine operating conditions to control the
vehicle canister cleaning.
6. Troubleshooting
Gasoline engine control system boasts the self-diagnostic function, i.e. when system
components fails, ECU will start the fault indicator to alert the driver to the vehicle
11B
maintenance. At this point, the system will ensure that the customer drives the vehicle
to the service station for repairs under the premise of protecting the gasoline engine.
(a) Self-diagnostic of system failure is an essential function of en engine control system;
When one or several system components work abnormally, the system will remind the
user of the necessary inspection and maintenance through lighting the fault indicator
in a timely manner; When a fault occurs, the system can also control the engine
operation by deploying a temporary emergency program to ensure that the user can
drive the vehicle for repair.
(b) When a sensor and an actuator are detected to be abnormal, the engine fault check
light will turn on to alert the driver.
(c) When a sensor and an actuator are detected to be abnormal, a fault code corresponding
to the fault condition will be outputted.
(d) RAM data in the ECM associated with the sensors and actuators can be read through
a fault diagnostic unit. Furthermore, the actuator can be driven by force in a specific
case.
7. Overvoltage Protection
In case of any fault in the charging system, leading to overvoltage, the system will
enter the protective mode and limit engine RPM, in order to protect the ECM from
damage.
8. Three-way catalytic converter
Also known as catalytic cleaner. Installed in the exhaust system of a vehicle, the device
is used to reduce the most emissions and pollutants discharged by an engine. The
three-way catalytic converter, consists of a metal housing, a network chassis and a
catalyst layer (containing platinum, rhodium and other precious metals), can remove
90% of the three major pollutants, i.e. HC (hydrocarbons), CO (carbon monoxide) and
NOx (nitrogen oxides) (the so-called three-way refers to a chemical reaction for
removing these three compounds). When the exhaust gas flows through the purifier,
the platinum catalyst will bring about the oxidation of HC and CO producing water
vapor and carbon dioxide; Rhodium catalyst will lead to the reduction of NOx to nitrogen
and oxygen. The oxidation and reduction reactions only occur when the temperature
reaches 250 ℃. The improper selection and use of gasoline or lubricant additive, i.e.
using the leaded fuel additives or engine oil additive with excessive levels of sulfur,
phosphorus, zinc, will lead to phosphorus, lead substance covering the surface of the
catalyst layer of the three-way catalytic converter, thus prevents the harmful ingredients
in the exhaust gas from contacting with the surface and loses the catalytic action, the
process of which is commonly known as of three-way catalytic converter "poisoning".
9. Cooling fan control
(a) The vehicle is equipped with two-speed electric engine cooling fan
(b) Electric fan control function: depending on the engine coolant temperature and whether
or not it meets the conditions required for enabling the A/C, the ECM determines
whether to turn on the fans or switch between high and low speed to reduce the internal
power consumption of the engine.
Basic Principles
11B 1. Starting control principle.
(a) After turning on the ignition switch, the fuel pump will stop following 1.5 seconds of
operation.
(b) Engine begins to rotate, ECM detects two valid 58X signal, then the fuel pump begins
to run.
(c) The fuel pump stops 0.8 seconds after the disappearing of RPM signal (analog signal
susceptible to interference).
(d) Pre-spray: Pre-spray only sprays once in the normal starting process (if fuel is absorbed
by carbon deposit, the mixture gas is diluted, start will not be easy).
(e) Initial stage of start: intake manifold internal pressure appears as ambient atmospheric
pressure. Throttle is closed, ECM is specified as a fixed parameter based on the start
temperature.
(f) In the starting process: the fuel injection amount varies according to the change of
engine coolant temperature, and the ignition angle is also constantly adjusted and
varies according to the engine coolant temperature, intake air temperature and the
engine speed.
(g) Starting process ends: engine speed exceeds 600rpm, starting condition ends.
2. Control principle of fuel injection.
(a) ECM controls the injector drive time and injection timing, allows the engine to obtain
the optimum air-fuel ratio of mixture gas in a variety of conditions.
(b) Each cylinder's intake ports are equipped with a fuel injector, the fuel pump inside the
fuel tank fuel pumps out the fuel and conveys it into the high pressure fuel rail. The
fuel pressure regulator allows the injection pressure to be stable, the fuel injector injects
the fuel directly into the air path of each cylinder. Each cylinder injects once (injection
order is 1-3-4-2) in every working cycle of the engine (twice revolutions of a crankshaft),
this spray method is called sequential injection.
(c) When the engine is operating in cold or in high load condition, ECM carries out
open-loop control and provides richer mixture in order to maintain good performance;
when the engine is in normal operating condition (small to medium load), ECM carries
out closed-loop control through the oxygen sensor feedback signal to get the best
air-fuel ratio, and allows the three-way catalytic converter to achieve the best cleaning
efficiency.
(d) Fuel injection pulse width control.

• Air-fuel ratio correction
• Closed-loop feedback correction
Calcula-
• Intake manifold pressure tion of
Fuel injection
fuel in-
• Inflation temperature pulse width
jection
• Inflation efficiency quantity
• Self-learning correction

11B
• Supply voltage correction
• Exhaust gas recirculation
• Acceleration Enrichment
• Reduction Dilution
• Reduction Fuel Stoppage
• Feul Injector Parameters
Control Signal Description:

• Starting air-fuel ratio
• Air-fuel ratio when the engine is operating
• Air-fuel ratio of engine low coolant temperature
Air-fuel ratio Includes • Air-fuel ratio of engine normal coolant temperature
• Theocratic air-fuel ratio
• Enriched air-fuel ratio
• Overheating protection air-fuel ratio
Closed-loop feedback • The actual air-fuel ratio controlled by the feedback signal
correction of the oxygen sensor is around the theoretical ratio
Intake manifold pres- • Read directly by a MAP mounted on the intake manifold
sure
• Correct the slow internal change of engine induced by long
Self-learning time operation
• When the battery voltage changes, voltage correction can
Power supply voltage ensure the correct amount of fuel injection
substantial increase in the value of the throttle opening,
Acceleration Enrich- engine mixture in order to avoid an instant thinning, and
ment increase the fuel injection quantity. to improve the power
performance
substantial decrease in the value of the throttle opening,
Reduction Dilution engine mixture in order to avoid an instant thickening, and
decrease the fuel injection quantity. To improve emissions
and driveability
• Control the fuel cut when the system detects a vehicle
Reduction Fuel Stop-
enters the deceleration state. To reduce emissions and
page
fuel consumption

11B • When the engine speed is higher than the set value, fuel
will be cut off
• When the ignition system is faulty, fuel will be cut off
• Provide relationship between engine and fuel injection
Injection parameters quantity
(e) Correction of engine mixture gas

• At normal operating temperature, engine's partial load control is a closed loop
fuel control. At this point, the system performs real-time correction of injection
quantity based on the voltage signal feedback of oxygen sensor to adjust the
concentration of the mixture to approach theoretical air-fuel ratio, so that to
ensure the best conversion efficiency of catalytic converters in converting harmful
gas in the exhaust gas, and in the same time guarantee better fuel economy.
• When the engine is in its normal operating temperature range, open-loop fuel
control will be adopted at full load operation. At this point, in order to ensure
optimal engine power output, the system will control fuel injection with a richer
air-fuel ratio, and modestly increases the ignition advance angle based on the
premise that the engine knock does not occur. The system will also use the
exhaust gas temperature mathematical model established during calibration to
control exhaust temperature in order to protect the engine and the three-way
catalytic converter.
• The determination made by the system on engine full load condition is based
on the signal provided by the throttle position sensor. The system usually
considers the engine being in a full load condition when the throttle opening
reaches 80% to 90%. When the driver depresses the accelerator pedal to
accelerate the vehicle, the system will be appropriately increases the fuel
injection quantity to guarantee the power required by the engine during
acceleration. The increased fuel injection amount is proportional to the change
rate of throttle opening. When accelerating, ECM will appropriately postpone
the ignition advance angle and then gradually recover it in order to prevent the
excessive increases of torque engendered during hard acceleration of the engine
from shocking the drivetrain.
• When acceleration conditions are close to the full load of an engine, the system
will temporarily disconnect automotive air conditioning systems automatically
to ensure the power output of the engine during acceleration. Whatever the
case, the system will cut off the fuel supply when the engine speed exceeds
the maximum speed set by the system to suppress the unlimited increase of
RPM so to protect the engine and prevent the "Galloping"; the system will
immediately restore oil when the RPM drops back below the specified maximum
RPM of the system.
3. Ignition Control Principle.
(a) Start: when an engine starts, a fixed ignition advance angle will be used, so that the
gas inside the cylinder will be ignited and provide positive torque. When the engine
RPM is increased to a certain speed, ECM will calculate the ignition advance angle
according to the input signals.
(b) Ignition advance angle control.

Correction signal ECM Output Control 11B
• Coolant Temperature
Correction
• Intake air temperature
correction
• Altitude correction
• Idle Correction
• Main ignition angle Calculate the ignition advance
Ignition advance angle
angle
• Speed Reduction Fuel
Stoppage Correction
• Acceleration Correction
• Power Enrichment
Correction
• Air conditioning correction
(c) Main ignition advance angle: when the engine temperature reaches the normal value,
the main ignition angle at throttle opening is usually the minimum ignition angle at the
optimum torque point. When the throttle is closed, the ignition angle should be reduced
in order to get the idle stability.
(d) Ignition advance angle correction:
• Acceleration correction: When the vehicle accelerates, ECM detects a knock
signal, corrects the ignition angle until the knock does not occur. And is used
to reduce engine speed fluctuations caused by the contortion and vibration of
drive system.
• Power Enrichment Correction: near external characteristic point, enrich air-fuel
ratio to the most optimum torque and most dilute air-fuel ratio value in order to
get better power and torque.
• Correction of deceleration fuel-cut: perform ignition advance angle correction
when exiting deceleration fuel-cut to make the transition smooth.
• Air conditioning control correction: when engine is idling, turn off the A/C and
correct the ignition advance angle, so that the RPM is steadily transmitted.
4. Idle Control Principle.
(a) Idle Control
• Control the amount of throttle valve bypass air according to the idling state and
the change of engine load when idling, so that the idle speed is maintained at
an optimum RPM. ECM drives the idle stepper motor according to the engine
coolant temperature and air conditioner load, so that the engine can run with
the default target idle speed. In addition, when the engine is idling, by turning
on or off the air conditioning switch the idle stepper motor will adjust the bypass
air amount based on the load condition of the engine to avoid idle instability.
(b) Calculate Target Idle.
11B Input ECM Output Control

• Basic Target Idle
• Voltage Compensation
• Speed Compensation
• Fan Compensation
Calculate Target Idle Target Idle
• Headlight Compensation
• Air Conditioning
Compensation
• Deceleration Adjustment
• Voltage Compensation: when the voltage is less than 12V, the system will
automatically increase the target idle to increase generating capacity of the
generator.
• Air Conditioning Compensation: when the A/C is on during idling, to compensate
for the dynamic consumption of the compressor, the target idle increases by
150 r/min.
• Headlight Compensation: after turning on the dim beam, the target idle increases
50rpm to compensate for their electricity consumption.
• Fan Compensation: when the coolant temperature rises, fan operates, to
compensate for the power consumption of fan operation, the target idle increases
by 50 r/min.
(c) Idle Control Parameters:
• Idle Air Volume Control.
• Fuel Injection Amount Control.
• Ignition timing Control.
(d) Idle Design Control Timing:
• Idle Stability Calibration.
• Acceleration Condition Calibration.
• Deceleration Condition Calibration.
• Deceleration Fuel-cut.
• Engine Transient State Transition Condition Fuel Supply Calibration.
• Constant Speed Calibration.
• Mechanical and Electrical Load/Deload Calibration.
(e) Target Idle Determinants:
• When engine water temperature is low, system provides a higher target idle to
accelerate the vehicle warming.
• When applied Load (e.g. headlights, air conditioning, cooling fans and other
appliances load) is turned on, the system will increase idling speed to
compensate for the increased load in order to maintain the stability of idling
speed.
11B
5. Knock Control Principle.
(a) Introduction of Knock Sensor:
• Mounted on engine cylinder block, the knock sensor is an vibration acceleration
sensor. Usually installed between 2,3 cylinders, it makes for the engine knock
balance. ECM makes use of the vibration frequency signal exported by the
sensor and by going through ECM internal filter to determine the occurrence of
engine knock. When knock signal is detected, ECM corrects the ignition angle
until the knock does not occur.
(b) Knock Control Conditions:
• Vehicle is equipped with knock sensors.
• Engine speed is greater than 800rpm.
• MAP is greater than 40kpa.
(c) Knock Control Mode:
• Steady State Control: During normal engine operation, ECM collects and
analyzes the sound during engine combustion through knock sensor to detect
the knock by means of filtering. Once the knock intensity exceeds the limit, the
system will quickly delay the cylinder advance angle that gives rise to knock to
eliminate knock.
• Transient State Control: Rapid acceleration or abrupt changes in engine speed
may easily give rise to knock. When the likelihood of knock occurrence is
predicted, system will automatically delay the ignition timing to avoid the
occurrence of overranging (strong) knock.
• Quickly delays the ignition angle: Once knock is detected, the system quickly
delays the ignition advance angle, depending on engine RPM, and returns back
to normal within the next 2-3 seconds.
• Adaptive ignition angle: difference or change will occur to the engine due to
manufacturing errors and wear after prolonged use (belts, toothed pulleys, cams
affect the phase angle relationship). During the initial work of the system and
the engine or re-energizing of the ECM the engine may produce knock which
will be recorded by the system. After a period of running-in, the system will
automatically generate an adaptive ignition adjustment correction value
(self-learning value). When the engine is running in the same operating
conditions, the system will automatically perform adaptive adjustment to the
ignition advance angle.The occurrence of strong knock shall be avoided. System
adaptive learning is constantly updated during engine operation.
6. Canister solenoid valve control principle.
(a) The flow used to control canister purge air flow. The canister solenoid valve is controlled
by the ECM according to the duration and the frequency (i.e. duty cycle) of electrical
pulse emitted through comprehensive calculations performed according to a series of
signals, such as the engine load, engine coolant temperature and so on. Excess
accumulation of gasoline vapor in charcoal canister will lead to gasoline leakage,
causing environmental pollution, so the role of the canister solenoid valve is to open
at the right time, allowing excess gasoline vapors entering the intake pipe and fully
mixing with air to take part in combustion.
11B (b) The canister will not participate in the work in the following situations:
• A period of time after engine old start and the engine coolant temperature is
high.
• Engine idling phases.
• Engine heavy load phase.
• Important system sensor is faulty.
Main Components
11B
Engine control system
General speed control Ignition and fuel injection control Exhaust control Self-diagnosis system Signal acquisition system
Diagnosis
TPS Ignition coil Fuel pump assembly Tail gas exhaust Fuel evaporating communication
CKP Sensor
Throttle body Sparking plug Fuel pipeline and discharge MAP Sensor
Idle stepper motor High voltage line Fuel guide rail assembly IAT Sensor
WTS Sensor
TPS Sensor
Oxygen sensor
Oxygen sensor Three-way Carbon canister Fault indicator Communication line

catalyst converter Solenoid valve and
diagnostic interface
fpwx11B0202
System Component Description

11B GUI widget Overview Amount Function
• ECM optimizes the control sys-
tem based on the signal provid-
ECM 16-bit CPU 1 ed by the sensor, making it suit-
able for the engine operating
conditions
• Detect the oxygen concentration
Front oxygen sensor Heater type 1 in the exhaust gas
• ECM compares the signals from
the front and rear oxygen sen-
Rear oxygen sensor Heater type 1 sors to determine the condition
of three-way catalytic converter
• Detect the intake air and deter-
Intake manifold pres- mine the compression top dead
Piezoelectric type 1
sure sensor center
Crankshaft position Magneto-electricity in- • Detect the position and speed

1 of crankshaft rotation
sensor duction coil type
Knock sensor Frequent-response type 1 • Detect the engine for knock
• Inject fuel according to the sig-
Fuel injector 4-hole type 4 nal from the ECM
Electromagnetic coil • Control the intake air
Idle stepper motor 1
type
• Control the emission according
Canister solenoid to the digital pulse square wave
Electromagnetic type 1
valve of ECM
Throttle position sen- 3 wire carbon film resis- • Detect throttle opening
1
sor tors sliding pointer type
Negative temperature • Detect the engine coolant tem-
Coolant Temperature
coefficient (NTC) ther- 1 perature
Sensor
mistor type
Thermal sensitivity of Negative temperature • Detect engine intake air temper-
air inlet temperature coefficient (NTC) ther- 1 ature
sensor mistor type
Vehicle speed sen- • Detect the vehicle speed
Hall-effect type 1
sor
Electromagnetic coil • Ignite the gas mixture
Ignition coil 1
type
Turbo type single-stage • Provide the system with fuel of
Gasoline pump 1 sufficient pressure
motor pump
Engine Control System(4W12) - Engine Control Module (ECM) 11B-17

Operating Principles 11B
signal input interface, an actuator drive circuit and a microprocessor as core
operating temperature: -40℃ - 105℃.
11B-18 Engine Control System(4W12) - Engine Control Module (ECM)
Replacement
11B 1. Turn off the ignition switch.
3. Remove the ECM.
Note
(a) Disconnect the ECM connector.
fpwx11B0002
(b) Remove the ECM connector.

Note
fpwx11B0003
(c) Remove 4 fixing bolts of the ECM.

Tool: 10mm sleeve
fpwx11B0004
(d) Remove the ECM module.
fpwx11B0005
Engine Control System(4W12) - Engine Control Module (ECM) 11B-19
Note
• Make sure to remove the battery negative 11B

removing the ECM.
avoid collisions.
ECM.
of the plug pins.

(a) Install 4 fixing bolts of the ECM.
Torque: 10±1N•m
Tool: 10mm sleeve
Note
fpwx11B0006
(b) Install the ECM connector.

Note
Gently pull it down with a hand to confirm the
ECM connector is installed in place.
fpwx11B0007

6. Put the seat back in place.
11B-20 Engine Control System(4W12) - Coolant Temperature Sensor
Coolant Temperature Sensor

11B Operating Principles
1. Coolant temperature sensor is used to
detect the operating temperature of an
engine. ECM provides the optimal control
scheme for an engine depending on the
temperature.
2. This coolant temperature sensor is a
two-wires type. A single-wire sensor is
generally used to provide coolant
fpwx11b0008
temperature signals for a meter.
Engine Control System(4W12) - Coolant Temperature Sensor 11B-21
Overhaul
1. Turn off the ignition switch. 11B
2. Open the engine cap, slowly unscrew the
expansion tank pressure cap.
Note
is heat. Do not open the radiator cover until the
engine cools down below 50°C. Otherwise, hot
coolant or steam may lead to personal injury.
fpwx11B0009 (See
17B Cooling(4W10/4W12) - Cooling System,
Precautions
)
3. Lift the vehicle, unscrew the drain bolt on

the lower part of the tank to discharge the
coolant.
Note
fpwx11B0010
4. Dismount the engine coolant temperature

(ECT) sensor.
(a) Loosen the clamp and disconnect the small
water hose.
fpwx11B0011
(b) Disconnect the engine coolant temperature

(ECT) sensor connector.
(c) Dismount the water temperature sensor.
Tool: 19mm wrench
Note

fpwx11B0012 removal.
• Clean the mounting hole threads after the
removal.
• Clean the sensor mounting threads after
the removal.
11B-22 Engine Control System(4W12) - Coolant Temperature Sensor
5. Check the ECT sensor.

(a) Immerse the temperature sensing part of the
11B
ECT sensor in hot water, and measure the
resistance between the terminals of the ECT
sensor with a multimeter.
(b) If the measurement results do not meet the
standard, replace the ECT sensor.
fpwx11B0013 Note
Apply sealant on the threaded portion. If you

check the ECT sensor in water, do not allow
water entering the terminal. Wipe dry the sensor
after checking.
6. Install the ECT sensor.

Note
Apply sealant on the threaded portion. The
specified sealant: 3M NUT LOCKING PART or
equivalents.
fpwx11b0014
(a) Tighten the water temperature sensor with a

wrench and connect the ECT sensor
connector.
Tool: 19mm wrench
fpwx11B0015
(b) Install the engine hose and lock the clamp.
fpwx11B0016
7. Add engine coolant. (See17B Cooling(4W10/4W12) - Coolant, Replacement)

8. Start the engine and check for coolant leaks.
Engine Control System(4W12) - Throttle valve body 11B-23
Throttle valve body

Cleaning of throttle body 11B
1. Start the engine and preheat it until the coolant temperature exceeds 80℃, then
stop the engine.
2. Remove the intake hose from the throttle body.
3. Block the bypass gas passage inlet of the throttle body with a plug.
Note
Do not allow the cleaning agent entering the bypass gas passage.
4. Inject the cleaning agent into the valve

through throttle body inlet port and hold
for 5 minutes.
5. Start the engine and idle for about 1
minute after several times of acceleration
operation, if the idling is unstable due to
the clogging of bypass gas passage (or
engine flameout), you may slightly open
fpwx11B0017
the throttle to keep the engine running.
6. If the deposit inside the throttle is not
cleared, then repeat step (4) and (5).
7. Pull out the plug of the bypass gas
passage.
8. Connect the intake hose.

9. Clear up the fault diagnosis code with a fault diagnostic unit (DTC).
10 . Adjust the basic idling.
Note
If there are irregular vibrations during engine idling after the adjustment of the basic
idling, you should disconnect the negative battery cable for more than 10 seconds,
then reconnect it and idle the engine for about 10 minutes.
11B-24 Engine Control System(4W12) - Throttle valve body
Adjustment of fixed idling adjusting screw (SAS)

11B 1. Do not adjust the "fixed SAS" unless necessary, because the fixed SAS was
precisely adjusted before delivery, thus has been fixed.
2. If the fixed SAS has been arbitrarily rotated, re-adjust it according to the following
steps:
(a) Fully relax the throttle cable.
(b) Loosen the SAS locknut.
(c) Counterclockwise exit the SAS, completely
switch on and off the throttle.
(d) Clockwise rotate the "fixed SAS" until it
reaches the point contacting with the throttle
lever (i.e., the point position where the throttle
starts to open).
(e) Lock the locknut while securing the "fixed
SAS".
(f) Adjust the throttle cable tension.
(g) Adjust the basic idling.
Adjustment of the basic idling

1. Standard idling is adjusted at the factory by the manufacturer with a idling 11B
adjustment screw (SAS), so usually you do not have to re-adjust.
2. If the SAS was incorrectly adjusted, it will cause too high or too low idling during
engine load change. When this occurs, adjust in the following manner.
Note
If you need to adjust the basic idling, you must first confirm that the spark plugs, fuel
injectors, idle stepper motor, cylinder compression pressure are in the normal state
before the adjustment.
(a) Before checking and adjustment, set the vehicle in the pre-delivery check status.
(c) Connect the fault diagnostic unit to the fault diagnosis connector.
(d) Start the engine and keep it at idling.
(e) Check the idling.
Standard value: 750 ± 50rpm
Note
• When driving a new car within 500Km, the engine speed may be lower than the
standard value of 20 - 100rpm, but it does not need to be adjusted.
• If the engine shuts down or the engine speed is still lower than the standard
value when the vehicle has traveled for more than 500Km, it may be caused by
the dirty throttle, so you must clean the throttle.
(f) If the idling speed is not within the standard

values, adjust the idling adjustment screw
(SAS).
Note
If the SAS has been fully turned to the end but
is still higher than the standard value of idling,
check if the "fixed SAS" has been turned. If the
fpwx11B0018 "fixed SAS" has been turned, then readjust the
"fixed SAS".
• Turn off the ignition switch.
• Remove the fault diagnostic unit.
• Start the engine and idle for 10 minutes to
confirm whether the idling condition is OK.
11B-26 Engine Control System(4W12) - Throttle valve body
Overhaul
4. Dismount the air intake piping.
(a) Remove the fixing clamp of the throttle side
intake hose.
(b) Remove the fixing clamp of the crankcase
ventilation pipe.
fpwx11B0020
5. Remove the throttle valve body.

(b) Disconnect the throttle position sensor
connector.
fpwx11B0021
(c) Loosen the throttle cable adjustment bolt on

the throttle and remove the throttle cable.
Dismount the adjusting nut of the throttle
cable.
Tool: 13mm wrench
fpwx11B0022
(d) Remove the throttle fixing bolts.
fpwx11B0023
(e) Remove the throttle valve body.

Note
11B
Check the throttle body and intake manifold
gasket for damage and replace if necessary.
fpwx11B0024
6. Install the throttle valve body.

(a) Install 4 fixing bolts of the throttle body.
Tool: 8mm sleeve
Torque: 10±1N.M
(10±1N·m) fpwx11B0025
(b) Install the throttle cable adjustment bolt on

the throttle and install the throttle cable. Install
(9±1N·m) the adjusting nut of the throttle cable.
Tool: 13mm wrench
Torque: 9±1N.M
fpwx11B0026
(c) Install 2 throttle connectors.
fpwx11B0027
7. Install intake pipings.

8. Lay down the seat and lock the seat fixing buckle.
11B-28 Engine Control System(4W12) - Idle stepper motor
Idle stepper motor

Idle stepper motor is essentially a miniature motor.
As the motor will rotate in different directions when
applying current of different directions to the motor
coil; The axis of rotation of the motor drives the
screw movement, therefore indirectly controls the
valve opening; The digital square wave signal
released by the ECM controls the motor's positive
fpwx11B0028 and negative rotations, and thus controls the stepper
motor travel.
Engine Control System(4W12) - Idle stepper motor 11B-29
Onboard Check
1. Check the operation sound. 11B
(a) Confirm that the engine coolant temperature (ECT) is below 20℃.
Note
If ECT is higher than 20℃, remove the harness connector of the WTS and connect
another WTS which is lower than 20℃ to it.
(b) When the ignition switch is turned ON (do not start the engine), check the stepper
motor for operation sound.
(c) If you can not hear the sound of the stepper motor operation, check the control harness
of the idle stepper motor. If the control harness is OK, then the stepper motor or the
ECM may be faulty.
2. Check the RPM.
software.
(e) Perform idle stepper motor test.
(f) When the diagnostic unit controls the stretch and rotation of an idle stepper motor, the
engine speed can simultaneously have high or low changes (you can feel the vibration
by touching the idle stepper motor with a hand).
(g) If the engine speed does not simultaneously have high or low changes, you should
check the idle stepper motor control harness. If the control harness is OK, then the
stepper motor or the ECM may be faulty.
3. Check the number of steps.
software.
(e) Select the following menu items:
Diagnostic unit
display items
• Engine coolant Increase 10 - 70
A/C switch: OFF→ON
temperature: 80 - steps
95℃
Idle stepper motor • Light and all
accessories: OFF A/C switch: OFF 2 - 25 steps
• Transmission:
Neutral
• Engine: idling
• When A/C switch is
11B
ON, A/C
compressor should
work
(f) If the result does not meet the requirements, check the idle stepper motor, harness or
ECM.
Engine Control System(4W12) - Idle stepper motor 11B-31
Overhaul
3. Dismount the idle speed stepper motor.
(b) Dismount 2 fixing screws of the idle stepper
motor.
fpwx11B0029
(c) Remove the idle stepper motor.

Note

removal.
• Clean the bypass air ducts after the
removal.
fpwx11B0030
4. Check the resistance of the stepper motor

coil.
1 2 3 4
(a) Connect special tools (wiring for test).
(b) Measure the resistance value between the
(c) Measure the resistance value between the
fpwx11B0031
(d) Replace the idle stepper motor if the result
does not meet the requirements.
5. Install the idle stepper motor.

(a) Install 2 retaining screws of the idle stepper
motor.
(b) Connect the harness connectors of the idle
stepper motor.
fpwx11B0032
Note
11B • Do not apply any kind of force in the axial
direction to push or pull the shaft.
• Before loading the idle stepper motor into
the throttle body, its shaft must be in fully
retracted position.
• After dismounting the battery or ECM,
attention should be paid in time on the
stepper motor self-learning.
6. Self-learning methods of idle stepper motor: turn on the ignition switch, wait for
5 seconds, and then start the engine.
seat.
Engine Control System(4W12) - Throttle position sensor 11B-33
Throttle position sensor

1. Throttle Position Sensor (TPS) is used to

provide the ECM with throttle angle, corner
speed and the engine idle position
information. Based on this information,
ECM can obtain engine load information,
condition information (such as starting,
idling, reverse towing, partial load, full
load) as well as acceleration and
fpwx11B0033
deceleration information. It is a three-wire
type sensor, ECM detects the throttle
opening by monitoring the voltage
changes.
2. Throttle position sensor consists of a
carbon resister and a sliding pointer.
3. The sensor sliding pointer is connected
to the throttle shaft and is operated with
the shaft. When the throttle opening is
changed with the accelerator pedal, the
position of the sliding pointer on carbon
film resistors will also change, the
resistance value output at the moment will
also change, which indirectly reflects the
throttle opening.
11B-34 Engine Control System(4W12) - Throttle position sensor
Onboard Check
11B 1. Start the engine and operate it to normal operating temperature.
of software.
Diagnostic unit
display items
Idle position 300 - 1000mV (0%)
• Ignition Switch: ON The throttle gradually Increase in direct

Throttle Position proportion to the
• Engine is not open
Sensor (TPS) throttle opening angle
running
4500 - 5500mV
Full open
(100%)
5. If the result does not meet the requirements, check the throttle position sensor,
harness or ECM.
Engine Control System(4W12) - Throttle position sensor 11B-35
Overhaul
2. Loosen the seat buckle, flip the front passenger seat.
3. Dismount the TPS.
(a) Disconnect the connectors of the throttle
position sensor (TPS).
(b) Remove2 fixing screws of TPS.
fpwx11B0034
(c) Remove the TPS.

Note
fpwx11B0035
4. Check the TPS resistance.

(a) Measure the resistance value between
1 2
connector.
3
(b) Measure the resistance value between
connector.
(c) If the resistance is outside the standard range
fpwx1B0036
or does not change smoothly, replace the
throttle position sensor.
5. Install TPS.
(a) Install 2 fixing bolts of TPS.
(b) Connect the TPS connector.
fpwx11B0037
seat.
11B-36 Engine Control System(4W12) - Air Intake Manifold Pressure/Temperature Sensor
Air Intake Manifold Pressure/Temperature Sensor

1. The system uses the speed-density-air
metering method to detect the amount of
air entering the engine, thereby controls
fuel injection pulse width and precisely
controls the engine power output; At the
same time, the system uses the MAP
sensor cylinder identification technology,
with MAP sensor installed near the air
fpwx11B0038
intake port of the four-cylinder intake
manifold, there is a instant drop at the
sensor for about 1Kpa in the moment of
intake valve opening; ECM detects this
instant pressure drop and determines the
compression top dead center signal
through software analysis and processing
after receiving this signal.
2. The sensing element of intake air
temperature is a negative temperature
coefficient (NTC) resistor, the resistance
value falls with the rise of intake air
temperature, the engine ECU detects
changes in intake air temperature through
an internal comparison circuit.
Engine Control System(4W12) - Air Intake Manifold Pressure/Temperature Sensor 11B-37
Onboard Check
1. Start the engine and operate it to normal operating temperature. 11B
of software.
Diagnostic unit
display items
Intake temperature:
-20℃
-20℃
Intake temperature:
0℃
0℃
• Ignition Switch: ON
Air inlet temperature Intake temperature:
• or engine is 20℃
sensor 20℃
operating
Intake temperature:
40℃
40℃
Intake temperature:
80℃
80℃
6. Set the digital multimeter in DC voltage

4 3 2 1 profile, connect the black pen to ground
and the red pen to MAP sensor 3rd and
4th terminals respectively.
(a) When in idling state, the 3rd terminal should
have a reference voltage of 5V , the 4th
terminal voltage is about 1.3V.
(b) When slowly open the throttle in no-load state,
fpwx11B0039
the 4th pin terminal voltage will have little
change.
(c) When quickly open the throttle, the 4th
terminal voltage can instantly reach 4V, then
drops to about 1.5V.
(d) Set the digital multimeter in DC voltage profile,
connect the black pen to ground and the red
pen to the intake temperature sensor 2nd
terminal. Measure the intake temperature
signal.
Diagnostic unit
Condition Check Normal value
display items
11B
Intake temperature:
3.2 - 3.8V
0℃
Intake temperature:
2.3 - 2.9V
Air inlet temperature 20℃
Ignition Switch: ON
sensor Intake temperature:
1.5 - 2.1V
40℃
Intake temperature:
0.4 - 1.0V
80℃
(e) If the result is not as specified, check the

intake manifold pressure / temperature
sensor, harness or ECM.
Overhaul
2. Loosen the seat fixing buckle, flip the front passenger seat.
3. Dismount the Intake Manifold
Pressure/Temperature Sensor.
(a) Disconnect the connectors of intake manifold
pressure sensor.
(b) Dismount 1 retaining bolt of the intake
manifold pressure sensor.
fpwx11B0040
(c) Dismount the intake manifold pressure

sensor.
Note
fpwx11B0041

4 3 2 1 sensor.
fpwx11B0042
(b) Replace the intake manifold pressure/
temperature sensor if the result does not meet
the requirements.
Diagnostic unit
Condition check Inspection Items Normal value
display items
Air inlet temperature Extreme pressure 655kPa
Ignition switch: ON
sensor Operating voltage 5V±0.1V
Operating current 10mA (maximum)
5. Install the intake manifold pressure

sensor.
11B
(a) Connect the connectors of intake manifold
pressure sensor.
(b) Install 1 retaining screw of the intake manifold
pressure sensor.
Note
fpwx11B0043
Proceed the installation with the press-in
is not allowed.
seat.
1. Function: detect the intake air temperature 11B
of an engine, convert the intake air
temperature into a voltage signal and input
it to the ECU as a fuel injection correction
signal.
2. Intake air temperature sensor which is
mounted on the intake pipe or in an air
flow meter is also a two-wire sensor. Intake
fpwx11B0044
air temperature sensor is a negative
temperature coefficient thermistor which
generates different signal voltages in
accordance with the resistance change.
The intake air temperature sensor signal
is substantially the same as the engine
coolant temperature sensor signal when
the vehicle is cold, yet the signal voltage
is about 2 to 3 times of the water
temperature sensor when the vehicle is
warmed.
3. One wire of the intake air temperature
sensor is supplied with 5V voltage THA by
the engine ECU, the other internally
grounded by the engine control module.
Overhaul
2. Loosen the front passenger seat fixing buckle, flip the front passenger seat.
3. Remove the intake air temperature sensor.
(a) Disconnect the intake air temperature sensor
connector.
(b) Unscrew the intake temperature sensor.
fpwx11B0045

sensor.
1 2 (a) Set the digital multimeter in ohm profile, then
fpwx11B0084
(b) Replace the intake temperature sensor if the
result does not meet the requirements.
5. Install the intake air temperature sensor.

(a) Install the intake air temperature sensor to
the intake manifold.
(b) Connect the intake air temperature sensor
connector.
fpwx11B0046
seat.
Engine Control System(4W12) - Knock Sensor 11B-43
Knock Sensor
1. The knock sensor is a vibration

acceleration sensor mounted on the
engine block, usually mounted between
the cylinder 2 and 3; It makes for the
balance of engine knock; ECM determines
the occurrence of engine knock by utilizing
the vibration frequency signal outputted
by the sensor and by going through ECM
fpwx11B0047
internal filter; When a signal is detected
ECM will gradually reduce until the
knocking does not occur, then gradually
restore to the knocking edge, and so forth.
11B-44 Engine Control System(4W12) - Knock Sensor
Onboard Check
3. Connect the diagnostic tester.
4. Switch the digital multimeter to millivolt profile to measure the signal voltage
on the 1st and the 2nd terminals.
5. Tap around the knock sensor with a hammer, then there should be a voltage
output.
6. Detect the sensor signal with an oscilloscope.
7. Tap around the knock sensor with a hammer, then there should be a wave form
output.
8. Replace the knock sensor if the result is abnormal.
Engine Control System(4W12) - Knock Sensor 11B-45
Overhaul
3. Remove the knock sensor.
(a) Remove the air intake manifold. (See14B Intake(4W10/4W12) - Intake Manifold,
Replacement)
(b) Remove the knock sensor connector.
fpwx11B0048
(c) Remove the knock sensor fixing bolts, remove

the knock sensor.
Tool: 12mm sleeve
Note

removal.
fpwx11B0049 • Contact with various liquids (such as: oil,
coolant, brake fluid, etc) is not allowed
after the removal. Prolonged exposure to
these liquid will cause sensor corrosion.
4. Check the knock sensor.

1 2
(a) Set the digital multimeter in ohm profile to
measure the resistance between the
terminals.
(b) Replace the knock sensor if the result does
not meet the requirements.
Operating temperature range: -40℃ - 150℃
fpwx11B0050 (gilt); - 40℃ - 130℃ (tinned)
Frequency response range: 3 - 18KHz
Sensor resistance: > 1MΩ (25 ± 5℃).
11B-46 Engine Control System(4W12) - Knock Sensor
5. Install the knock sensor.

(a) Install the fixing bolt of knock sensor.
11B
Torque: 20±5N•m
(20±5N·m)
Note
• Make sure the knock sensor is in the right

direction.
fpwx11B0051 • Proceed the installation with the press-in
• The sensor must be tightly attached to the
cylinder block with its metal surface, no
gaskets of any type is allowed for the
installation.
• When wiring the sensor signal cable, be
careful of signal cable resonance to avoid
break.
(b) Connect the knock sensor connector.
fpwx11B0052
6. Install the air intake manifold. (See14B Intake(4W10/4W12) - Intake Manifold,

Replacement)
Engine Control System(4W12) - Crankshaft position sensor 11B-47
Crankshaft position sensor

1. The system is furnished with s a magnetic

induction coil type rotational speed sensor
which generates alternating current and
voltage signals through rotating the
cutting magnetic field lines. By utilizing
the alternating signal and through shaping
the ECM converts the signal into a digital
signal recognizable by the engine ECM for
fpwx11B0053
controlling the engine system. The
flywheel ring gear and signal wheel are
mounted together, the signal wheel
features a 58X-tooth form for providing
RPM, rotation angle and TDC for ECM.The
continuous gap is the TDC of a cylinder.
11B-48 Engine Control System(4W12) - Crankshaft position sensor
Overhaul
3. Remove the CKP Sensor.
(a) Disconnect the crankshaft position sensor
connector.
fpwx11a0062
(b) Dismount 1 crankshaft position sensor fixing

bolt on a flywheel housing.
Tool: 10mm sleeve
fpwx11B0055
(c) Remove the crankshaft position sensor.

Note
fpwx11B0056
4. Check the crankshaft position sensor.

(a) Working temperature: -40℃～150℃
3 2 1 Air gap: 0.5mm - 1.5mm
Coil inductance: 290±30mH@1kHz
fpwx11B0057 replace the sensor.
Engine Control System(4W12) - Crankshaft position sensor 11B-49
5. Install the crankshaft position sensor.

Note
11B
• Apply a thin layer of engine oil on the
O-ring of the crankshaft position sensor.
• Proceed the installation with the press-in
fpwx11B0058
(a) Screw the crankshaft position sensor into the

mounting hole.
(b) Tighten 1 fixing bolt.

(10±1N·m)
Tool: 10mm sleeve
Torque: 10±1N.M
fpwx11B0059
(c) Connect the crankshaft position sensor

connector.
fpwx11a0068
11B-50 Engine Control System(4W12) - Front oxygen sensor
Front oxygen sensor

1. The front oxygen sensor is used to detect
oxygen content in the vehicle emissions,
thereby determining whether the engine
gas mixture is concentrated or dilute, and
then sends the generated signal to the
engine control unit, allowing the engine
control unit to change the fuel injection
timing based on the signal. The ultimate
fpwx11B0061
aim is to better control emissions, making
emissions up to the standard as well as
saving the fuel.
Engine Control System(4W12) - Front oxygen sensor 11B-51
Onboard Check
bottom of the front passenger.
of software.
Diagnostic unit
display items
When suddenly
decelerate the engine ≤200mV
state
from 4000rpm
• Air-fuel ratio: diluted
during deceleration When suddenly 600 - 1000mV
accelerate the engine
Front oxygen sensor • Engine: warming up 100 - 900mV
state (periodically changing
When engine is idling
• Check the air-fuel 5-8 times within 10
ratio with oxygen seconds)
sensor signal,
check the control At 2500 rpm 600 - 1000mV
condition with ECM
11B-52 Engine Control System(4W12) - Front oxygen sensor
Overhaul
3. Dismount the front oxygen sensor.
(a) Disconnect the front oxygen sensor
connector.
(b) Unscrew the front oxygen sensor with a
wrench.
Tool: 22mm wrench
fpwx11B0062
Note

4. Check the front oxygen sensor.

(a) Ignition temperature of sensing element is
4 3 2 1 approximately: 400℃
Sensor's optimal operating temperature
range: 650℃ - 800℃
The maximum superheat temperature: 1000℃
fpwx11B0063 Standard resistance: 2.5 - 4.5 (20℃)
replace the sensor.
5. Install the front oxygen sensor.

Note

(55±5N·m)
(a) Place the oxygen sensor in the installation
fpwx11B0064 position and tighten the front oxygen sensor.
Tools: special tool for removing the
oxygen sensor
Torque: 55±5N•m
(b) Install the front oxygen sensor connector.

Engine Control System(4W12) - Rear oxygen sensor 11B-53
Rear oxygen sensor

1. The rear oxygen sensor is used to detect

the oxygen content of the exhaust gas
after the three-way catalytic conversion;
The sensor converts this signal into a
point signal and sends it to the ECM; The
ECM compares the signals of the front and
the rear oxygen sensors to the judge
whether the three-way catalytic conversion
fpwx11B0065
is working well.
2. The rear oxygen sensor features the same
construction as the front oxygen sensor.
11B-54 Engine Control System(4W12) - Rear oxygen sensor
Onboard Check
of software.
Diagnostic unit display items Check the conditions (range) Normal value
state
• Check the air-fuel ratio When the en- Approximately
Rear oxygen sensor
with oxygen sensor sig- gine is running 100mV
nal, check the control
condition with ECM
Engine Control System(4W12) - Rear oxygen sensor 11B-55
Overhaul
3. Dismount the rear oxygen sensor.
(a) Disconnect the rear oxygen sensor connector.
(b) Unscrew the rear oxygen sensor with a
wrench.
Tool: 22mm wrench
Note
fpwx11B0066
4. Check the rear oxygen sensor.

4 3 2 1 connect two pens to the 3rd and the 4th
terminal of the sensor respectively to measure
the resistance between the terminals.
Standard resistance: 2.5 - 4.5 (20℃)
fpwx11B0067 replace the sensor.
5. Install the rear oxygen sensor.

Note
(55±5N·m)

(a) Install and tighten the rear oxygen sensor.

fpwx11B0068
Tool: 22mm wrench
Torque: 55±5N•m
(b) Install the rear oxygen sensor connector.

11B-56 Engine Control System(4W12) - Canister solenoid valve

fpwx11B0069
1. When the engine starts in cold, the solenoid valve installed between the charcoal
canister and the intake manifold opens, allowing the gasoline vapor in the
charcoal canister to be carried into the cylinder for combustion by the clean air
under the influence of the vacuum degree of the intake manifold. This not only
reduces the emissions, but also reduces fuel consumption.
Engine Control System(4W12) - Canister solenoid valve 11B-57
Onboard Check
of software.
(EVAP) with a hand.
valve action test.
(b) Vacuum method.
11B-58 Engine Control System(4W12) - Canister solenoid valve
Overhaul
2. Lift the vehicle to the proper height.
(b) Loosen the clamps on the inlet and outlet
hoses of the canister and disconnect the inlet
and outlet hoses from the solenoid valve.
Note
Please note, for vehicle with a long mileage, you
fpwx11B0070
should first twist the hose when disconnecting
the it, and do not disconnect the hose before
making sure it is loosened.
4. Check the canister solenoid valve.

fpwx11B0071

2 1
valve
• Impedance: 19 - 22Ω
fpwx11B0072
Engine Control System(4W12) - Canister solenoid valve 11B-59

11B
(b) Install the connecting clamps of inlet and
outlet hoses of the canister and the solenoid
valve, connect the canister solenoid valve
connector.
fpwx11B0073
11B-60 Engine Control System(4W12) - Vehicle speed sensor

fpwx11B0074
1. The vehicle speed sensor is a Hall-effect sensor. It works together with a signal
wheel on the transmission output shaft. ECM determines the current vehicle
speed by receiving a digital voltage signal through this sensor.
Engine Control System(4W12) - Vehicle speed sensor 11B-61
Onboard Check
of software.
5. Drive the vehicle and read the diagnostic data flow: vehicle speed.
6. Vehicle speed: the display value is consistent with the actual vehicle speed.
7. If the display value is inconsistent with the actual vehicle speed, check the speed
sensor, wiring harness and ECM.
9. Turn on the ignition switch without starting engine. Check as specified below:
(a) Set the digital multimeter in voltage profile,
then connect the 1st and the 2nd terminal of
1 2 3
the sensor with two pens respectively, it
should have 12V reference voltage. If not OK,
check the wiring harness.
(b) Start the engine and engage the gear, check
the 3rd terminal of the sensor with an
oscilloscope for wave form of the output
fpwx11B0075
signal. If not OK, check the wiring harness
and sensors.
11B-62 Engine Control System(4W12) - Vehicle speed sensor
Overhaul
3. Dismount the vehicle speed sensor.
(a) Disconnect the connectors of the vehicle
speed sensor.
(b) Dismount the fixing bolts of vehicle speed
sensor.
Tool: 10mm sleeve
fpwx11B0076
(c) Rotate and remove the vehicle speed sensor.

Note
fpwx11B0077
4. Install the vehicle speed sensor.

(a) Install the vehicle speed sensor and tighten
1 fixing bolt.
Torque: 10±1N.M
Note
fpwx11B0078 Proceed the installation with the press-in
is not allowed.
(b) Connect the connectors of the vehicle speed
sensor.
5. Lay down the vehicle.

(a) Start the vehicle and check whether there is oil leak at the speed sensor and further
check whether the speedometer combination meter is working properly.
Engine Control System(4W12) - Ignition Module 11B-63
Ignition Module
fpwx11B0079
1. By deploying the grouping ignition technology and utilizing the principle of

electromagnetic coil inductance to produce high-energy, the ECM controls the
power-on and power-off time of the primary coil, and breaks down the spark
plug gap with the high-voltage generated in the secondary coil to produce a
strong spark and ignite the mixed gas. Since air ionization is strong and
resistance is low during engine exhaust stroke, the spark plug gap could be
broken down with very low voltage, therefore the system uses the grouping
ignition technology to avoid wasting energy.
11B-64 Engine Control System(4W12) - Ignition Module
Overhaul
2. Loosen the seat buckle, turn over the driver seat.
(b) Unplug the high-voltage lines.
Note
Mark the order of the high-voltage lines of each
cylinder to facilitate the installation.
fpwx11B0080
(c) Remove 2 fixing bolts of the ignition module.

Tool: 8mm sleeve
(d) Remove the ignition module.
fpwx11B0081
4. Install the ignition module.

Tool: 8mm sleeve
Torque: 10±1N.M
fpwx11B0082
(b) Connect high-voltage lines in the correct

order.
(c) Connect the ignition module connectors.
fpwx11B0083
5. Turn down the driver seat, lock the fixing buckle of the driver seat.
Engine Control System(4W10)
System Overview................................11C-1
Engine Control Module (ECM)...........11C-5 11C
Operating Principles.........................11C-5
Replacement....................................11C-6
Canister solenoid valve.....................11C-8
Operating Principles.........................11C-8
Onboard Check................................11C-9
Overhaul.........................................11C-10
11C
Engine Control System(4W10) - System Overview 11C-1
System Overview
1. General Introduction
4W10 is an electronically controlled multi-point fuel injection (MPI) engine control system. It
uses Continental Easy U2engine control module (ECM) as the control center, and measures 11C
a variety of work parameters of the engine by utilizing a variety of sensors mounted on
different parts of the engine, and precisely controls the fuel injection with a fuel injector
according to a preset control program in the computer, thus allows the engine to obtain the
optimum concentration of gas mixture under a variety of conditions. In addition, the electronic
control fuel injection system can also achieve starting enrichment, warm-up enrichment,
acceleration enrichment, full load enrichment, deceleration dilution, forced idling fuel-cut,
automatic idling speed control and other functions through the control program in the ECM,
thus meets the requirements on gas mixture placed by the special conditions of the engine,
not only allows the engine to obtain good fuel economy and emissions, but also improves
the vehicle performance. In addition, ECM also boasts several fault diagnosis modes allowing
you to simplify the fault finding.
2. Engine control system functions include:
• Knock control
• Mileage memory
Engine control system functions include • Vehicle main power relay control
identification]

11C-2 Engine Control System(4W10) - System Overview
Engine control module (ECM) Function
11C System 5V Sensor reference voltage


supply
12V Power ground

Fuel injector A

Air Intake Pressure/Temperature Sensor Fuel injector B
Fuel injector C
Fuel injector D
Analog signal input

Engine control module (ECM)
Idle valve control

Coolant temperature (WTS) Sensor Idle stepper motor coil
Front oxygen sensor Idle stepper motor coil
Rear oxygen sensor Idle stepper motor coil
Oil lever sensor
Fuel pump relay

System components
power control


Knock sensor


Engine speed
A/C request signal
Instrument signal
Coolant temperature
Oil level signal

Communication
Diagnosis CAN BUS communication Diagnosis K line

Signal
fpwx11c10000
Engine Control System(4W10) - System Overview 11C-3
4. Engine Control System Diagram
8 7 3 2 1
11C
10
11
12 13 14 15 16 5 6
fpwx11C0200
1 Air inlet 9 Fuel Rail

3 Idle stepper motor 11 Positive crankcase ventilation valve
4 Throttle position sensor (TPS) (PCV
5 Canister solenoid valve 12 Crankshaft position (CKP) sensor
6 Carbon Canister 13 Front oxygen sensor
7 Air Intake Pressure/Temperature 14 Three-way catalytic converter
Sensor 15 Rear oxygen sensor
8 Connects the fuel filter 16 Knock sensor

11C-4 Engine Control System(4W10) - System Overview
3 4
11C
5 6 7 8
2
1
11
10
fpwx11C0201
1 Variable control solenoid valve of 7 Fuel injector 3

intake passage 8 Fuel injector 4
2 Starter 9 Engine
3 Front oxygen sensor 10 ECM connector 1 (E002)
4 Exhaust Gas Recirculation Valve 11 ECM connector 2 (E003)
5 Fuel injector 1
6 Fuel injector 2
There are following differences between 4W10 engine and 4W12 engine:
• 4W10 engine's intake air pressure sensor which is mounted on the intake
manifold is integrated with the intake air temperature sensor.
• 4W12 engine's intake air temperature sensor is mounted on the front intake hose
of the throttle, the intake air pressure sensor is mounted on the intake manifold.
• 4W10 engine ECM has two connectors, i.e. E002 and E003.
• 4W12 engine ECM has one connector, i.e. E001.
Engine Control System(4W10) - Engine Control Module (ECM) 11C-5

signal input interface, an actuator drive circuit and a microprocessor as core 11C
operating temperature: -40℃ - 105℃.
fpwx11C0001
11C-6 Engine Control System(4W10) - Engine Control Module (ECM)
Replacement
11C Note
3. Remove the ECM.

(a) Turn over the front passenger seat.
(b) Remove 4 fixing bolts of the ECM.
Tool: 10mm sleeve
fpwx11C0002
(c) Open the safety device, and disconnect the

ECM connectors.
Note
fpwx11C0003
(d) Remove the ECM module.

Note
• Make sure to remove the battery negative

removing the ECM.
avoid collisions.
fpwx11C0004
ECM.
of the plug pins.
Engine Control System(4W10) - Engine Control Module (ECM) 11C-7

(a) Connect the ECM connector and fasten the
safety device.
Note 11C
fpwx11C0005
(b) Install 4 fixing bolts of the ECM.

Torque: 10±1N•m
Tool: 10mm sleeve
(10±1N·m)
fpwx11C0006
5. Lay down the front passenger seat, buckle up the fixing buckle, connect the
negative battery cable.
11C-8 Engine Control System(4W10) - Canister solenoid valve

11C
1. When the engine starts in cold, the
solenoid valve installed between the
charcoal canister and the intake manifold
opens, allowing the gasoline vapor in the
charcoal canister to be carried into the
cylinder for combustion by the clean air
under the influence of the vacuum degree
of the intake manifold. This not only
fpwx11C0065
reduces the emissions, but also reduces
fuel consumption.
Engine Control System(4W10) - Canister solenoid valve 11C-9
Onboard Check
3. Connect the diagnostic unit to the troubleshooting connectors (16-pin) on the 11C
of software.
(EVAP) with a hand.
valve action test.
(b) Vacuum method.
Overhaul
11C
fpwx11C0066
(b) Loosen the clamps on the inlet and outlet

hoses of the canister and disconnect the inlet
and outlet hoses from the solenoid valve.
Note
fpwx11C0067 loosened.

fpwx11C0068

2 1
valve
• Impedance: 19 - 22Ω
fpwx11C0069
Engine Control System(4W10) - Canister solenoid valve 11C-11

(a) Install the connecting clamp of the canister
intake and outlet hoses and a solenoid valve.
11C
fpwx11C0070
(b) Engage the canister solenoid valve into a

groove, connect the canister solenoid valve
connector.
fpwx11C0071
seat.
11C
Fuel(LJ465)
Fuel System........................................12A-1
Precautions......................................12A-1
Release the fuel system pressure....12A-2
Drain the Oil Tank.............................12A-3 12A
Fuel Pipe Cleaning...........................12A-4
Table of Fault Symptom....................12A-5
Component Diagrams......................12A-7
Maintenance Data............................12A-8
Oil Tank Assembly..............................12A-9
Replacement....................................12A-9
Air Filter Assembly...........................12A-12
Replacement..................................12A-12
Electric Fuel Oil Pump Assembly....12A-13
Replacement..................................12A-13
Fuel Injector Assembly....................12A-16
Replacement..................................12A-16
Oil Tank Door....................................12A-21
Replacement..................................12A-21
Oil Tank Door Lock...........................12A-23
Replacement..................................12A-23
Oil Tank Cap......................................12A-24
Overhaul.........................................12A-24
Fuel Filling Pipe and Breathing
Pipe....................................................12A-26
Replacement..................................12A-26
Accelerator Pedal.............................12A-30
Replacement..................................12A-30
12A
Fuel(LJ465) - Fuel System 12A-1
Fuel System
Precautions
1. Disconnect the battery negative cable before checking and repairing the fuel
system.
2. Store the discharged fuel with an appropriate container when removing the fuel
line. 12A
3. Since fuel is flammable, do not operate the fuel system until the temperature of
vehicle parts is dropped to ambient temperature, keep cigarettes, fire, lights,
arc equipment and switch away from the work area, and deploy ventilation
equipments in the work area to avoid injury or death.
4. There is high pressure fuel in the pump high-pressure fuel lines and fuel oil rail.
To avoid injury, do not release any fuel pipe joint when the engine is running.
5. Keep the fuel away from the rubber or leather parts.
6. The residual oil pressure of the fuel system will last for a very long time after
flameout. You must first release the fuel pressure before repairing the fuel
system. Failure to follow these tips may result in personal injury.
7. Check around fuel joint before disconnecting the fuel system piping to make
sure there is no dirt or impurities. Otherwise, clear up the dirt or impurities as
they may damage the fuel system or the engine.
8. Do not allow detergent to make contact with the sealing rubber or plastic parts
of the fuel system, as detergent may damage the fuel system.
9. Do not bend or twist the fuel system tubing.
10 . Make sure no pipe joint is damaged before connecting fuel system pipelines.
Replace the pipeline assembly there are damages or cracks to ensure that the
pipeline connecting surface is free of dirt.
12A-2 Fuel(LJ465) - Fuel System
Release the fuel system pressure

2. Lift the main engine cap.
(a) Loosen the fixing buckle of driver seat.
(b) Flip the driver seat, open the main engine
12A
cap.
fpwx12A0001
3. Disconnect the fuel pump fuse in the

battery side fuse box.
fpwx12A0002
4. Start the engine and keep idling until the engine flameout.
5. Re-start the engine for about 5 seconds to confirm that the fuel injection pressure
has been released completely.
6. Turn off the ignition switch and plug the fuel pump fuse.
Drain the Oil Tank

1. Check the fuel level of the fuel gauge.
2. Drain the fuel tank.
(a) Turn off the ignition switch.
(b) Insert a hose, whose diameter is smaller than a filling nozzle, into the filling pipe through
the filling nozzle to draw off the fuel in the filling pipe. 12A
(c) After evacuating fuel in the filling pipe, disconnect the fuel filling pipe from the fuel tank
inlet nozzle.
(d) Insert the hose into the fuel tank through the tank inlet nozzle to draw off fuel.
Fuel Pipe Cleaning

1. Clean the fuel system with a fuel system detergent approved by Fukuda.
2. Clean the fuel system with a fuel additive approved by Fukuda.
12A
Table of Fault Symptom

The following table will help to you find the cause of the fault. The serial number indicates
the possibility sequence for the fault causes. Check every parts according to this sequence,
and replace where necessary.
Fault symptom Suspicious positions Refer to 12A

12A Fuel(LJ465) - Electric Fuel Oil
1. Electric Fuel Pump (damaged)
Pump Assembly, Replacement
12A Fuel(LJ465) - Fuel System,
2. Fuel Pipe (blocked)
Fuel Pipe Cleaning
3. The fuel pressure regulator is
Engine is un- damaged (the fuel pressure is too Replace
able to start. low)
4. Fuel tank (no fuel) Add fuel
5. Fuel Pump Relay (damaged) Replace
12A Fuel(LJ465) - Fuel Injector
6. Fuel injection nozzle (damaged)
Assembly, Replacement
1. Fuel Pipe (blocked) Fuel pipe cleaning
2. The fuel pressure regulator has 12A Fuel(LJ465) - Fuel Injector
failed (the fuel pressure is too low) Assembly, Replacement
3. Fuel injection nozzle (leaking or 12A Fuel(LJ465) - Fuel Injector
blocked) Assembly, Replacement
Engine Start-up
Difficulties 12A Fuel(LJ465) - Electric Fuel Oil
4. Electric fuel pump (poor working)
5. Injection Control System (failure) -
6. At the oil return valve port of a oil
pressure regulator or at the check -
valve of a fuel pump (oil spill)
Poor Engine
2. Fuel injection nozzle (poor atomiza- 12A Fuel(LJ465) - Fuel Injector
Idling
tion, leaking or blocked) Assembly, Replacement
3. Fuel Pipe (blocked) Fuel pipe cleaning
Insufficient en- 2. Fuel injection nozzle (blocked or 12A Fuel(LJ465) - Fuel Injector
gine power poor atomization) Assembly, Replacement
12A Fuel(LJ465) - Electric Fuel Oil
3. Electric fuel pump (poor working)
Fault symptom Suspicious positions Refer to

12A Fuel(LJ465) - Fuel System,
4. Fuel Pipe (blocked)
Precautions
5. Fuel (poor quality) Replacement
12A
Component Diagrams
LJ465 Engine
12
14 12A
15
13 5
6
7
10
11
2 4
9
3
fpwx12A0080
1 Oil tank assembly 9 Oil tank cap assembly

2 Electric fuel oil pump assembly 10 Fuel filling pipe assembly
3 Fuel pump 11 Oil filling breather hose
4 Fuel level sensor 12 Canister assembly
5 Nylon oil delivery pipe assembly 13 Canister bracket
6 Nylon oil return pipe assembly 14 Canister to intake manifold hose
7 Fuel filter assembly 15 Fuel tank to canister hose
8 Nylon oil delivery pipe assembly
Maintenance Data
1. Oil Rail Assembly (see table)
The fuel rail assembly, which is made of fuel rail pressure regulator and injector, is
mounted between the upper and lower body of an intake manifold. The fuel rail
assembly is used to assign fuel to each cylinder. The ECU achieves accurate fueling
12A
by controlling the injector opening time during fuel assignment.
EFI System Delphi (E1)
Graphics
fpwx12A0078

Parameters
System max pressure: 900kPa
2. Electromagnetic injector (see table)

The injector timely and accurately injects the appropriate amount of fuel into the intake
manifold according to gasoline engine ECU signals. ECU controls the fuel injection
amount according to the gasoline engine RPM, coolant temperature, intake air quantity
(intake pressure) and the oxygen content in the exhaust gas.
Graphics
fpwx12A0079
Minimum operating voltage: 6V

Parameters Fuel system pressure: 300kPa
Coil resistance: 12Ω±0.6Ω (maximum)
Set Pulse Width: 2.5ms
Fuel(LJ465) - Oil Tank Assembly 12A-9
Oil Tank Assembly

Replacement
1. Release the fuel system pressure. (See12A Fuel(LJ465) - Fuel System, Release
the fuel system pressure)
2. Drain the fuel tank as required. (See12A Fuel(LJ465) - Fuel System, Drain the
Oil Tank) 12A

4. Lift the vehicle to a proper position.
5. Support the fuel tank with a top pump.
Note
• As the left and right height at the bottom of the fuel tank may be different, please
support the tank with a wood board or similar object.
• The support position should not stick the fuel tank fixing strap.
6. Dismount the fuel tank.

(a) Dismount the fuel tank vent pipe clamp A.
(b) Dismount the fuel tank filler hose clamp B.
A (c) Disconnect the fuel tank breathing pipe and
B the filling pipe.
Note
• When disconnecting the fuel tank filler

hose, check the fuel inlet hose rubber
fpwx12A0003
sleeve for cracks, damage or ageing and
replace as needed.
• Keep joint clean and avoid damage and
foreign material from entering it, cover it
completely with a plastic bag or similar
object.
(d) Dismount the fuel filter inlet pipe clamp A.

(e) Dismount clamp B of the fuel return pipe.
A
(f) Dismount clamp C of the canister vent hose.
(g) Disconnect the fuel filter inlet hose, return
B
pipe and canister vent hose.
C
fpwx12A0004
12A-10 Fuel(LJ465) - Oil Tank Assembly
(h) Support the fuel tank with a top pump.
12A
fpwx12A0005
(i) Dismount 4 fixing bolts of the fuel tank.

Tool: 13mm sleeve
fpwx12A0006
(j) Lower the tank slowly into place.

(k) Disconnect the wiring harness connectors of
the electric fuel pump.
fpwx12A0007
(l) Remove the fuel tank.

(m) Dismount clamp A of the fuel pump outlet
pipe.
A C
(n) Dismount clamp B of the fuel return pipe.
B (o) Dismount clamp C of the canister vent pipe.
(p) Disconnect the fuel pump outlet hose, return
pipe and canister breathing pipe.
fpwx12A0008
7. Install the fuel tank assembly.

Fuel(LJ465) - Oil Tank Assembly 12A-11
(a) Connect the fuel pump outlet pipe and fix

clamp A.
(b) Connect the fuel return pipe and fix clamp B.
A C
(c) Connect the canister vent hose and fix clamp
B C.
12A
fpwx12A0009
(d) Slowly lift the fuel tank to a proper position

with a jack.
(e) Connect the wiring harness connectors of the
electric fuel pump.
fpwx12A0010
(f) Install 4 fixing bolts of the fuel tank.

Tool: 13mm sleeve
Torque: 25±1N•m
(25±1N·m)
fpwx12A0011
(g) Connect the fuel pump inlet pipe and fix clamp
A.
A
(h) Connect the fuel return pipe and fix clamp B.
(i) Connect the canister vent hose and fix clamp
B
C.
C
fpwx12A0012

10 . Check the fuel pipe.
(a) Turn on the ignition switch so that fuel pressure is applied to the fuel line, check the
connections for leaks.
(b) Start the engine and increase the RPM, make sure there is no fuel leak at the fuel pipe
joint.
12A-12 Fuel(LJ465) - Air Filter Assembly
Air Filter Assembly

Replacement
Oil Tank)
12A
3. Remove the fuel filter.
(a) Dismount inlet and outlet pipe clamps on both
sides of the fuel filter.
(b) Disconnect the inlet and outlet pipes.
(c) Dismount 1 fixing bolt of the fuel filter.
Tool: 10mm sleeve
fpwx12A0013
(d) Remove the fuel filter.

Note
• When disconnect the fuel filter inlet and outlet pipes, check the pipe for cracks,
damage or ageing and replace as needed.
• Keep joint clean and avoid damage and foreign material from entering it, cover
it completely with a plastic bag or similar object.
4. Install a new fuel filter.

Note
Install the filter according to the direction of the filter logo arrow.
(a) Install the fuel filter and tighten 1 fixing bolt of

the filter.
Tool: 10mm sleeve
Torque: 5±1N•m
(5±1N·m)
(b) Connect the inlet and outlet pipes of the fuel
filter and tighten fuel pipe clamps.
fpwx12A0014

6. Check the fuel pipe.
joint.
Fuel(LJ465) - Electric Fuel Oil Pump Assembly 12A-13
Electric Fuel Oil Pump Assembly

Replacement
Oil Tank) 12A

5. Remove the fuel tank assembly. (See12A Fuel(LJ465) - Oil Tank Assembly,
Replacement)
6. Dismount the electric fuel pump assembly.
(a) Dismount 7 setscrews of the electric fuel
pump.
fpwx12A0015
(b) Remove the electric fuel pump.

Note
When removing the electric fuel pump assembly,
be careful not to over-bend the crank arm.
fpwx12A0016
7. Dismount and check the gasket.

(a) Please remove the gasket promptly to avoid
being soaked in fuel, which will lead to
distortion.
(b) Check the gasket for cracks, damage or
ageing and replace as needed.
fpwx12A0017
8. Dismount the fuel level sensor.

12A-14 Fuel(LJ465) - Electric Fuel Oil Pump Assembly
(a) Disconnect the sensor harness connector.

(b) Press the snaps on both sides of the sensor,
take them out along the direction of the arrow.
12A
fpwx12A0018
(c) Check the sensor and the float.

Note
Check that copper contact surface is free of
fouling and impurities to ensure good contact
between the two, and the float is not damaged.
fpwx12A0019
9. Install the fuel level sensor.

(a) Install the fuel sensor along the direction of
the arrow until you hear a clicking sound, hard
stretch the sensor to make sure the
connection is secure.
(b) Connect the sensor harness connector.
fpwx12A0020
10 . Install the electric fuel pump assembly.

(a) Mount the gasket on the fuel tank.
fpwx12A0021
Fuel(LJ465) - Electric Fuel Oil Pump Assembly 12A-15
(b) Place the electric fuel pump in the fuel tank.

Note
When positioning the electric fuel pump
assembly position, make sure its mark is aligned
with the mark position on the fuel tank.
12A
fpwx12A0022
(c) Install 7 setscrews of the electric fuel pump.
fpwx12A0023
11 . Install the fuel tank assembly. (See12A Fuel(LJ465) - Oil Tank Assembly,
Replacement)
12 . Check the vehicle after the installation.
(a) Turn on the ignition switch so that fuel pressure is applied to the the fuel line; Check
the connections for leaks and check the fuel gauge on the instrument cluster for fuel
display level.
joint and confirm that the fuel pump is working properly.
12A-16 Fuel(LJ465) - Fuel Injector Assembly
Fuel Injector Assembly

Replacement
1. Discharge the pressure in the fuel system. (See12A Fuel(LJ465) - Fuel System,
Release the fuel system pressure)
12A
3. Dismount the fuel injector assembly.
(a) Disconnect the fuel injection nozzle connector.
fpwx12A0024
(b) Dismount the oil pressure regulator vacuum

tube.
fpwx12A0025
(c) Dismount 2 fixing bolts of the fuel injector

assembly.
Tool: 13mm sleeve
fpwx12A0026
(d) Shake gently, lift upward in the direction of

the arrow and remove the fuel injector
assembly.
fpwx12A0027
Fuel(LJ465) - Fuel Injector Assembly 12A-17
(e) Dismount the inlet and outlet pipe clamps of

the fuel injector assembly and disconnect the
fuel pipe.
12A
fpwx12A0028
(f) Remove the fuel injector assembly.

Note
Confirm that the O-ring between fuel injection
nozzle and the intake manifold is in good
condition.
fpwx12A0029
4. Check the fuel pressure regulator.

(a) Pull out the bayonet lock and dismount the
fuel pressure regulator.
Note
Check the fuel pressure regulator return spring
for proper operation.
fpwx12A0030
5. Dismount the fuel injection nozzle.

(a) Dismount the clamp from the fuel injection
nozzle clamp groove.
(b) Rotate and pull out the fuel injection nozzle.
Note
Confirm that the O-ring between the injection
nozzle and the injector is in good condition.
fpwx12A0031
6. Check the fuel injection nozzle.

(a) Test the resistance between 2 pins of a fuel

injection nozzle with a multimeter.
Standard resistance: 13 - 16 Ω
(b) Check the fuel injection nozzle hole for carbon
deposit or dirt blocking. If blocked, promptly
12A remove it.
fpwx12A0032
(c) Install the fuel injection nozzle, which needs

to be checked, on a pressure test station to
check for leaks.
fpwx12A0033
7. Install the fuel injection nozzle.

(a) Install a new O-ring on each fuel injector.
Note
• O-rings on the upper and lower ends of

the fuel injection nozzle are different, do
not be confused.
• Apply a layer of bearing oil or gasoline
onto each new O-ring. Do not use engine
fpwx12A0034
oil, gear oil, brake fluid oil.
(b) Install the fuel injection nozzle onto the fuel

rail.
Note
Try to pull the fuel injection nozzle outward to
confirm that the clamp locks the fuel injection
nozzle in place.
fpwx12A0035
8. Install the fuel pressure regulator.

Note
Check whether the fuel pressure regulator can rotate smoothly or not, if not, it indicates
that the O-ring may be clamped, then remove the fuel pressure regulator and check
the O-ring for damage, and then insert the pressure regulator into the fuel rail and
check again.
9. Install the fuel injector assembly.
Fuel(LJ465) - Fuel Injector Assembly 12A-19
(a) Install the inlet and outlet pipes of the fuel

injector assembly and fix the clamps.
12A
fpwx12A0036
(b) Align each fuel injection nozzle with the

cylinder upper injection hole and gently press
it to a predetermined position.
fpwx12A0037
(10±1N·m)
(c) Install the fuel injector assembly and tighten
2 fixing bolts.
Tool: 13mm sleeve
Torque: 10±1N•m
fpwx12A0038
(d) Connect the oil pressure regulator vacuum

tube.
fpwx12A0039
(e) Connect the fuel injection nozzle connector.
fpwx12A0040
10 . Connect the battery negative cable.

joint.
12A
Fuel(LJ465) - Oil Tank Door 12A-21
Oil Tank Door

Replacement
1. Dismount the fuel tank flap.
(a) Insert the key into the lock hole of the fuel
tank flap. 12A
(b) Counterclockwise turn the key to open the
tank flap.
fpwx12A0041
(c) Dismount 2 fixing bolts of the tank flap.

(d) Remove the fuel tank flap.
Tool: 10mm sleeve
[Note] premium
above
# and
Use 93 gasoline
d
unleade
fpwx12A0042
2. Remove the fuel tank flap lock.

(a) Remove the mounting bracket of the fuel tank
[Note] flap lock in the direction of the arrow.
Use 93# and above premiu
m
unleaded gasoline
(b) Remove the fuel tank flap lock.
fpwx12A0043
3. Install the fuel tank flap lock.

(a) Install the fuel tank flap lock.
(b) Install the mounting bracket of the fuel tank
flap lock in the direction of the arrow.
fpwx12A0049
4. Install the fuel tank flap.

12A-22 Fuel(LJ465) - Oil Tank Door
(a) Install fuel tank flap and tighten 2 fixing bolts.

Tool: 10mm sleeve
Torque: 9±1N•m
(b) Close the fuel tank flap, turn the key clockwise
(9±1N·m) to lock the tank flap, pull out the key.
12A
fpwx12A0045
5. Adjust the fuel tank flap.

Note
If the fuel tank flap is not tightly closed, adjust
the position of 2 fixing bolts of the fuel tank.
fpwx12A0046
Fuel(LJ465) - Oil Tank Door Lock 12A-23
Oil Tank Door Lock

Replacement
1. Open the fuel tank flap.
tank flap. 12A
tank flap.
fpwx12A0047
2. Remove the fuel tank flap lock.

(a) Remove the mounting bracket of the fuel tank
(b) Remove the fuel tank flap lock.
fpwx12A0048
3. Install the fuel tank flap lock.

(a) Install the fuel tank flap lock.
[Note]
Use 93# and above premiu
m
(b) Install the mounting bracket of the fuel tank
unleaded gasoline
fpwx12A0049
4. Close the fuel tank flap.

(a) Close the fuel tank flap, turn the key
clockwise.
(b) Lock the fuel tank flap and pull out the key.
fpwx12A0050
12A-24 Fuel(LJ465) - Oil Tank Cap
Oil Tank Cap

Overhaul
12A tank flap.
tank flap.
fpwx12A0051
2. Dismount the fuel tank cap.

(a) Counterclockwise unscrew the fuel tank cap.
(b) Remove the retaining clips from the fuel tank
cap grommet.
(c) Remove the fuel tank cap.
fpwx12A0052
3. Check the fuel tank cap.

(a) Check the fuel tank cap holder for deformation
or damage, replace if necessary.
(b) Check the fuel tank cap seal, replace if
necessary.
fpwx12A0053
4. Install the fuel tank cap.

(a) Snap the fuel tank cap clip into the grommet.
(b) Clockwise tighten the fuel tank cap, and make
sure to hear Clicking" sound.
fpwx12A0054

Fuel(LJ465) - Oil Tank Cap 12A-25

clockwise.
12A
fpwx12A0055
12A-26 Fuel(LJ465) - Fuel Filling Pipe and Breathing Pipe
Fuel Filling Pipe and Breathing Pipe

Replacement
Oil Tank)
12A
tank flap.
tank flap.
fpwx12A0056
4. Dismount the fuel tank cap.

(a) Counterclockwise unscrew the fuel tank cap.
(b) Remove the retaining clips from the fuel tank
cap grommet.
(c) Remove the fuel tank cap.
fpwx12A0057
5. Dismount the fuel filling pipe and breathing pipe.

(a) Dismount 2 fixing bolts of the fuel filling pipe.
Tool: 10mm sleeve
Note
When disconnecting the fuel pipe, check the

hose for cracks, damage or ageing and replace
as needed.
fpwx12A0058
Keep joint clean and avoid damage and foreign
material from entering it, cover it completely with
a plastic bag or similar object.
Fuel(LJ465) - Fuel Filling Pipe and Breathing Pipe 12A-27
(b) Dismount the fuel filler hose clamps.

(c) Dismount 1 fixing bolt of the fuel filling pipe.
Tool: 10mm sleeve
(d) Disconnect the fuel tank filler hose.
12A
fpwx12A0059
(e) Dismount the fuel filler hose clamps, and

disconnect fuel hose.
A (f) Dismount the breathing pipe clamps and
B disconnect the breathing pipe.
fpwx12A0060
(g) Loosen the breathing pipe retaining clips.

(h) Remove the fuel filling pipe and the breathing
pipe.
fpwx12A0061
6. Install the breathing pipe and fuel filler pipe.

(a) Install the breathing hose retaining clips.
fpwx12A0062
12A-28 Fuel(LJ465) - Fuel Filling Pipe and Breathing Pipe
(b) Connect the breathing pipe at the fuel tank

and tighten the clamps.
A (c) Connect the fuel filler hose and tighten the
B clamps.
12A
fpwx12A0063
(d) Mount the forepart of the fuel tank filling pipe

in place.
(10±1N·m) (e) Tighten 2 fixing bolts of the filling nozzle.
Tool: 10mm sleeve
Torque: 10±1N•m
fpwx12A0064
(f) Install the fuel filling pipe and tighten 1 bolt.

Tool: 10mm sleeve
(10±1N·m)
Torque: 10±1N•m
(g) Connect the fuel filler hose and fix the clamps.
fpwx12A0065

Fill the fuel tank as needed. Check whether the fuel filling is smooth, and there are no
oil leaks.
8. Install the fuel tank cap.
(a) Snap the fuel tank cap clip into the grommet.
(b) Clockwise tighten the fuel tank cap, and make
sure to hear clicking sound.
fpwx12A0066

Fuel(LJ465) - Fuel Filling Pipe and Breathing Pipe 12A-29

clockwise.
12A
fpwx12A0067
12A-30 Fuel(LJ465) - Accelerator Pedal
Accelerator Pedal
Replacement
12A (a) Loosen the fixing buckle of the front

passenger seat.
(b) Flip the driver seat, open the subsidiary
engine cap.
fpwx12A0068
3. Dismount the throttle cable.

4. Dismount the accelerator pedal assembly.
(a) Dismount two fixing bolts of the accelerator
pedal.
Tool: 12mm sleeve
fpwx12A0069
Fuel(LJ465) - Accelerator Pedal 12A-31
(b) Dismount the throttle cable on the accelerator

pedal assembly.
12A
fpwx12A0070
(c) Remove the accelerator pedal assembly.
fpwx12A0071
5. Check the accelerator pedal

(a) Dismount the circlip.
(b) Check the accelerator pedal fixing pin and the
bracket for abnormal wear.
fpwx12A0072
(c) Move the pedal fixing pin, dismount the inner

circlip, disassemble the accelerator pedal.
(d) Check the accelerator pedal fixing pin and the
bracket for abnormal wear.
(e) Check the tension of the return spring.
12A
fpwx12A0073
6. Install the accelerator pedal.

(a) Assemble the accelerator pedal.
fpwx12A0074
(b) Install the throttle cable on the accelerator

pedal assembly.
fpwx12A0075
Fuel(LJ465) - Accelerator Pedal 12A-33
(c) Install the accelerator pedal in place. Insert

the assembly into the fixing bracket.
(d) Tighten 2 fixing bolts of the accelerator pedal.
Tool: 12mm sleeve
Torque: 10±1N•m
12A
(10±1N·m)
fpwx12A0076
7. Lay down the front passenger seat.

(a) Place the front passenger seat and the engine
cap to their normal positions.
(b) Lock the fixing buckle of the front passenger
seat.
fpwx12A0077

After installation, press the accelerator pedal, check whether the accelerator pedal is
smooth and free of sluggishness.
12A
Fuel(4W10/4W12)
Fuel System........................................12B-1
Component Diagrams......................12B-1
Oil Tank Assembly..............................12B-2
Replacement....................................12B-2
Air Filter Assembly.............................12B-5
12B
Replacement....................................12B-5
Electric Fuel Oil Pump Assembly.....12B-7
Replacement....................................12B-7
Fuel Injector Assembly......................12B-9
Replacement....................................12B-9
12B
Fuel(4W10/4W12) - Fuel System 12B-1
Fuel System
Component Diagrams
12B
8
5
2
6
7
fpwx12b0300
1 Oil tank cap assembly 5 Fuel rail nylon pipe assembly

2 Fuel filling pipe assembly 6 Oil filling hose
3 Hard pipe to canister breather hose 7 Electric fuel oil pump assembly
4 Oil filling breather hose 8 Oil tank assembly
12B-2 Fuel(4W10/4W12) - Oil Tank Assembly
Oil Tank Assembly

Replacement
Oil Tank)
12B
5. Dismount the fuel tank pipe.
(a) Dismount the inlet/outlet pipe clips of the fuel
filter and remove the fuel pipe.
(b) Dismount the fuel tank filling pipe retaining
clamp and break the connection.
Note
• When disconnecting the fuel tank filler

fpwx12b0002
hose, check the fuel inlet hose rubber
sleeve for cracks, damage or ageing and
replace as needed.
object.
(c) Dismount the fuel tank breathing pipe

retaining clamps and break the connection.
(d) Dismount the carbon tube breathing pipe
retaining clamps and disconnect.
6. Support the fuel tank with a top pump.

Note
• As the left and right height at the bottom

of the fuel tank may be different, please
support the tank with a wood board or
similar object. Support position should
not impede the removal of the fuel tank.
fpwx12b0004
• Select the support position in the center
of a fuel tank when using a top pump and
complete protective measures.
Fuel(4W10/4W12) - Oil Tank Assembly 12B-3
7. Dismount 4 fixing bolts of the fuel tank.

Tool: 13mm sleeve
fpwx12b0003 12B
8. Slowly lower the tank to a proper position,

and disconnect the electric fuel pump
wiring harness connectors.
fpwx12b0005
9. Remove the fuel tank assembly.

(a) Dismount fuel pump outlet pipe clips and
disconnect.
(b) Dismount fuel pump return line clips and
disconnect.
(c) Dismount canister breathing pipe clamps and
disconnect.
fpwx12b0006
(d) Remove the fuel tank assembly.
10 . Install the fuel tank assembly.

(a) Connect the fuel pump outlet pipe and fix the
clips.
(b) Connect the fuel pump inlet pipe and fix the
retaining clips.
(c) Connect the canister vent hose and fix the
clamp.
fpwx12b0007
11 . Slowly lift the tank to a proper position

using a top pump, and connect the electric
fuel pump wiring harness connector.
fpwx12b0008
12B-4 Fuel(4W10/4W12) - Oil Tank Assembly
(25±3N·m)
12 . Mount and tighten 4 fixing bolts of the fuel
tank.
Tool: 13mm sleeve
Torque: 25 ± 3N • m
12B fpwx12b0009
13 . Install the fuel tank pipe.

(a) Connect the fuel filter inlet/outlet pipe and fix
the clip.
(b) Connect the fuel tank filling pipe and fix the
clamp.
(c) Connect the fuel tank breathing pipe and fix
the clamp.
fpwx12b0010
(d) Connect the carbon tube breathing pipe and
fix the clamp.
14 . Lower the vehicle.

16 . Check the fuel pipe.
joint.
Fuel(4W10/4W12) - Air Filter Assembly 12B-5
Air Filter Assembly

Replacement
Oil Tank)
3. Remove the fuel filter.
(a) Dismount fuel filter inlet/outlet pipe clamps 12B
and disengage the fuel pipe.
fpwx12b0011
(b) Dismount fuel filter fixing bolts and remove

the fuel filter.
Note
• When disconnect the fuel filter inlet and

outlet pipes, check the pipe for cracks,
damage or ageing and replace as needed.
fpwx12b0012
object.
4. Install a new fuel filter.

Note
Install the filter according to the direction of the filter logo arrow.
(a) Install the fuel filter and tighten 1 fixing bolt of

the filter.
Tool: 10mm sleeve
Torque: 10±1N•m
(10±1N·m)
fpwx12b0014
12B-6 Fuel(4W10/4W12) - Air Filter Assembly
(b) Connect the fuel filter inlet/outlet pipe and fix

clamps.
12B fpwx12b0013

6. Check the fuel pipe.
joint.
Fuel(4W10/4W12) - Electric Fuel Oil Pump Assembly 12B-7
Electric Fuel Oil Pump Assembly

Replacement
Oil Tank)
12B
5. Remove the fuel tank assembly. (See12B Fuel(4W10/4W12) - Oil Tank Assembly,
Replacement)
6. Dismount the electric fuel pump assembly.
(a) Dismount 7 setscrews of the electric fuel
pump.
fpwx12b0015
(b) Remove the electric fuel pump.

Note
When removing the electric fuel pump assembly,
be careful not to over bend the crank arm.
fpwx12b0016
7. Dismount and check the gasket.

(a) Please remove the gasket promptly to avoid
being soaked in fuel, which will lead to
distortion.
(b) Check the gasket for cracks, damage or
ageing and replace as needed.
fpwx12b0026
8. Install the electric fuel pump assembly.

12B-8 Fuel(4W10/4W12) - Electric Fuel Oil Pump Assembly
(a) Mount the gasket on the fuel tank.
12B fpwx12b0017
(b) Place the electric fuel pump in the fuel tank.

Note
When positioning the electric fuel pump
assembly position, make sure its mark is aligned
with the mark position on the fuel tank.
fpwx12b0018
(c) Mount and tighten 7 setscrews of the electric

fuel pump.
fpwx12A0023
9. Install the fuel tank assembly. (See12A Fuel(LJ465) - Oil Tank Assembly,
Replacement)
(a) Turn on the ignition switch so that fuel pressure is applied to the the fuel line; Check
the connections for leaks and check the fuel gauge on the instrument cluster for fuel
display level.
joint and confirm that the fuel pump is working properly.
Fuel(4W10/4W12) - Fuel Injector Assembly 12B-9
Fuel Injector Assembly

Replacement
1. Discharge the pressure in the fuel system. (See12A Fuel(LJ465) - Fuel System,
Release the fuel system pressure)
3. Dismount the fuel injector assembly.
(a) Disconnect the fuel injection nozzle connector. 12B
fpwx12b0020
(b) Dismount 2 fixing bolts of the fuel injection

nozzle rail and disconnect the inlet pipe clip.
Tool: 10mm sleeve
(c) Remove the fuel injector assembly.
Note
Confirm that the O-ring between fuel injection
nozzle and the intake manifold is in good
fpwx12b0021
condition.
4. Dismount the fuel injection nozzle.

(a) Dismount the clamp from the fuel injection
nozzle clamp groove.
(b) Rotate and pull out the fuel injection nozzle.
Note
Confirm that the O-ring between the injection
nozzle and the injector is in good condition.
fpwx12b0022
5. Check the fuel injection nozzle.

12B-10 Fuel(4W10/4W12) - Fuel Injector Assembly
(a) Test the resistance between 2 pins of a fuel

injection nozzle with a multimeter.
Standard resistance: 13 - 16 Ω
(b) Check the fuel injection nozzle hole for carbon
deposit or dirt blocking. If blocked, promptly
remove it.
12B fpwx12b0027
(c) Install the fuel injection nozzle, which needs

to be checked, on a pressure test station to
check for leaks.
fpwx12b0028
6. Install the fuel injection nozzle.

(a) Install a new O-ring on each fuel injector.
Note
• O-rings on the upper and lower ends of

the fuel injection nozzle are different, do
not be confused.
• Apply a layer of bearing oil or gasoline
onto each new O-ring. Do not use engine
fpwx12b0023
oil, gear oil, brake fluid oil.
(b) Install the fuel injection nozzle onto the fuel

rail.
Note
Try to pull the fuel injection nozzle outward to
confirm that the clamp locks the fuel injection
nozzle in place.
fpwx12b0029
7. Install the fuel injector assembly.

Fuel(4W10/4W12) - Fuel Injector Assembly 12B-11
(a) Mount the fuel injector in place.

(b) Tighten 2 fixing bolts of the fuel injection
nozzle rail and connect inlet pipe clips.
Tool: 10mm sleeve
Torque: 10±1N•m
(10±1N·m)
fpwx12b0024 12B
(b) Connect the fuel injection nozzle connector.
fpwx12b0025

joint.
12B-12 Fuel(4W10/4W12) - Fuel Injector Assembly
12B
Emission Control(LJ465)
Oil Tank Cap........................................13A-1
Overhaul...........................................13A-1
Carbon Canister.................................13A-2
Overhaul...........................................13A-2
Canister solenoid valve.....................13A-5
Overhaul...........................................13A-5
Crankcase Bleed Pipe........................13A-8
13A
Overhaul...........................................13A-8
13A
Emission Control(LJ465) - Oil Tank Cap 13A-1
Oil Tank Cap

Overhaul
1. Open the fuel tank flap. (See12A Fuel(LJ465) - Oil Tank Cap, Overhaul)
2. Dismount the fuel tank cap. (See12A Fuel(LJ465) - Oil Tank Cap, Overhaul)
3. Check the fuel tank cap. (See12A Fuel(LJ465) - Oil Tank Cap, Overhaul)
4. Install the fuel tank cap. (See12A Fuel(LJ465) - Oil Tank Cap, Overhaul)
5. Close the fuel tank flap. (See12A Fuel(LJ465) - Oil Tank Cap, Overhaul)
13A
13A-2 Emission Control(LJ465) - Carbon Canister
Carbon Canister
Overhaul
2. Lift the front passenger seat.
(a) Loosen 2 fixed buckles of the front passenger
seat.
(b) Turn up the front passenger seat.
13A
fpwx13a0001
3. Dismount the canister

(a) Loosen the canister outlet clamp and
disconnect the hose connection (connected
to a canister solenoid valve).
Note
fpwx13a0002 loosened.
(b) Loosen the canister inlet port clamp and

disconnect the hose connection (connected
to the fuel tank).
fpwx13a0003
(c) Loosen canister retaining clips and remove

the canister.
fpwx13a0004
4. Check the canister.

Emission Control(LJ465) - Carbon Canister 13A-3
(a) Visual check the appearance of the canister

for cracks or deformation, if damaged, please
replace it with a new one.
(b) Gently blow compressed air into the intake
port (connected to the fuel tank) and feel the
outlet port (connected to the canister solenoid
valve) for air with a hand.
Note
fpwx13a0005
The canister is clogged if there is no air blown

out, replace it with a new one. 13A
5. Install the canister.

(a) Mount the canister to the mounting bracket
and fix the clips.
fpwx13a0014
(b) Connect the canister intake port hose and fix

the clips (connecting the fuel tank).
fpwx13a0015
(c) Connect the canister outlet hose, and fix the

clamp (connecting the canister solenoid
valve).
fpwx13a0016
6. Install the front passenger seat.

13A-4 Emission Control(LJ465) - Carbon Canister
(a) Lay down the front passenger seat.

(b) Fix 2 securing buckles of front passenger
seat.
fpwx13a0023
13A
Emission Control(LJ465) - Canister solenoid valve 13A-5

Overhaul
seat.
13A
fpwx13a0017

(a) Loosen the clamp of canister solenoid valve
connection (connecting to the canister).
Note
fpwx13a0007 loosened.
(b) Disconnect canister solenoid valve connector.
fpwx13a0008
(c) Loosen the clip of canister solenoid valve

connection (connecting to the rear intake
manifold of a throttle body).
fpwx13a0009
13A-6 Emission Control(LJ465) - Canister solenoid valve
(d) Remove the canister solenoid valve.
fpwx13a0010
13A 4. Check the canister solenoid valve.

+ - port (connecting to the intake manifold),
fpwx13a0018

valve
2 1
• Set the digital multimeter in ohm profile,
then connect two pens to the 1st and
the 2nd terminal of the solenoid valve
respectively to measure the resistance
Ω
between the terminals.
+ -
fpwx13a0019 Standard resistance: 19 - 22 Ω
(20℃)
• If the resistance is not as specified,

fpwx13a0011
Emission Control(LJ465) - Canister solenoid valve 13A-7
(b) Mount the canister solenoid valve outlet port

clip (connecting the intake manifold).
fpwx13a0020
(c) Connect the canister solenoid valve 13A

connector.
fpwx13a0021
(d) Connect the clip of canister solenoid valve

intake port (connecting to canister).
fpwx13a0022
6. Install the front passenger seat.

(a) Place the front passenger seat into place.
seat.
fpwx13a0023
13A-8 Emission Control(LJ465) - Crankcase Bleed Pipe
Crankcase Bleed Pipe

Overhaul
seat.
13A
fpwx13a0001
3. Dismount the positive crankcase ventilation valve.

(a) Disconnect the hose connected to the cylinder
head vent valve.
fpwx13a0012
(b) Disconnect 3 clips connected to the three-way

valve.
fpwx13a0013
4. Install the positive crankcase ventilation valve pipe.

(a) Fix 3 clips connected to the three-way valve.
fpwx13a0025
Emission Control(LJ465) - Crankcase Bleed Pipe 13A-9
(b) Connect the hose connected to the cylinder

head vent valve.
fpwx13a0026
5. Install the front passenger seat. 13A
(a) Turn down the front passenger seat.

seat.
fpwx13a0027
13A-10 Emission Control(LJ465) - Crankcase Bleed Pipe
13A
Emission Control(4W10/4W12)
Exhaust Control System....................13B-1
Canister solenoid valve.....................13B-2
Overhaul...........................................13B-2
Crankcase Bleed Pipe........................13B-5
Overhaul...........................................13B-5
EGR System........................................13B-7
Overview..........................................13B-7
Operating Principles.........................13B-8
13B
Exhaust Gas Recirculation Pipe.......13B-9
Overhaul...........................................13B-9
EGR Valve..........................................13B-10
Overhaul.........................................13B-10
13B
Emission Control(4W10/4W12) - Exhaust Control System 13B-1
Exhaust Control System

Component Diagrams
4W10 / 4W12 Engine
3 13B
5
4
5
6
8 9
fpwx13b300
1 Canister assembly 6 Components of hexagon headed

2 A type worm drive hose hoop bolt, spring washer and flat washer
3 Canister to engine breather hose 7 Canister solenoid valve
4 Canister to engine breather hose 8 Canister solenoid valve
5 Canister bracket 9 EGR control valve component
13B-2 Emission Control(4W10/4W12) - Canister solenoid valve

Overhaul
(a) Loosen 2 fixed buckles of the front passenger seat.
3. Remove the intake pipe. (See14B Intake(4W10/4W12) - Air Inlet Pipe, Replacement
)
13B
(a) Remove 1 fixing bolt of carbon tube solenoid
valve.
Tool: 8mm sleeve
fpwx13b0004
(b) Disconnect canister solenoid valve connector.

(c) Loosen the mounting clamp on the intake side
of the carbon tube solenoid valve and
disconnect hose connection.
(d) Loosen the mounting clamp on the outlet side
of the carbon tube solenoid valve and
disconnect hose connection.
fpwx13b0005
(e) Pry up the fixing buckle with a flat screwdriver

and upward pull out the solenoid valve.
Note
loosened.
fpwx13b0006

Emission Control(4W10/4W12) - Canister solenoid valve 13B-3

fpwx13b0007
the solenoid valve should remain 13B

2 1
valve
• Set the digital multimeter in ohm profile,
then connect two pens to the 1st and
the 2nd terminal of the solenoid valve
respectively to measure the resistance
between the terminals.
• If the resistance is not as specified,
fpwx13b0008

(a) Snap the canister solenoid valve bracket into
a groove.
fpwx13b0015
(b) Connect the carbon tube solenoid valve inlet

hose and tighten fixing clamps.
(c) Connect the carbon tube solenoid valve outlet
hose and tighten fixing clamps.
(d) Connect the carbon tube solenoid valve
connector.
fpwx13b0009
13B-4 Emission Control(4W10/4W12) - Canister solenoid valve
(e) Install and tighten 1 fixing bolt of the carbon

tube solenoid valve.
Tool: 8mm sleeve
Torque: 10±1N•m
fpwx13b0010
7. Install intake pipings. (See14B Intake(4W10/4W12) - Air Inlet Pipe, Replacement

)
13B 8. Lay down the front passenger seat, lock the fixing buckle of front passenger
seat.
Emission Control(4W10/4W12) - Crankcase Bleed Pipe 13B-5
Crankcase Bleed Pipe

Overhaul
(a) Loosen the driver seat fixing buckle and flip the driver seat.
(b) Loosen the front passenger fixing buckle and flip the front passenger seat.
3. Dismount the crankcase breathing pipe

above the valve chamber cover.
(a) Dismount the crankcase intake pipe
connected to the valve chamber cover. 13B
(b) Dismount the crankcase outlet pipe connected
to the valve chamber cover.
fpwx13b0011
4. Dismount the crankcase breathing pipe.

(a) Dismount the crankcase escape pipe
connected to the intake manifold.
(b) Dismount the crankcase inlet pipe connected
to the intake manifold.
fpwx13b0012
5. Install the crankcase breathing pipe.

(a) Install the crankcase intake pipe connected
(b) Install the crankcase escape pipe connected
fpwx13b0013
6. Install the crankcase breathing pipe above

the valve chamber cover.
(a) Install the crankcase intake pipe connected
(b) Install the crankcase escape pipe connected
fpwx13b0014
7. Install the front seats.

13B-6 Emission Control(4W10/4W12) - Crankcase Bleed Pipe
(a) Flip the driver seat and fasten the driver seat fixing buckle.
(b) Flip the front passenger seat and fasten the front passenger seat fixing buckle.
13B
Emission Control(4W10/4W12) - EGR System 13B-7
EGR System
Overview
1. EGR system, also known as exhaust gas recirculation system, consists mainly
of the ECU, EGR valve, valve position sensor, temperature sensor, speed sensor,
throttle position sensor, front/rear oxygen sensor, exhaust gas recirculation
piping and other components. Its main function: allow part of the waste gas in
the exhaust pipe to be recycled back to the intake manifold and mix with the
fresh air and then enters the combustion chamber to reduce the combustion
temperature, thus reduce the formation of nitrogen oxides, and ultimately reduce
atmospheric pollution.
2. EGR valve is used to control the opening of the valve by means of ECU signals
13B
in order to control the circulation of the exhaust gas. Valve opening is detected
by the valve position sensor and returned to ECU. Serious blockage of EGR
valve can cause engine emitting black smoke.
3. Whenever traveling 4000 - 5000Km, you should check the exhaust pipe
connecting nut for looseness, the exhaust pipe for cracks and holes and the
pad for damage or signs of erosion.
13B-8 Emission Control(4W10/4W12) - EGR System
By directing a small amount of engine exhaust gas into the intake manifold to dilute the fresh
air, EGR system reduces the combustion pressure and the peak temperature, thereby inhibits
the generation of NOx, CO and other contaminants in the emissions. During engine operation,
the throttle position sensor, speed sensor, water temperature sensor, the front/rear oxygen
sensor timely input instantaneous engine state signal to the ECU; Based on these signals,
ECU determines the instant engine operating condition and controls the opening of the valve
through ECU based on pre-stored data therein; In turn the valve opening is detected and
passed back to ECU through a valve position sensor; The whole working process allows
each operating condition of the engine in an optimum EGR rate (equals the ratio of exhaust
13B gas recirculation quality mE and fresh air quality mA , i.e. mE/mA).
Emission Control(4W10/4W12) - Exhaust Gas Recirculation Pipe 13B-9
Exhaust Gas Recirculation Pipe

Overhaul
1. Dismount 5 fixing bolts of EGR valve
breathing pipe.
Tools: 10mm sleeve, T20 hexagon socket
head
fpwx13b0016
13B
2. Remove the EGR valve breathing pipe.

3. Check the seals and pipes for wear or
damage.
fpwx13b0017
4. Install and tighten 5 fixing bolts of EGR

valve breathing pipe.
head
Torque: 10±1N•m
(10±1N·m)
fpwx13b0018
13B-10 Emission Control(4W10/4W12) - EGR Valve
EGR Valve
Overhaul
1. Dismount the exhaust gas recirculation pipe (see 13B Emission
Control(4W10/4W12) - Exhaust Gas Recirculation Pipe, Overhaul)
2. Dismount the EGR valve.
(a) Disconnect the EGR valve connector.
13B
fpwx13b0019
(b) Dismount 2 fixing bolts of the EGR valve, and

remove the EGR valve.
Tool: 13mm sleeve
fpwx13b0020
3. Clean and inspect the EGR valve

(a) Clean the sealing surface of the EGR valve
with a blade.
(b) Blow off the dirt and debris in the EGR valve
with high-pressure gas.
(c) Check the EGR valve sealing surface for
intactness, the sealing surface must not have
fpwx13b0021
serious defects.
(d) Check the EGR valve gasket for intactness,
replace it with a new one if it is worn or
defective.
4. Install the EGR valve

(a) Place the EGR valve in the correct installation
position, and tighten 2 fixing bolts.
Tool: 13mm sleeve
(23±2N·m)
fpwx13b0023
Emission Control(4W10/4W12) - EGR Valve 13B-11
(b) Connect the EGR valve connector.
fpwx13b0022
5. Install the exhaust gas recirculation pipe (see 13B Emission Control(4W10/4W12)
- Exhaust Gas Recirculation Pipe, Overhaul)
13B
13B-12 Emission Control(4W10/4W12) - EGR Valve
13B
Intake(LJ465)
Air Intake System...............................14A-1
Precautions......................................14A-1
Air Inlet Pipe.......................................14A-4
Replacement....................................14A-4
Air Cleaner Assembly........................14A-5
Replacement....................................14A-5
Intake Manifold...................................14A-7
Component Diagram........................14A-7
Replacement....................................14A-9
14A
14A
Intake(LJ465) - Air Intake System 14A-1
Air Intake System

Precautions
1. Engine intake air must be filtered to prevent dirt and debris from entering the
engine. If the intake pipe is damaged or loose, unfiltered air will accelerate the
engine wear after entering the engine.
2. Inlet pipe connecting port should be solid, reliable and free of leaks or looseness
and so on.
3. The connection between the intake manifold and the bracket should be solid
and reliable. There should be no cracks on the surface and no air leaks at the
interface with the air intake hose.
4. The connection between each gasket and the intake manifold bracket should
be solid and reliable.
14A
14A-2 Intake(LJ465) - Air Intake System
Component Diagrams
1
2
3
11
4
8
10
14A 12
9
13
7 6 5
14
15
fpwx14a0032
1 Components of hexagon headed 9 Pipe joint

bolt and flat washer 10 Components of hexagon headed
2 Air cleaner assembly bolt, spring washer and flat washer
3 A type worm drive hose hoop 11 Bleed pipe
4 Bleed pipe 12 Forepart bleed pipe
5 A type worm drive hose hoop 13 Components of hexagon headed
6 A type steel belt flexible hose clamp bolt, spring washer and flat washer
7 Crankcase waste pipe 14 Components of hexagon headed
8 A type steel belt flexible hose clamp bolt, spring washer and flat washer
15 Pipe joint
Intake(LJ465) - Air Intake System 14A-3


1. Pipeline leaky -
Engine shake
Air intake pressure/temperature sensor -
1. Intake Pipe (blocked) -
Engine Start-up Diffi-
Air intake pressure/temperature sensor -
culties
3. Intake Pipe leaky -
14A
1. Intake Pipe (blocked) -
Poor Engine Idling 2.Air intake pressure/temperature sensor -
3. Intake Pipe leaky -
14A-4 Intake(LJ465) - Air Inlet Pipe
Air Inlet Pipe

Replacement
(a) Loosen the fixing buckle of the front
passenger seat.
(b) Flip and turn over the front passenger seat.
fpwx14a0023
2. Dismount the intake hose clamp.

14A
fpwx14a0001
3. Remove the intake hose.

Note
For vehicle with a long mileage, you should first twist the hose when disconnecting
it, and do not disconnect the hose before making sure it is loosened.
4. Install the intake hose.
(a) Install the inlet hose to the correct position.
(b) Install the intake hose clamp.
fpwx14a0002
seat.
Intake(LJ465) - Air Cleaner Assembly 14A-5
Air Cleaner Assembly

Replacement
passenger seat.
fpwx14a0024
14A
2. Dismount the air filter upper cap.
(a) Dismount the clamp of the air filter and intake
hose.
(b) Disconnect the intake hose.
(c) Dismount 2 setscrews of the air filter upper
cap.
fpwx14a0003
3. Remove the air filter upper cap and take out the air filter element.
Note
As the air filter is made of paper materials, you can clean it with a high-pressure air
gun from inside to outside if necessary. Do not clean the air filter with water.
4. Dismount 2 fixing bolts of the air cleaner

assembly.
Tool: 10mm sleeve
fpwx14a0004
5. Remove the air cleaner assembly.

14A-6 Intake(LJ465) - Air Cleaner Assembly
6. Install 2 fixing bolts of the air filter

assembly.
Tool: 10mm sleeve
Torque: 5±1N•m
(5±1N·m)
fpwx14a0005
7. Install the air filter element.

8. Install the air filter upper cap.
(a) Place the air cleaner upper cover in the
14A correct position, connect the inlet hose and
the air cleaner upper cover.
(b) Mount 2 setscrews of the air filter upper cap.
(c) Install the clamp of the intake hose and the
air cleaner upper cover.
fpwx14a0006
seat.
Intake(LJ465) - Intake Manifold 14A-7
Intake Manifold
Component Diagram
1 2 3 4 5 6 7 8 9 10 11 12
40
13
39
38
37
14
36
14A
35 15
34 16
33 12
17
18
21
14
19
20
18
32 31 29 30 28 26 27 26 23 25 24 22
fpwx14a0031
1 Vacuum connecting pipe 21 PCV valve breathing pipe

2 Hexagon headed bolt assembly 22 Intake manifold assembly
3 Shouldered tap bolt of intake 23 Canister control valve bracket
manifold 24 Fasten the cylinder head cover with
4 Fuel distribution assembly shoulder bolts
5 I type hexagon nut 25 Canister solenoid valve
6 spring washer 26 Backwater rubber hose clamp
7 Exhaust manifold stud 27 Canister control valve breathing pipe
8 Hook 28 Throttle body gasket
9 Hexagon headed bolt assembly 29 Hexagon headed bolt assembly
10 Thermostat cover 30 Throttle body assembly
11 Thermostat cover gasket 31 Intake manifold pipe bracket
12 Clamp II 32 Hexagon headed bolt assembly
13 Crankcase breathing pipe I 33 Hexagon headed bolt assembly
14 Throttle body clamp 34 PCV valve
15 Coolant temperature sensor 35 Hexagonal flange face nut
16 Throttle body outlet pipe 36 Intake manifold stud
17 Three way pipe 37 Hexagonal flange face bolt - extra
18 Clamp I size range
19 Fasten the cylinder head cover with 38 Short support sheet
shoulder bolts 39 Intake Pressure/Temperature
20 Long support sheet Sensor
14A-8 Intake(LJ465) - Intake Manifold
40 Intake manifold gasket
14A
Replacement
1. Disconnect the battery negative cable. (See 20A Starting and Charging(LJ465)
- Battery, Replacement)
passenger seat.
fpwx14a0025
14A
3. Dismount the intake hose clamp.
fpwx14a0007

Note
For vehicle with a long mileage, you should first twist the hose when disconnecting
it, and do not disconnect the hose before making sure it is loosened.
5. Disconnect the idle motor connector, the

throttle position sensor connector.
fpwx14a0008
6. Remove 4 fixing bolts of the throttle.

Tool: 10mm sleeve
fpwx14a0026
7. Loosen the throttle cable adjustment nut

so that the throttle cable is relaxed.
Tool: 10mm wrench
14A
fpwx14a0009
8. Dismount 3 setscrews of the throttle cable

bracket.
fpwx14a0010
9. Dismount the throttle cable head column and remove the throttle cable and the
bracket.
10 . Disassemble 1 fixing bolt of the canister
solenoid valve.
Tool: 10mm sleeve
fpwx14a0011
11 . Dismount the clip, disconnect the vacuum

hose canister solenoid valve.
fpwx14a0012
12 . Dismount the clamp, disconnect the

vacuum booster pump hose and the
vacuum hose.
14A
fpwx14a0013
13 . Dismount the generator. (See 20A Starting and Charging(LJ465) - Engine,

Overhaul)
14 . Drain the coolant. (See 17A Cooling(LJ465) - Coolant, Replacement)
15 . Dismount the water temperature sensor.
(a) Disconnect the water temperature sensor
connector.
(b) Dismount the water temperature sensor.
Tool: 19mm wrench
fpwx14a0014
16 . Remove the thermostat. (See 17A Cooling(LJ465) - Thermostat, Overhaul)

17 . Dismount the fuel injector assembly. (See 12A Fuel(LJ465) - Fuel Injector
Assembly, Replacement)
18 . Remove the air intake manifold.
(a) Dismount 2 fixing bolts and 5 retaining nuts

of the intake manifold.
(b) Remove 1 fixing bolt of the dipstick.
(c) Dismount 1 fixing bolt on the lower part of the
intake manifold.
(d) Remove the intake manifold.
Tools: 12mm sleeve, 13mm sleeve
fpwx14a0028
14A
19 . Install the air intake manifold.
(a) Place the intake manifold in the correct
position.
(10±1N·m) (b) Install 1 fixing bolt on the lower part of the
intake manifold.
(c) Install 1 fixing bolt of the dipstick.
(d) Install 2 fixing bolts and 5 retaining nuts of the
intake manifold.
Tools: 12mm sleeve, 13mm sleeve
Torque: 10±1N•m
Note
Note the installation difference between bolts

fpwx14a0029
and nuts during installation and removal.
20 . Install the fuel injector assembly. (See 12A Fuel(LJ465) - Fuel Injector Assembly,
Replacement)
21 . Install the thermostat. (See 17A Cooling(LJ465) - Thermostat, Overhaul)
22 . Install the water temperature sensor.
(a) Install the water temperature sensor.
(b) Connect the water temperature sensor
connector.
(24±2N·m)
Tool: 19mm wrench
fpwx14a0015
23 . Connect the vacuum booster pump hose

and the vacuum hose and mount the
clamp.
fpwx14a0016
24 . Connect the solenoid valve vacuum

canister hose and mount the clamp.
14A
fpwx14a0017
25 . Place the canister solenoid valve in the

correct position and mount fixing bolts.
(5±1N·m)
Tool: 10mm sleeve
Torque: 5±1N•m
fpwx14a0018
26 . Install the throttle cable.

(a) Install the throttle cable head column.
(b) Mount 3 setscrews of the throttle cable
bracket.
fpwx14a0019
(c) Adjust the tightness of the throttle cable and

(5±1N·m)
the nut to conform free travel requirements
on the accelerator pedal.
Tool: 10mm wrench
Torque: 5±1N•m
Check the free travel of the accelerator pedal.
fpwx14a0020
27 . Install 4 fixing bolts of the throttle.

Tool: 12mm sleeve
Torque: 10±1N•m
14A
(10±1N·m)
fpwx14a0027
28 . Connect the idle motor connector, the

throttle position sensor connector.
fpwx14a0021
29 . Connect the inlet hose and install clamps.
fpwx14a0022
30 . Turn down the front passenger seat, lock the fixing buckle of front passenger
seat.
31 . Install the battery negative cable.
32 . Fill the coolant to the required level. (See17A Cooling(LJ465) - Coolant,
Replacement)
Intake(4W10/4W12)
Air Intake System...............................14B-1
Precautions......................................14B-1
Air Inlet Pipe.......................................14B-3
Replacement....................................14B-3
Air Cleaner Assembly........................14B-6
Replace............................................14B-6
Intake Manifold...................................14B-9
Replacement..................................14B-10
14B
14B
Intake(4W10/4W12) - Air Intake System 14B-1
Air Intake System

Precautions
1. Engine intake air must be filtered to prevent dirt and debris from entering the
engine. If the intake pipe is damaged or loose, unfiltered air will enter the engine
and accelerate the engine wear.
2. Inlet pipe connecting port should be solid, reliable and free of light leaks or
looseness and so on.
3. The connection between the intake manifold and the bracket should be solid
and reliable. There should be no cracks on the surface and no air leaks at the
interface with the air intake hose.
4. The connection between each gasket and the intake manifold bracket should
be solid and reliable.
5. When cleaning with solvents, acid or alkaline materials, you should follow the
manufacturer's recommendations.Wear goggles and protective clothing to avoid
personal injury. 14B
6. When handling corrosive work, you should use skin and eye protection devices
to reduce the possibility of personal injury.
7. When using compressed air, you should wear suitable protective goggles and
mask. Flying debris and dirt can cause personal injury.
14B-2 Intake(4W10/4W12) - Air Intake System
Component Diagrams
5 6
8
9
10
2 11
1 7
3
14B 2
fpwx14b0301
1 Forepart bleed pipe 7 A type worm drive hose hoop

2 Components of hexagon headed 8 Air inlet bellows assembly
bolt, spring washer and flat washer 9 A type steel belt flexible hose clamp
3 Pipe joint 1
4 Bleed pipe 10 Crankcase waste pipe
5 Components of hexagon headed 11 A type steel belt flexible hose clamp
bolt and flat washer
6 Air cleaner assembly
Intake(4W10/4W12) - Air Inlet Pipe 14B-3
Air Inlet Pipe

Replacement
(a) Loosen the fixing buckle of the front passenger seat.
2. Dismount the inlet pipe between the engine compartment air filter and the throttle.
Take 4W12 engine as an example
(a) Dismount fixing clamps on the side of the air
filter element.
(b) Disconnect the intake air temperature sensor
connector.
fpwx14B0001
14B

(a) Dismount fixing clamps on the side of the
throttle.
(b) Dismount fixing clamps on the side of the air
filter element.
(c) Remove the fixing clamp of the crankcase
ventilation pipe.
fpwx14B0050
3. Dismount the inlet pipeline on the side of

the throttle.
(a) Dismount fixing clamps on the side of the
throttle.
(b) Remove the fixing clamp of the crankcase
ventilation pipe.
fpwx14B0002

Note
loosened.
fpwx14B0003
14B-4 Intake(4W10/4W12) - Air Inlet Pipe
5. Dismount the bleed pipe.

(a) Dismount 1 fixing bolt on the upper part of the
bleed pipe.
Tool: 10mm sleeve
fpwx14B0004
(b) Dismount 1 fixing bolt on the lower part of the

bleed pipe and remove the bleed pipe.
Tool: 10mm sleeve
14B
fpwx14B0005
6. Install a bleed pipe.

(a) Install the bleed pipe to the correct position
and tighten 1 fixing bolt on the lower part.
Tool: 10mm sleeve
Torque: 9±1N•m
(9±1N·m)
fpwx14B0006
(b) Install and tighten 1 fixing bolt on the upper

part of the bleed pipe.
Torque: 9±1N•m
fpwx14B0007
Intake(4W10/4W12) - Air Inlet Pipe 14B-5
7. Install the inlet pipeline on the side of the

throttle.
(a) Install the inlet hose to the correct position.
(b) Install the intake hose clamp.
fpwx14B0008
8. Install the inlet pipeline on the side of the engine compartment air filter.
(a) Install the intake hose fixing clamp on the side
of the air filter.
(b) Install the intake air temperature sensor
connector. 14B
fpwx14B0009

(a) Install fixing clamps on the side of the throttle.
(b) Install fixing clamps on the side of the air filter.
(c) Install the fixing clamp of crankcase ventilation
pipe.
fpwx14B0051
seat.
10 . Check the connection of each component for tightness and damage after
installation to avoid air leakage which may affect the proper working of the
engine.
14B-6 Intake(4W10/4W12) - Air Cleaner Assembly

Replace
(a) Loosen the fixing buckle of the front passenger seat.
2. Dismount the air filter upper cap.

(a) Loosen the clamp of intake hose and air
cleaner upper cover.
(b) Disconnect the intake hose.
(c) Dismount 2 setscrews of the air filter upper
cap.
fpwx14B0010
14B
fpwx14B0011
3. Remove the air filter upper cap and take out the air filter element.
Note
As the air filter is made of paper materials, you can clean it with a high-pressure air
gun from inside to outside if necessary. Do not clean the air filter with water.
4. Dismount the air filter base.

(a) Dismount 2 fixing bolts of the air cleaner
assembly.
Tool: 10mm sleeve
fpwx14B0012
Intake(4W10/4W12) - Air Cleaner Assembly 14B-7
(b) Dismount 1 fixing bolt of the air cleaner

breathing pipe.
Tool: 10mm sleeve
(c) Remove the air cleaner base.
fpwx14B0013
5. Install the air filter base.

(a) Install the air filter base to the correct position
and tighten 1 bleed pipe fixing bolt.
Tool: 10mm sleeve
(10±1N·m)
Torque: 10±1N•m
14B
fpwx14B0014
(b) Install fixing bolts on the lower part of an air

filter assembly.
Tool: 10mm sleeve
Torque: 10±1N•m
(10±1N·m) fpwx14B0015
fpwx14B0016
6. Install the air filter.

14B-8 Intake(4W10/4W12) - Air Cleaner Assembly
7. Install the air filter upper cap.

(a) Place the air cleaner upper cover in the
correct position, connect the inlet hose and
the air cleaner upper cover.
(b) Mount 2 setscrews of the air filter upper cap.
(c) Tighten the clamp of air intake hose and air
cleaner upper cover.
fpwx14B0017
seat.
14B
Intake(4W10/4W12) - Intake Manifold 14B-9
Intake Manifold
Component Diagrams
7
6
8
10
4
9
10 14B
3
12 11
2
10
1 12
fpwx14b300
1 Hexagonal flange face bolt 7 EGR pipe connecting gasket

2 Mounting bracket of canister 8 Stud
solenoid valve 9 Hexagonal flange face bolt
3 Throttle body component 10 Hexagonal flange face bolt - extra
4 Throttle valve body cable bracket 1 size range
5 Intake manifold component 11 Intake manifold pipe bracket
6 Hexagonal flange face nut 12 Hexagonal flange face bolt
14B-10 Intake(4W10/4W12) - Intake Manifold
Replacement
1. Drain the coolant. (See17B Cooling(4W10/4W12) - Coolant, Replacement)
2. Flip the driver/front passenger seat.
(a) Loosen the driver seat fixing buckle and flip the seat.
(b) Loosen the fixing buckle of front passenger seat and flip the seat.
4. Dismount the engine compartment intake pipeline. (See14B Intake(4W10/4W12)
- Air Inlet Pipe, Replacement)
5. Dismount 2 throttle connectors.
(a) Dismount the throttle position sensor
connector.
(b) Dismount the idle control valve connector.
14B
fpwx14B0018
6. Remove 4 fixing bolts of the throttle.

Tool: 8mm sleeve
fpwx14B0019
7. Loosen the throttle cable adjustment nut

so that the throttle cable is relaxed.
Tool: 13mm wrench
fpwx14B0020
8. Dismount 2 clamps of the throttle heating

pipes and disconnect the hose.
fpwx14B0021
9. Dismount the brake booster vacuum

retaining clamps and break the 14B
connection.
10 . Dismount crankcase ventilation pipe
retaining clamps and break the
connection.
fpwx14B0022
11 . Dismount the mounting clamp on the

intake pipe side of the carbon tube
solenoid valve and disconnect the intake
pipe.
12 . Disconnect the intake air pressure sensor
connector.
fpwx14B0023
13 . Dismount 5 fixing bolts of the EGR valve

breathing pipe and remove the breathing
pipe.
head
Note
Dismount the rear sealing pipeline joints and
fpwx14B0024
check seals.
14 . Dismount 2 crankcase ventilation tube

clamps above the valve chamber cover
and break the connection.
fpwx14B0025
15 . Disconnect 4 connectors of the fuel injection nozzle.

14B
fpwx14B0026
fpwx14B0046
16 . Dismount fixing bolts of the fuel injection nozzle rail and disconnect the inlet
pipe clip.
fpwx14B0027
fpwx14B0047
17 . Disconnect the variable gas passage

solenoid valve connector.
14B
fpwx14B0028
18 . Remove the air intake manifold.

(a) Dismount 2 fixing bolts of the mounting
bracket on the lower part of the intake
manifold.
Tool: 13mm sleeve
fpwx14B0029
(b) Dismount 8 fixing bolts and 2 retaining nuts

on the upper part of the intake manifold.
Tool: 10mm sleeve
fpwx14B0030
(c) Remove the intake manifold gasket.

Note
Always replace the intake manifold gasket after
removing the intake manifold.
fpwx14B0031
19 . Install the air intake manifold.

(a) Mount a new intake manifold gasket.
(b) Install 8 intake manifold fixing bolts and 2
retaining nuts.
(10±2N·m)
Tool: 10mm sleeve
14B
fpwx14B0032
(c) Install 2 fixing bolts of the mounting bracket

on the lower part of the intake manifold.
Tool: 13mm sleeve
(10±2N·m)
fpwx14B0033
20 . Connect the variable gas passage solenoid

valve connector.
fpwx14B0034
21 . Install 2 fixing bolts of the fuel injection nozzle rail, connect the inlet pipe
connector and fix the clip

Tool: 10mm sleeve
Torque: 13±1N•m
(13±1N·m)
fpwx14B0035
(13±1N·m)
Tool: 10mm sleeve
Torque: 13±1N•m
14B
fpwx14B0048
22 . Connect 4 connectors of the fuel injection nozzle.

fpwx14B0036
fpwx14B0049
23 . Connect the crankcase ventilation pipe

above the valve chamber cover and the
fasten the clamp.
fpwx14B0037
24 . Connect EGR valve breathing pipe and

tighten 5 fixing bolts.
head
Torque: 10±1N•m
14B
(10±1N·m)
fpwx14B0038
25 . Connect the carbon tube solenoid valve

inlet pipe and tighten fixing clamps.
26 . Connect the intake pressure sensor
connector.
fpwx14B0039
27 . Connect the brake booster vacuum tube

and tighten clamps.
28 . Connect the crankcase ventilation pipe
and tighten clamps.
fpwx14B0040
29 . Connect the throttle heating pipe and

tighten 2 clamps.
fpwx14B0042
30 . Tighten the throttle cable adjustment nut.

Tool: 13mm wrench 14B
Torque: 9±1N•m
(9±1N·m)
fpwx14B0043
31 . Install and tighten 4 bolts of the throttle.

Tool: 8mm sleeve
Torque: 9±1N•m
(9±1N·m)
fpwx14B0044
32 . Connect 2 connectors of the throttle.

(a) Dismount the throttle position sensor
connector.
(b) Dismount the idle control valve connector.
fpwx14B0045
33 . Connect the engine compartment inlet pipeline. (See14B Intake(4W10/4W12) -

Air Inlet Pipe, Replacement)
35 . Turn down the driver/front passenger seat.
(a) Turn down the driver seat and fix 2 fixing buckle.
(b) Turn down the front passenger seat and fix 2 fixing buckles.
36 . Fill the coolant to the required level. (See17B Cooling(4W10/4W12) - Coolant,
Replacement
14B
Engine Mechanism System(LJ465)
Engine Mechanism.............................15A-1
Precautions......................................15A-1
Engine assembly................................15A-5
Replacement....................................15A-5
Timing Belt Front Cover...................15A-16
Replacement..................................15A-16
Timing Belt........................................15A-18
Component Diagrams....................15A-18
Overhaul.........................................15A-19
Rocker, rocker shaft and camshaft..15A-25
Overhaul of rocker, rocker shaft.....15A-26
Camshaft Overhaul........................15A-31
Cylinder Head and Valve..................15A-34
15A
Cylinder Head Overhaul.................15A-35
Valve Overhaul...............................15A-38
Piston and Connecting Rod
Assembly..........................................15A-42
Overhaul.........................................15A-43
Crankshaft, Cylinder Block &
Flywheel............................................15A-51
Overhaul.........................................15A-52
15A
Engine Mechanism System(LJ465) - Engine Mechanism 15A-1
Engine Mechanism
Precautions
1. Read this manual carefully before any maintenance operation to avoid
unnecessary losses due to improper operation.
2. Operate in accordance with the steps described in this manual during
maintenance operations to avoid technical errors in order to realize safe operation
and ensure efficiency.
3. If necessary, a fire extinguisher must be placed at a predetermined position
before maintenance operation so that it can be used in time when needed.
4. If necessary, staff should wear safety shoes, gloves and goggles before
maintenance operation to ensure personal safety.
5. Make sure that appropriate protective measures have been taken for the vehicle
before performing maintenance operation, such as putting protective cover on
the seat, steering wheel, floor, engine compartment etc.
6. Before lifting a vehicle, check that the lift is working well, the parking location
is suitable, the lift arm is appropriately adjusted to the vehicle lift point. Make
sure no one and irrelevant items are underneath the vehicle during lifting or 15A
dropping process.
7. Handle in accordance with procedure during operations that require oil-cut,
power-cut, pressure relief, e.g. when dismounting fuel rail you need oil-cut and
pressure relief, when dismounting electrical components you need to disconnect
the negative battery cable, otherwise it may easily lead to vehicle damage and
threat personal safety.
8. Protective measures should be taken to prevent external contaminants or dust
from entering pipeline and fittings after disconnecting them.
9. When repairing engine interior, be sure to operate in accordance with the
prescribed steps and gently handle brittle, breakable and vulnerable components.
10 . Bolts and nuts must be tightened in accordance with the provisions on moment,
order, direction or angle and other specifications to avoid excessive force.
11 . Components must be thoroughly cleaned and lubricated before installation
during engine overhaul, such as maintenance of crankshaft, pistons, cylinder
heads, etc.
12 . During engine maintenance, used sealant must be cleaned before installing an
oil pan to ensure that the sealing joint surface is smooth, install a new gasket
and apply the right amount of sealant.
13 . Check the polarity of battery grounding, this gasoline engine adopts negative
grounding.
14 . Do not adjust the throttle position screw, otherwise the throttle angle will be
changed when close, so that the engine does not work.
15 . Disconnection of spark plug cable is prohibited during engine operation. Engine
misfiring will cause unburned mixture entering the three-way catalytic converter
thus leading to ablation. Remove the three-way catalytic converter if necessary.
16 . You must use engine oil of prescribed grade and viscosity. Otherwise engine
wear will be increased.
17 . Do not use non-genuine engine parts, rather you should use original authentic
parts, otherwise it will result in engine damage or engine fault.
15A-2 Engine Mechanism System(LJ465) - Engine Mechanism
18 . A new engine must have a running-in in accordance with the regulations. Sudden
acceleration or high load operation is not allowed during running-in period.
19 . Do not shutdown the engine immediately when it is working, especially with
high-speed or under high load, rather you should stop it after running it at low
speed for 3 - 5 minutes, so that the engine is evenly cooled.
20 . Sealant is used in many parts of the engine. Sealant is used to fully fulfill sealing
purpose, therefore special attentions must be paid to applying amount, applying
location and the state of applied surface. Apply too little can lead to leaks, apply
too much can lead to sealant spills which may result in water or oil passage
blockage or passage narrowing.Therefore, sealant should be applied according
to specifications.
21 . In some cases it is necessary to tap the parts in order to damage the sealant on
the bonding surface with a mallet, rubber mallet or similar tool or gently drive
into the bonding surface with a smooth and thin sealant spatula, but be careful
not to damage the bonding surface.
22 . Remove the debris on the sealing surface with a sealant scraper or a wire brush.
Confirm that the sealing surface is flat and smooth, free of oil and foreign matters.
15A Do not forget to remove the sealant in mounting holes and threaded holes.
23 . Apply sealant evenly on a specified diameter and fence the mounting holes. Do
not remove sealant that is not hardened. Mount it at a predetermined position
when the sealant is wet (within 15 minutes). Be careful not to apply the sealant
to unwanted positions. Wait for the sealant to be fully hardened after installation
(1 hour or so). Do not apply oil on the applied part or dampen it or start the
engine within this period of time.
Engine Mechanism System(LJ465) - Engine Mechanism 15A-3

Fault symptom Possible cause Maintenance recommendation
The battery voltage is too low Check the battery, replace if necessary
Battery cable is loose, corroded Clean the battery and tighten connec-
tions
Starter fault Check the starter, replace if necessary
Ignition coil fault Check the ignition coil, replace if neces-
sary
Spark plug cable fault Check the spark plug cable, replace the
spark plug cable if necessary
The engine can Spark plug jump-spark gap is too Replace the spark plug
not be started large
Fuel filter clogged, excessive Clean the fuel system and replace the
impurities in fuel system fuel filter
15A
Fuel pump fault Check the fuel pump and replace it if
necessary
Timing belt jumping chain Reinstall or replace the timing toothed
belt
Other related electrical compo- Check the related electrical components
nents are not working correctly and replace if necessary
Air cleaner is blocked Replace the air cleaner and clean the
air cleaner housing
Idle speed stepper motor gets Clean the idle stepper motor and the
stuck throttle
Intake manifold leaks Check the intake manifold, the intake
Engine idling is
manifold gasket and the crankshaft
not stable
ventilation hose
Ignition coil fault Check related harness and replace the
ignition coil if necessary
Spark plug jump-spark pole gap Replace the spark plug
is too large
Insufficient en- impurities in fuel system fuel filter
gine power
Incorrect valve timing Reinstall the timing toothed belt and
adjust the timing
Cylinder lining leakage Replace cylinder gasket
15A-4 Engine Mechanism System(LJ465) - Engine Mechanism

Cylinder pressure is too low Measure cylinder pressure, repair if
necessary
Throttle valve is not airtight. Check the valves and valve seats, re-
place if necessary
Three-way catalytic converter Replace with quality fuel, replace catalyt-
clogged ic converters
Spark plug cable resistance is Check spark plug cable resistance, re-
too large place if necessary
sary
Poor atomization of fuel injector Replace the fuel filter, cleaning the fuel
injector, replace if necessary
Obstructed exhaustion of ex- Check exhaust system
15A
haust system
Inadequate intake by intake Check air inlet system
system
Ignition timing deviation Check knock sensor and other related
components
Engine Mechanism System(LJ465) - Engine assembly 15A-5
Engine assembly
Replacement
Note
• Before removing the engine assembly, drain all engine fluids, and disconnect
the harness, pipe connector and other connections between the engine and the
body.
• Before disconnecting all harnesses and pipes, mark them properly to prevent
mismatching or missing harness and pipes during installation.
• Once a fitting is disconnected, seal up the opening to prevent foreign objects
from entering.
• All drained fluids must be collected and handled as required. Keep the site clean
and neat.
15A
3. Drain the coolant. (See 17A Cooling(LJ465) - Coolant, Replacement)
4. Drain engine oil. (See 18A Lubrication System(LJ465) - Engine Oil, Replacement)
5. Drain transmission oil. (See Chapter 41A Transmission - Transmission Assembly,
Replacement )
7. Lift the driver seat.
8. Disconnect the battery negative cable. (See20A Starting and Charging(LJ465) -
Battery, Replacement)
10 . Disconnect the engine control unit
connector.
fpwx15a0002
11 . Dismount the air intake piping. (See14A Intake(LJ465) - Air Inlet Pipe,
Replacement )
15A-6 Engine Mechanism System(LJ465) - Engine assembly
12 . Dismount 1 ground point fixing bolt next

to the battery.
Tool: 10mm sleeve
fpwx15a0003
13 . Disconnect 2 harness connectors next to

the battery.
15A fpwx15a0004
14 . Dismount brake booster vacuum tube

clamps.
Note
Be sure to seal the vacuum tube after
disconnecting it to prevent dust and debris from
entering the tube, thus leading to brake failure.
fpwx15a0005
15 . Dismount canister solenoid valve intake

pipe clamps.
fpwx15a0006
16 . Dismount 1 nut at the generator output

terminal line.
Tool: 10mm sleeve
fpwx15a0007
17 . Dismount the throttle cable fixing nut.

Tool: 13mm wrench
fpwx15a0008
18 . Dismount inlet/outlet pipe fixing clamps

of the fuel injection nozzle.
Note
• Discharge pressure when dismounting the

oil pipe.
• Seal the oil pipe connector after
dismounting the pipe to prevent foreign
fpwx15a0009
matter from entering. 15A
19 . Dismount engine cooling pipe.

(a) Dismount thermostat overflow pipe clamps.
fpwx15a0010
(b) Dismount lower water pipe fixing clamps.
fpwx15a0011
(c) Dismount upper water pipe fixing clamps.

Note
Block the engine cooling water pipe with a piece
of clean service cloth to prevent dust from
entering.
fpwx15a0012
20 . Dismount the starter (see 20A Starting and Charging(LJ465) - Starter, Overhaul).
21 . Dismount vehicle speed sensor
connectors.
15A
fpwx15a0015
22 . Remove the reverse gear switch.
fpwx15a0016
23 . Dismount 1 gearbox grounding line bolt

and disconnect the grounding line.
Tool: 13mm sleeve
fpwx15a0017
24 . Dismount the oxygen sensor connector.
fpwx15a0018
25 . Dismount the clutch cable fixing nut.

Tool: 10mm sleeve
fpwx15a0019 15A
26 . Dismount the transmission shift cable

locking pin.
fpwx15a0020
27 . Dismount retaining clips on the

transmission shift cable bracket.
fpwx15a0021
28 . Dismount the exhaust pipe. (See 16A Exhaust(LJ465) - Exhaust Pipe,

Replacement)
29 . Dismount the drive shaft. (See Chapter 34 Bridge and Drive Shaft - Drive Shaft
Assembly, Overhaul)
30 . Dismount the gearbox rear bracket nut.

Tool: 16mm sleeve
(a) Loosen the nut between the transmission rear
suspension and the frame.
(b) Adjust the jack height, pull out the bolt,
separate the transmission rear mounting
bracket.
fpwx15a0024
Note
Lower the vehicle to an appropriate height, hold
the bottom of the engine subframe and the
transmission with a hydraulic lifting device to
ensure safety and smoothness.
31 . Dismount the engine mounting bracket

assembly on both sides of the engine.
Tool: 16mm sleeve
15A
fpwx15a0025
32 . Slowly lower the engine and transmission assembly to completely separate them
from the frame.
Note
• Check whether the engine and gearbox are completely separated from the
vacuum hose, fuel and coolant hoses and electrical wires.
• Slowly lower the engine to an appropriate location, check again that all hoses
and electrical wires have been disconnected from the engine/gearbox.
33 . Separate the engine from the transmission assembly. (See Chapter 41A
Transmission - Transmission Assembly, Replacement )
34 . Install the engine and the transmission assembly. (See Chapter 41A
35 . Correctly position the engine and transmission assembly on the hydraulic lifting
device in an appropriate location underneath the vehicle.
36 . Lift the hydraulic lifting device until the lower engine mounting bracket and the
frame are properly engaged and the transmission rear suspension is in place.
37 . Install the lower bracket on both sides of
the engine and tighten the bolts.
Torque: 70±5N•m
(70±5N·m)
15A
fpwx15a0026
38 . Install the gearbox rear bracket and tighten

nuts.
Tool: 16mm sleeve
(70±5N·m)
Torque: 70±5N•m
fpwx15a0024
39 . Install the drive shaft. (See Chapter 34 Bridge and Drive Shaft - Drive Shaft
Assembly, Overhaul)
40 . Install the exhaust pipe. (See16A Exhaust(LJ465) - Exhaust Pipe, Replacement)
41 . Install shift cable retaining clips on the
gearbox shift bracket.
fpwx15a0030
42 . Install the gearbox shift mechanism cable

locking pin.
fpwx15a0031
43 . Install the clutch cable and tighten 2 nuts.

Tool: 10mm sleeve
Torque: 5±1N•m
(5±1N·m)
15A fpwx15a0032
44 . Connect the oxygen sensor connector.
fpwx15a0033
45 . Ground the gearbox grounding line and

tighten bolts.
(10±1N·m)
Tool: 13mm sleeve
Torque: 10±1N•m
fpwx15a0034
46 . Install the reverse gear switch.
fpwx15a0035
47 . Connect the vehicle speed sensor

connector.
fpwx15a0036
48 . Install the starter (see 20A Starting and Charging(LJ465) - Starter, Overhaul).
49 . Install the engine cooling pipe.
(a) Install the thermostat and overflow pipe and
fix the clamp.
15A
fpwx15a0039
(b) Install the engine cooling water pipe and fix

the clamp.
fpwx15a0040
(c) Install the engine cooling water pipe and fix

the clamp.
fpwx15a0041
50 . Install the inlet/outlet pipe of the engine

fuel injection nozzle and fix the clamp.
Note
Clamps must be replaced with new one.
fpwx15a0042
51 . Install the throttle cable and tighten the

nut.
Tool: 13mm wrench
Torque: 5±1N•m
(5±1N·m)
15A fpwx15a0043
52 . Install the generator output terminal line

and tighten the nut.
Tool: 10mm sleeve
Torque: 5±1N•m
(5±1N·m)
fpwx15a0044
53 . Install canister solenoid valve intake pipe

clamps.
fpwx15a0045
54 . Install brake booster vacuum tube clamps.
fpwx15a0046
55 . Install harness connectors next to the

battery.
fpwx15a0047
56 . Install the engine grounding line next to

the battery and tighten the bolts.
Tool: 10mm sleeve
Torque: 10±1N•m
(10±1N·m)
fpwx15a0048 15A
57 . Install intake pipings. (See14A Intake(LJ465) - Air Inlet Pipe, Replacement )

58 . Install engine control module connectors.
fpwx15a0049
59 . Lay down the front passenger seat.

60 . Connect the battery negative cable. (See20A Starting and Charging(LJ465) -
61 . Lay down the driver seat.
62 . Refill coolant. (See 17A Cooling(LJ465) - Coolant, Replacement)
63 . Refill transmission oil. (See Chapter 41A Transmission - Transmission Assembly,
Replacement )
64 . Refill engine oil. (See 18A Lubrication System(LJ465) - Engine Oil, Replacement)
15A-16 Engine Mechanism System(LJ465) - Timing Belt Front Cover
Timing Belt Front Cover

Replacement
3. Dismount the A/C compressor driving belt. (See Chapter 61 Heating and A/C -
A/C Compressor, Overhaul)
4. Dismount the generator driving belt. (See 20A Starting and Charging(LJ465) -
Engine, Overhaul)
5. Dismount 4 fixing bolts of the water pump
pulley and remove the water pump pulley.
Tool: 10mm sleeve
15A
fpwx15a0053
6. Dismount 5 fixing bolts of the driving V

pulley and remove the driving pulley.
Tool: 8mm sleeve
fpwx15a0054
7. Dismount 6 fixing bolts of the timing belt

front cover and remove the front cover.
Tool: 10mm sleeve
fpwx15a0055
8. Clean up the impurities at the inner surface of the timing belt front cover and
the timing belt side.
Engine Mechanism System(LJ465) - Timing Belt Front Cover 15A-17
9. Install the timing belt front cover and

tighten 6 fixing bolts.
Tool: 10mm sleeve
Torque: 4 - 5 N•m
(4~5N·m)
fpwx15a0056
10 . Install the drive pulley to the correct

position, and tighten 5 flange bolts of the
driving V pulley.
Tool: 8mm sleeve
Torque: 6 - 8 N•m
(6~8N·m)
fpwx15a0057 15A
11 . Install the water pump pulley to correct

(7~9N·m) position and tighten 4 bolts.
Tool: 10mm sleeve
Torque: 7 - 9 N•m
fpwx15a0058
12 . Install the generator driving belt. (See 20A Starting and Charging(LJ465) - Engine,
Overhaul)
13 . Install the A/C compressor driving belt. (See Chapter 61 Heating and A/C - A/C
Compressor, Overhaul)
15A-18 Engine Mechanism System(LJ465) - Timing Belt
Timing Belt
Component Diagrams
1 2 3 4 5 6 7 20 8 9 10 11 12
13
14
12
15A
15
27 26 25 24 23 18 16 17 10
19
fpwx15a0172
1 Cylinder head cover shoulder bolt 15 Back up plate

2 Long support sheet 16 Rear casing bolt assembly
3 Front cover 17 Rear casing rubber gasket ring
4 Rubber gaskets of front and rear 18 Tension pulley assembly shoulder
housing bolt
5 Camshaft bolt assembly 19 Tension pulley assembly shoulder
6 Timing Belt bolt
7 Camshaft timing belt pulley 20 Torsional spring bushing
8 Rear casing bolt assembly 21 Torsional spring
9 Rear casing rubber gasket 22 Tension pulley assembly
10 bush 23 Crankshaft timing belt pulley
11 Rear casing welding assembly 24 Pipe Clamp
12 Gelatin sponge gasket ring 25 Short support sheet
13 Gelatin sponge gasket 26 Front cover window cover
14 Gelatin sponge gasket ring 27 Front cover retainer
Engine Mechanism System(LJ465) - Timing Belt 15A-19
Overhaul
2. Remove the engine harness.
Engine, Overhaul)
A/C Compressor, Overhaul)
5. Dismount the engine timing belt front cover. (See15A Engine Mechanism
System(LJ465) - Timing Belt Front Cover, Replacement )
6. Mark the direction of timing belt rotation
in order to confirm the installation
direction during installation.
15A
fpwx15a0061
7. Turn the crankshaft to align the timing

mark.
Note
Turn the crankshaft in accordance with engine
running direction.
fpwx15a0062
8. Mark the timing symbol of a camshaft

timing pulley.
fpwx15a0063
9. Mark the timing symbol of a crankshaft

timing pulley.
fpwx15a0064
10 . Dismount tension pulley assembly

mounting bolts and remove the tension
pulley.
Tool: 12mm sleeve
15A fpwx15a0065
11 . Check the tension pulley.

(a) Check the tension pulley for free rotation.
(b) Check the rod end for wear or damage,
ZD
replace with a new one if necessary.
6
20
2ES
fpwx15a0066
(c) Check the tension pulley and the torsional

spring.
fpwx15a0067
12 . Remove and check the timing belt, replace it if there are following damages:
Note
• Adhesion of water or oil to a toothed belt will drastically reduce the life of the
toothed belt. Be very careful not to allow water or grease contaminating or
adhering to a toothed belt, toothed pulley, tensioner and other parts. Do not
wash these parts. If seriously contaminated, replace it with a new piece.
• If water or grease is found on these parts, you should check the front cover oil
seal, camshaft oil seal and water pump for leaks.
(a) Back rubber is aging and reflective, no trace

is left by nail scratch.
fpwx15a0068
15A
(b) There are cracking and peeling marks on

canvas.
(c) Back rubber cracks.
(d) There are cracks in the bottom of the belt.
(e) There are cracks on the side of the belt.
fpwx15a0069
(f) Abnormal wear of the belt side, the belt side

is correct when it is as neat as cut by a sharp
knife.
fpwx15a0070
(g) Abnormal belt wear.

(h) Tooth loss.
fpwx15a0071
13 . Dismount 1 fixing bolt of the camshaft

timing belt pulley and remove the camshaft
timing pulley.
Tool: 17mm sleeve
fpwx15a0072
14 . Dismount 5 fixing bolts of the timing rear

cover weld assembly and remove the rear
cover weld assembly.
Tool: 10mm sleeve
15A fpwx15a0073
15 . Install the timing rear cover weld assembly

to the correct position and tighten 5 bolts.
Tool: 10mm sleeve
Torque: 4 - 5N•m
(4~5N·m)
fpwx15a0074
16 . Install the camshaft timing pulley and

tighten 1 bolt.
Tool: 17mm sleeve
(55~65N·m)
Torque: 55 - 65N • m
fpwx15a0075
17 . Align the timing symbol of a camshaft

timing pulley.
fpwx15a0076
18 . Align the timing symbol of a crankshaft

timing pulley.
fpwx15a0077
19 . Install the timing belt.

Note
Installation direction of a timing belt is consistent
with the marked belt rotation direction.
fpwx15a0078 15A
20 . Install the tension pulley to the correct

(18~28N·m) position and tighten 2 bolts.
Tool: 12mm sleeve
fpwx15a0079
21 . Checking and adjustment method of a timing belt.

Open the toothed belt cover and check the position of driving and driven synchronous
gear assembly marks, check as specified below if the position is incorrect or the timing
is believed to be inaccurate:
• Dismount the spark plug.
• Rotate the engine flywheel according to the direction of engine operation by
referring to flywheel scale within the observation hole on the transmission
housing, so that the keyway on the front part of the crankshaft is aligned with
the arrow on the toothed belt inner cover.
• Check that the first piston (next to radiator end) of the engine is at TDC of a
compression stroke, i.e. the intake and exhaust valves and the rocker arm
adjusting screw should have a clearance. If not, then turn the crankshaft for
360°.
• By now the circular mark (opposite to the key) on the edge of the driven
synchronous gear is aligned with the arrow on a toothed belt inner cover. If there
is a considerable difference, it should be adjusted.
• Rotate the crankshaft for 360°, so that the first cylinder is at the TDC of an
exhaust stroke, the fourth cylinder at the TDC of a compression stroke, therefore
one of the two marks on the driven synchronization gear edge should be aligned
with the triangle (△) mark on the toothed belt cover.
22 . Install the engine timing belt front cover. (See15A Engine Mechanism
System(LJ465) - Timing Belt Front Cover, Replacement )
Overhaul)
24 . Install the A/C compressor driving belt. (See Chapter 61 Heating and A/C - A/C
Compressor, Overhaul)
25 . Reset the engine harness.
15A
Engine Mechanism System(LJ465) - Rocker, rocker shaft and camshaft 15A-25
Rocker, rocker shaft and camshaft

Component Diagrams
1 2 3 4
17
5
16
6
7
15 8
14
9
15A
13
10
12
11
fpwx15a0173
1 Rocker assembly 10 Camshaft assembly

2 Rocker shaft assembly 11 Camshaft front oil seal assembly
3 Hexagonal flange face bolt 12 Whitney key
4 Cross recessed countersunk head 13 Intake Valve
screw 14 Valve spring seat
5 Camshaft thrust plate 15 Valve oil seal assembly
6 Valve spring seat 16 Rocker adjusting screw
7 Conical locker 17 Valve rocker adjusting nut
8 Valve spring
9 Exhaust Valve
15A-26 Engine Mechanism System(LJ465) - Rocker, rocker shaft and camshaft
Overhaul of rocker, rocker shaft

2. Dismount the engine intake pipeline. (See14A Intake(LJ465) - Air Inlet Pipe,
Replacement )
Engine, Overhaul)
A/C Compressor, Replacement)
5. Remove the engine harness.
6. Dismount the timing belt. (See15A Engine Mechanism System(LJ465) - Timing
Belt, Overhaul).
7. Dismount crankcase ventilation pipe
clamps and break the connection.
N
ENGINE
E
OP
OIE
15A
fpwx15a0080
8. Disconnect the high-voltage line on the

side of a spark plug.
fpwx15a0081
9. Disconnect the high-voltage line on the

side of an ignition coil.
fpwx15a0082
10 . Dismount 2 fixing bolts of an ignition coil

and remove the ignition coil.
Tool: 8mm sleeve
Note
Before disconnecting the spark plug high-voltage
on an ignition coil, confirm the corresponding
position of spark plug high-voltage on the
fpwx15a0083
ignition coil of each cylinder and make the
appropriate notation to avoid confusion during
installation.
11 . Remove 2 fixing bolts of ignition coil weld

bracket assembly.
Tool: 10mm sleeve
15A
fpwx15a0084
12 . Dismount 4 bolts of the cylinder head

cover and remove the cylinder head cover
assembly.
Tool: 10mm sleeve
N
Note
E
OIE E
OP
ENGIN
Cylinder head gasket can only be used once,

replace it with a new one before installation.
fpwx15a0085
13 . Dismount 5 hexagon flange face bolts in

1 3 5 4 2 numerical order.
Tool: 10mm sleeve
fpwx15a0086
14 . Remove the rocker shaft assembly

according to arrow direction.
fpwx15a0087
15 . Remove the rocker assembly.
15A fpwx15a0088
16 . Check the rocker assembly:

(a) Check the roller surface, replace the rocker
if there are any scratches or other damage.
(b) Check that the roller can rotate smoothly. If
TH
6-3 the rotation is not smooth or is loose, replace
the rocker.
(c) Check the rocker assembly bore, replace the
rocker if there are any scratches or other
damage.
fpwx15a0089
17 . Check and clean the rocker shaft and the rocker, replace it in time if damage is
identified:
Note
• Rocker shaft and rocker are precision parts. Its surface should be free of dust
and foreign matter.
• Clean the rocker shaft and the rocker with clean diesel.
(a) Prepare 1 container and diesel. Pour enough

diesel into the container to completely
submerge the upright rocker shaft and rocker.
(b) Place the rocker shaft and the rocker into the
container and clean their outer surface
Note
Remove the hard deposit with a nylon brush.
fpwx15a0091
18 . Install the rocker and the rocker shaft.

Note
Align the rocker shaft assembly positioning hole
with the cylinder head bracket to make sure
correct installation position.
fpwx15a0092
(6~8N·m)
19 . Tighten 5 hexagon flange face bolts in
4 2 1 3 5 numerical order.
Tool: 10mm sleeve
fpwx15a0093 15A
20 . Install the cylinder head cover assembly

to the correct position and tighten 4
connecting bolts of the cylinder head
(6~8N·m)
cover.
Tool: 10mm sleeve
N
E
OIE E
OP
ENGIN
fpwx15a0094
21 . Install the ignition coil bracket weld

assembly to the correct position and
tighten 2 bolts.
Tool: 10mm sleeve
(6~8N·m)
fpwx15a0095
22 . Install the ignition coil and tighten 2 bolts.

Tool: 8mm sleeve
(6~8N·m)
fpwx15a0096
23 . Connect the high-voltage line on the side

of an ignition coil.
fpwx15a0097
24 . Connect the high-voltage line on the side

of a spark plug.
15A fpwx15a0098
25 . Install the crankcase ventilation pipe and

tighten clamps.
N
ENGINE
E
OP
OIE
fpwx15a0099
26 . Install the timing belt. (See15A Engine Mechanism System(LJ465) - Timing Belt,
Overhaul).
Overhaul)
28 . Install the A/C compressor driving belt. (See 20A Starting and Charging(LJ465)
- Engine, Overhaul)
29 . Install the engine intake pipeline. (See14A Intake(LJ465) - Air Inlet Pipe,
Replacement )
30 . Reset the engine harness.
Camshaft Overhaul
1. Dismount the engine rocker and rocker shaft. (See 15A Engine Mechanism
System(LJ465) - Rocker, rocker shaft and camshaft, Overhaul of rocker, rocker
shaft)
2. Dismount 1 bolt of the cylinder head rear
cover and remove the cylinder head rear
cover.
Tool: 10mm sleeve
fpwx15a0100
3. Dismount 2 cross recessed countersunk

head bolts and remove the camshaft thrust
plate.
15A
fpwx15a0101
4. Remove the camshaft in accordance with

arrow direction.
fpwx15a0102
5. Check the camshaft:

(a) Observe the camshaft axis surface for pitting, wear and crack. Once found, replace it
with a new camshaft.
(b) Measure the cam height

25-50mm
0.01mm
Name Standard value

Intake cam 34.0662±0.08
Exhaust cam 33.7727±0.08
fpwx15a0103
6. Remove the camshaft oil seal.

Note
Once dismounted, the camshaft oil seal should
be replaced with new one.
fpwx15a0104
7. Install the camshaft oil seal with a special

tool.
15A fpwx15a0105
8. Install the camshaft in accordance with

arrow direction.
Note
Apply a little oil on camshaft oil seal lip area and
outer side of camshaft front end.
fpwx15a0106
9. Install camshaft thrust plate and fix 2 cross

recessed countersunk head screw.
fpwx15a0107
10 . Install the cylinder head rear cover to the

correct position and tighten 1 fixing bolt.
Tool: 10mm sleeve
(6~8N·m)
fpwx15a0108
11 . Install the engine rocker and rocker shaft. (See 15A Engine Mechanism
shaft)
15A
15A-34 Engine Mechanism System(LJ465) - Cylinder Head and Valve
Cylinder Head and Valve

Component Diagrams
1 2 3 4 5 6
7
8
9
10
22 11
21 12
14
15A 13
20
15
19
18 16 17
fpwx15a0174
1 Cylinder Head Cover Assembly 12 Ignition coil bracket weld assembly

2 Filler Cap Assembly 13 Cylinder head rear cover
3 Cylinder head cover connecting bolt 14 Shouldered tap bolt of intake
4 Bracket manifold
5 High-voltage wire soft clip 15 Distributor seat gasket
6 Ignition high-voltage wire assembly 16 Front cover locating pin
7 Hexagonal flange face bolt 17 Spark plug
8 Ignition coil 18 Cylinder gasket assembly
9 Short support sheet 19 Cylinder head locating pin
10 Fasten the cylinder head cover with 20 Cylinder head components
shoulder bolts 21 Cylinder head connecting bolt
11 Hexagonal flange face bolt 22 Sealing Gasket for Cylinder Head
Cover
Engine Mechanism System(LJ465) - Cylinder Head and Valve 15A-35
Cylinder Head Overhaul

2. Drain the engine coolant. (See 17A Cooling(LJ465) - Coolant, Replacement)
3. Dismount the engine intake pipeline. (See14A Intake(LJ465) - Air Inlet Pipe,
Replacement )
Engine, Overhaul)
Belt, Overhaul).
6. Dismount the engine rocker and rocker shaft. (See 15A Engine Mechanism
shaft)
7. Remove the camshaft. (See 15A Engine Mechanism System(LJ465) - Rocker,
rocker shaft and camshaft, Camshaft Overhaul)
8. Dismount 10 cylinder head bolts in
numerical order and remove the cylinder 15A
4 8 10 6 2
head assembly.
Tool: 14mm sleeve
1 5 9 7 3
Note
When dismounting cylinder head bolts, loosen
them evenly and gradually so that to apply even
fpwx15a0109
force on the cylinder head.
9. Remove and check the cylinder head

gasket.
fpwx15a0110
10 . Clean the cylinder head assembly and check the cylinder head for cracks or
serious damage, replace if necessary.
11 . Check the flatness of cylinder head bottom
surface with a straightedge and a
clearance gauge, grind (grind the cylinder
head together with the cylinder block) or
replace it if there is excessive deformation.
Standard value of flatness: 0.03mm
fpwx15a0111
12 . Check the cylinder head height and replace the head if the standards are not
met.
13 . Install a new cylinder head gasket.
Danger
Properly install the cylinder head gasket, the cylinder gasket oil duct must match along
with the oil duct on the upper plane of the cylinder block, otherwise it will cause serious
engine damage
14 . Install the cylinder head components.

Note
Only fix the cylinder head assembly after
installing a locating pin in place.
fpwx15a0112
15A
15 . Make sure the bolt length is within the
standard range before installing cylinder
head bolts.
fpwx15a0113
16 . Tighten 10 cylinder head component bolts

(55~68N·m)
one by one in numerical order.
7 3 1 5 9
Tool: 14mm sleeve

10 6 2 4 8
Note
• Apply right amount of engine oil on

fpwx15a0114
threaded parts of cylinder head bolts and
washers to facilitate screw tightening.
• If bolts are over-tightened, you should
completely loosen the bolts and then
retighten them.
17 . Install the camshaft. (See 15A Engine Mechanism System(LJ465) - Rocker, rocker
shaft and camshaft, Camshaft Overhaul)
18 . Install the engine rocker and rocker shaft. (See 15A Engine Mechanism
shaft)
Overhaul).
Overhaul)
21 . Install the engine intake pipeline. (See14A Intake(LJ465) - Air Inlet Pipe,
Replacement )
22 . Refill engine coolant. (See 17A Cooling(LJ465) - Coolant, Replacement)
15A
Valve Overhaul
1. Remove the cylinder head component. (See15A Engine Mechanism
System(LJ465) - Cylinder Head and Valve, Cylinder Head Overhaul).
Note
Removed valve, valve spring and other parts should be put up with a label marked
with cylinder number and installation location and well stored for the correct installation
during assembly.
2. Dismount the valve lock conical locker

with a tool and remove the valve spring
seat and the valve spring respectively.
fpwx15a0116
15A
3. Remove the valve oil seal.
Note
The valve oil seal cannot be reused.
fpwx15a0117
4. Check the valve spring:

(a) Measure whether the valve spring free height
meets the standard value.
Standard value: 50.94(+0.3/-0.9)mm
(b) Measure the perpendicularity of spring
centerline with bottom surface.
fpwx15a0118
5. Check the valve:

(a) Check the valve working surface and the valve seat for contact seal. If the contact
seal is poor, reground them with a valve grinder. The valve seat contact surface must
be consistent with the valve working face center.
(b) Check the valve edge thickness, replace the

valve if the thickness is not as specified and
grind it with a valve grinder.
fpwx15a0119
(c) Check whether the total valve height meets

the standard value:
Valve total height Standard value
Air inlet 109.5mm
Exhaust 108.5mm
fpwx15a0120 15A
6. Check whether the gap between the valve

duct and the valve stem meets the criteria:
Gap Standard value
Air inlet 0.020 - 0.047mm
Exhaust 0.045 - 0.077mm
fpwx15a0121
7. Follow the following steps when replacing a valve duct:

Note
Do not use a new valve duct which has the same size as the one removed.
(a) Heat the cylinder head and remove the valve seat.
(b) Press out the valve tube towards the cylinder head lower plane with a tool.
(c) Machine the valve tube hole of the cylinder head, so that the hole diameter reaches
the dimension of an enlarged valve duct:
Valve duct bore diameter
Increase the size for 0.05mm φ5（0,0.012）mm
(d) Install a new valve duct, press the valve duct

downward from cylinder head top surface until
its protruding amount meets the standard.
Note
• Press down the valve duct from cylinder

head top surface.
• Intake valve duct length is different from
fpwx15a0122
that of exhaust valve duct (intake valve:
107.2mm, exhaust valve: 106.2mm).
(e) Insert a new valve after installing the valve duct and check the valve for smooth axial
movements.
8. Assemble the valve and measure the protruding height of valve stem between
the valve stem end and the valve spring seat. Replace the valve seat if the
standards are not met.
9. Trim the valve seat:
15A (a) Check the clearance between valve duct and valve stem, if necessary, trim it after
replacing the valve duct.
(b) Trim the width and angle of a valve seat to specified values with a grinder.
(c) After trimming the valve seat, grind the valve and the valve seat in pairs with abrasive
paste. Then check the valve stem projection height.
10 . Replace the valve seat:

(a) Cut a slice of valve seat, which is to be
replaced, from the inside and remove it after
it becomes thinner.
(b) True the cylinder head valve seat hole
according to the enlarged outer diameter of
the valve seat.
(c) Before assembling a valve seat ring, cool the
cylinder head in liquid nitrogen to prevent the
valve seat ring from being seized in the
cylinder head.
(d) Trim the valve seat to the specified width and
fpwx15a0124
angle with valve seat cutters.
11 . Install the valve in accordance with marks made during the removal.
12 . Install the valve spring gasket.
13 . Install a new valve seal with tools.
fpwx15a0125
14 . Install the valve spring.

Note
When installing the valve spring, the end
smeared with identification color should face to
the valve spring upper seat.
fpwx15a0126 15A
15 . Install the valve spring seat to the correct

position and install the valve conical
locker.
fpwx15a0127
16 . Install the cylinder head components. (See15A Engine Mechanism System(LJ465)

- Cylinder Head and Valve, Cylinder Head Overhaul).
15A-42 Engine Mechanism System(LJ465) - Piston and Connecting Rod Assembly
Piston and Connecting Rod Assembly

Component Diagrams
3
5
6
4
15A
7 8
fpwx15a0175
1 First gas ring 1 5 Piston pin snap ring

2 Second gas ring 1 6 Piston pin
3 Oil ring blade 2 7 Connecting rod components
4 Piston 8 Bearing bush of the connecting rod
Engine Mechanism System(LJ465) - Piston and Connecting Rod Assembly 15A-43
Overhaul
1. Dismount the engine assembly. (See15A Engine Mechanism System(LJ465) -
Engine assembly, Replacement)
2. Remove the cylinder head. (See15A Engine Mechanism System(LJ465) - Cylinder
Head and Valve, Cylinder Head Overhaul).
3. Remove the oil tray. (See 18A Lubrication System(LJ465) - Oil pan, Replacement)
4. Remove the engine oil strainer. (See18A Lubrication System(LJ465) - Engine Oil
Pump, Overhaul )
5. Mark the big end of connecting rod with a
cylinder number for correct assembly.
Note
7763 776 J0Z
Place the removed connecting rod, connecting

rod cap and connecting rod bearing according
to cylinder number to avoid confusion during
installation.
fpwx15a0128
15A
6. Dismount 8 fixing bolts of connecting rod

cap one by one according to numeric
3 1 2 4
order.
Tool: 12mm sleeve
3 1 2 4
fpwx15a0129
7. Gently knock out the connecting rod

assembly with a wooden or a plastic stick.
fpwx15a0130
8. Dismount the piston pin snap ring.
fpwx15a0131
9. Press out the piston pin and separate the

piston from the connecting rod.
fpwx15a0132
10 . Dismount the first gas ring, the second

gas ring and the oil ring.
Note
• Clean up the carbon deposit on the piston

surface and in the air ring and the greasy
dirt in the oil ring.
• Be careful not to scratch the piston
15A fpwx15a0133
surface.
11 . Check the piston ring for damage, excessive wear and crack and replace it if
any. When replacing a piston, replace its piston ring all together.
12 . Check the lateral clearance between a
piston ring and a piston ring groove, if too
large, replace the piston ring or replace
the piston and the piston ring.
Standard value: 0.03 - 0.08mm
fpwx15a0134
13 . Place the piston ring into the cylinder, put

it right with the piston head, then measure
the piston ring end clearance with a
clearance gauge. If the end clearance
exceeds the standard value, replace the
piston ring:
First gas Second
Oil ring
ring gas ring
Standard 0.15 - 0.23 - 0.25 -
value 0.30mm 0.38mm 0.75mm
fpwx15a0135
14 . Check the oil clearance of a crankpin with

a plastigauge:
(a) Clean up the engine oil on rod journal and rod
bearing.
(b) Cut the plastigauge to the same length as the
bearing width and then place it on the
crankpin, so that it is parallel to the shaft
centerline.
fpwx15a0136
(c) Carefully install the rod cover and tighten the
nut to the specified torque.
(d) Carefully remove the rod cover.
(e) Measure the width of widest part of a flattened

plastic wire with the ruler printed on a
packaging bag of a plastigauge to obtain the
clearance value.
15A
fpwx15a0137
15 . Install the piston pin:

(a) Measure the following dimensions of a piston,
piston pin and rod:
A: Piston pin insertion hole length
A B B: Inter pin seat width
C: Piston pin length
D: Rod small head width
(b) Add above measured sizes into the following
formula to calculate the dimension L. L＝[(A
C D
－C)－(B－D)]/2。
(c) Install duct A on a strut end after inserting a
special tool strut into the piston pin.
fpwx15a0138
(d) Assemble the piston forward mark and the

rod forward mark in the same direction.
fpwx15a0139
(e) Apply engine oil on the outside diameter of the piston pin.
(f) Insert the assembled piston pin, strut and duct components from the forward mark
side into a piston pin hole with duct A end.
15A
(g) Hold the piston forward mark upward, install
the piston rod components on the mounting
base of the piston pin and press it into the
piston pin.
(h) Install the piston pin snap ring.
fpwx15a0140
16 . After installing the piston pin, check

whether the piston can rotate freely
against the connecting rod or not.
fpwx15a0141
17 . Install the oil ring:

Note
There is no difference between topside and
underside for the oil ring blade and the main
ring.
(a) Put in the upper blade. When installing a
blade, simply press one end of the blade into
the piston oil ring groove, then press the rest
of the blade with your thumb into the oil ring
groove as shown.
Note
fpwx15a0142 Do not install the oil ring blade with a piston ring
plier as the blade may be broken when expended
by the piston ring plier.
(b) Install the lower blade by following the same
steps as (a).
(c) Confirm that the installed oil ring can rotate 15A
freely.
18 . Install the first gas ring and the second gas ring:
(a) Install the second gas ring with a piston ring
plier, then install the first gas ring.
Note
When installing the piston ring, put the
distinguishing mark upward, toward the top of
the piston.
fpwx15a0143
(b) The open end of the gas ring is marked with

an identification marks, namely M1 and M2.
M2
M1
fpwx15a0144
19 . Adjust the opening direction of the gas ring and the oil ring:
(a) Apply clean engine oil on the piston ring groove, the gas ring and the oil ring.
(b) Adjust the opening position of the gas ring

and the oil ring to the position shown.
1 5
Oil ring upper blade
1
opening
2 Piston pin position
6 2 Oil ring lower blade
3
opening
Collar and second
4
gas ring openings
4 3
First gas ring
5
fpwx15a0145
opening
Crankshaft belt
6
pulley side
15A 20 . Rotate the crankshaft, so that the crank pin is in the central section of a cylinder.
21 . Before inserting the piston and the connecting rod assembly into a cylinder, the
connecting rod bolt should be furnished with an appropriate thread protective
device. Be careful not to bruise the crank pin.
22 . When installing the piston and the
connecting rod assembly, make sure that
the dot mark on the top of the piston faces
to the timing side.
fpwx15a0146
23 . Install the piston and the connecting rod

assembly with a piston ring compression
tool.
Note
• When installing the piston and connecting

rod assembly into the cylinder, be careful
not to bruise the crank pin with a
fpwx15a0147
connecting rod cap bolt.
• When installing the piston and rod
assembly, gently press the piston and the
connecting rod assembly with a wood or
plastic tool and avoid pressing vigorously,
otherwise the piston ring or crank pin may
be broken.
24 . Install the connecting rod cap according

to marks marked during dismounting. If
the link is a new part and without
combination marks, then install the upper
connecting rod bearing and the lower
connecting rod bearing groove on the
same side as shown.
fpwx15a0148
25 . Measure the axial clearance of connecting

rod big end with a clearance gauge.
fpwx15a0149 15A
26 . Install the connecting rod nut:

(28~40N·m)
Note
Before installing a connecting rod cap, you
should first dismount the spark plug and then
install the connecting rod cap nut if a cylinder
head has been fitted.
(a) Connecting rod bolts and nuts adopt a plastic
fpwx15a0150
range tightening method. Check a bolt for
stretch before re-using the bolt.
Note
Method for checking bolt stretch: tighten a nut
onto the bolt thread for the full thread length
with your fingers. If the nut cannot be screwed
smoothly to the end, this indicates that the
threaded portion of the bolt may be stretched,
so the bolt should be replaced.
(b) Before tightening a nut, apply oil on the
threaded portion of the nut and the seat
surface.
(c) Tighten the nut on the bolt with your fingers,
then alternately tighten the nut, so that the
connecting rod cap can be assembled
correctly.
(d) Tighten the connecting rod nut.
27 . Install the oil strainer. (See18A Lubrication System(LJ465) - Engine Oil Pump,
Overhaul )
28 . Install the oil pan. (See 18A Lubrication System(LJ465) - Oil pan, Replacement)
29 . Install the cylinder head. (See15A Engine Mechanism System(LJ465) - Cylinder
30 . Install the engine assembly. (See15A Engine Mechanism System(LJ465) - Engine
assembly, Replacement)
15A
Engine Mechanism System(LJ465) - Crankshaft, Cylinder Block & Flywheel 15A-51
Crankshaft, Cylinder Block & Flywheel

Component Diagrams
14
2
4 13
3
12
15A
5
8 9 10 11
fpwx15a0176
1 Cylinder block assembly 8 Main bearing bush (lower)

2 Main bearing bush 9 Flywheel alignment pin
3 Hexagonal flange face bolt 10 Crankshaft rear cover gasket
4 Crankshaft thrust washer 11 Crankshaft rear cover shoulder bolt
5 Main bearing bush (upper) 12 Crankshaft rear oil seal assembly
6 Whitney key 13 Flywheel
7 Crankshaft 14 Hexagon headed bolt and spring
washer assembly
15A-52 Engine Mechanism System(LJ465) - Crankshaft, Cylinder Block & Flywheel
Overhaul
1. Dismount the engine assembly. (See15A Engine Mechanism System(LJ465) -
Engine assembly, Replacement)
2. Remove the cylinder head. (See15A Engine Mechanism System(LJ465) - Cylinder
3. Fix the engine block to the engine roll-over stand for disassembly.
5. Remove the oil strainer and the oil pump. (See18A Lubrication System(LJ465)
- Engine Oil Pump, Overhaul )
6. Dismount 6 fixing bolts of a flywheel one
1
by one according to numeric order and
3 remove the flywheel.
6 Tool: 17mm sleeve
5
4
15A
fpwx15a0153
7. Remove 6 fixing bolts of the rear cover

and remove the rear cover.
Tool: 10mm sleeve
fpwx15a0154
8. Flip the engine, so that the oil pan is facing upward.

9. Dismount 10 bolts of the crankshaft main
bearing cap one by one in numerical order.
3 7 10 6 2
Tool: 12mm sleeve
4 8 9 5 1
fpwx15a0155
10 . Remove the crankshaft main bearing cap.

Note
The marked arrow direction of crankshaft main
130701 130901 130701 130701 130701 bearing cap.
fpwx15a0156
11 . Remove the crankshaft and follow these steps to measure the crankshaft oil
film clearance with a plastic gauge:
(a) Clear out the oil film on crankshaft inner
surface.
15A
fpwx15a0157
(b) Clear out the oil film on crankshaft journal

surface.
fpwx15a0158
(c) Install the crankshaft.

(d) Cut off plastigauge material with a length
equals to the bearing width and place it on
the crankshaft journal, so that it is parallel to
the crankshaft journal.
(e) Carefully install the crankshaft main bearing
cap and tighten bolts to the specified torque.
(f) Dismount crankshaft main bearing cap bolts,
fpwx15a0159
then carefully remove the crankshaft main
bearing cap.
(g) Measure the pressed part of the plastigauge
material with the gauge printed on the
plastigauge packaging material.
12 . Remove the cylinder block assembly from the roll-over stand and check:
(a) Visually inspect the cylinder body for scratch, rust and other corrosions, or check for
cracks with testing agent. Trim or replace if there are obvious defects.
(b) Check the cylinder body surface flatness with

a surface gauge and a thickness gauge and
confirm the surface is free of debris and
impurities.
Standard value: 0.05mm
(c) If the flatness of cylinder upper surface is too
large, you should adjust or replace it.
fpwx15a0160 (d) Check the cylinder wall for scratches or other
injuries, trim or replace if there are obvious
scratches.
(e) Check the cylinder bore and cylindricity with

a cylinder gauge, if badly worn, trim it to a
A
larger size and replace the piston.
B
15A Standard value: 65.5(+0.03/0)mm
12mm
fpwx15a0161
(f) Measure the outer diameter of the piston to

be used in the thrust direction as shown.
(g) Calculate the boring size of cylinder bore
according to the piston outer diameter
measurement:
Boring size = piston outer diameter +
(clearance between the piston and the
fpwx15a0162 cylinder) -0.02mm (honing)
Note
If the cylinder needs to be bored, four cylinders
should be bored to the same size.
(h) Bore the diameter of each cylinder to the
boring size.
Note
Bore a cylinder in the following order in order to
avoid errors due to temperature rise: No.2 →
No.4 → No.1 → No.3
(i) Hone to the final cylinder diameter (piston
diameter + clearance between the piston and
the cylinder).
(j) Check the clearance between the piston and
the cylinder.
13 . Install a bearing thrust washer in

accordance with the following items:
(a) Install a grooved bearing on the cylinder block
side.
(b) Install the crankshaft thrust washer at the third
spindle bore of the cylinder body. Apply a little
oil on the thrust bearing surface to facilitate
the installation.
fpwx15a0163
Note
Please note marked points during installation.
14 . Install the crankshaft main bearing cap.

Note
The arrow on crankshaft main bearing cap points
130701 130901 130701 130701 130701 toward the timing toothed belt. 15A
fpwx15a0164
15 . Install crankshaft main bearing cap bolts according to following items.

(a) Measure the bolt length before tightening
crankshaft main bearing cap bolts.
(b) Smear a little oil on the threaded portion of a
bolt and the seat surface.
fpwx15a0165
(c) Tighten 10 fixing bolts of the crankshaft main

(43~55N·m)
8 4 1 5 9
Tool: 12mm sleeve
Torque: 43 - 55N•m
7 3 2 6 10
fpwx15a0166
16 . After installing the crankshaft main

bearing cap, confirm that crankshaft
rotates smoothly and check that the axial
clearance meets the standard value.
fpwx15a0167
17 . Install the crankshaft cap to the correct

position and tighten 6 bolts.
Tool: 10mm sleeve
(7~9N·m)
Note
• Clear up the debris on the rear end cap

15A fpwx15a0168
surface after installing the crankshaft rear
end cap, be careful not to scratch the
contact surface.
• Apply sealant on the oil cap contact
surface.
• Make sure to install the rear end cap
quickly when the sealant is wet (≤15 min).
• After installation, keep lubricant and
coolant away from the sealing region for
about 1 hour.
18 . Tighten 6 flywheel bolts one by one in

1
numerical order.
3
Tool: 17mm sleeve
6
5
4
2
(45~50N·m)
fpwx15a0169
19 . Install the oil strainer and the oil pump. (See18A Lubrication System(LJ465) -
Engine Oil Pump, Overhaul )
21 . Install the cylinder head. (See15A Engine Mechanism System(LJ465) - Cylinder
22 . Install the engine assembly. (See15A Engine Mechanism System(LJ465) - Engine
assembly, Replacement)
Engine Mechanism System(4W10/4W12)
Engine Mechanism.............................15B-1
Precautions......................................15B-1
Table of Fault Symptom....................15B-3
Engine assembly................................15B-5
Replacement....................................15B-5
Timing Front Cover..........................15B-16
Replace..........................................15B-16
Timing Chain.....................................15B-19
Component Diagrams....................15B-19
Overhaul.........................................15B-20
Valve Tappet and Camshaft.............15B-26
Valve Tappet Overhaul....................15B-26
Camshaft Overhaul........................15B-30
Cylinder Head and Valve..................15B-32
Cylinder Head Overhaul.................15B-35
Valve Overhaul...............................15B-37
15B
Assembly..........................................15B-41
Overhaul.........................................15B-42
Flywheel............................................15B-48
Overhaul.........................................15B-50
15B
Engine Mechanism System(4W10/4W12) - Engine Mechanism 15B-1
Engine Mechanism
Precautions
3. If necessary, a fire extinguisher must be placed at a predetermined position
before maintenance operation so that it can be used in time when needed.
4. If necessary, staff should wear safety shoes, gloves and goggles before
maintenance operation to ensure personal safety.
5. Make sure that appropriate protective measures have been taken for the vehicle
before performing maintenance operation, such as putting protective cover on
the seat, steering wheel, floor, engine compartment etc.
6. Before lifting a vehicle, check that the lift is working well, the parking location
is suitable, the lift arm is appropriately adjusted to the vehicle lift point. Make
sure no one and irrelevant items are underneath the vehicle during lifting or
dropping process.
7. Handle in accordance with procedure during operations that require oil-cut, 15B
power-cut, pressure relief, e.g. when dismounting fuel rail you need oil-cut and
pressure relief, when dismounting electrical components you need to disconnect
the negative battery cable, otherwise it may easily lead to vehicle damage and
threat personal safety.
8. Protective measures should be taken to prevent external contaminants or dust
from entering pipeline and fittings after disconnecting them.
9. When repairing engine interior, be sure to operate in accordance with the
prescribed steps and gently handle brittle, breakable and vulnerable components.
10 . Bolts and nuts must be tightened in accordance with the provisions on moment,
order, direction or angle and other specifications to avoid excessive force.
11 . Components must be thoroughly cleaned and lubricated before installation
during engine overhaul, such as maintenance of crankshaft, pistons, cylinder
heads, etc.
12 . During engine maintenance, used sealant must be cleaned before installing an
oil pan to ensure that the sealing joint surface is smooth, install a new gasket
and apply the right amount of sealant.
13 . Check the polarity of battery grounding, this gasoline engine adopts negative
grounding.
14 . Do not adjust the throttle position screw, otherwise the throttle angle will be
changed when close, so that the engine does not work.
15 . Disconnection of spark plug cable is prohibited during engine operation. Engine
misfiring will cause unburned mixture entering the three-way catalytic converter
thus leading to ablation. Remove the three-way catalytic converter if necessary.
16 . You must use engine oil of prescribed grade and viscosity. Otherwise engine
wear will be increased.
17 . Do not use non-genuine engine parts, rather you should use original authentic
parts, otherwise it will result in engine damage or engine fault.
15B-2 Engine Mechanism System(4W10/4W12) - Engine Mechanism
18 . A new engine must have a running-in in accordance with the regulations. Sudden
acceleration or high load operation is not allowed during running-in period.
19 . Do not shutdown the engine immediately when it is working, especially with
high-speed or under high load, rather you should stop it after running it at low
speed for 3 - 5 minutes, so that the engine is evenly cooled.
20 . Sealant is used in many parts of the engine. Sealant is used to fully fulfill sealing
purpose, therefore special attentions must be paid to applying amount, applying
location and the state of applied surface. Apply too little can lead to leaks, apply
too much can lead to sealant spills which may result in water or oil passage
blockage or passage narrowing.Therefore, sealant should be applied according
to specifications.
21 . In some cases it is necessary to tap the parts in order to damage the sealant on
the bonding surface with a mallet, rubber mallet or similar tool or gently drive
into the bonding surface with a smooth and thin sealant spatula, but be careful
not to damage the bonding surface.
22 . Remove the debris on the sealing surface with a sealant scraper or a wire brush.
Confirm that the sealing surface is flat and smooth, free of oil and foreign matters.
Do not forget to remove the sealant in mounting holes and threaded holes.
23 . Apply sealant evenly on a specified diameter and fence the mounting holes. Do
15B not remove sealant that is not hardened. Mount it at a predetermined position
when the sealant is wet (within 15 minutes). Be careful not to apply the sealant
to unwanted positions. Wait for the sealant to be fully hardened after installation
(1 hour or so). Do not apply oil on the applied part or dampen it or start the
engine within this period of time.
24 . Record the engine manufacturing number, the engine type and the vehicle model
in order to get repair service from Beiqi Foton authorized workshop (Seen from
the engine rear end,the engine manufacturing number is printed in its cylinder's
left inclined surface).
Engine Mechanism System(4W10/4W12) - Engine Mechanism 15B-3

The battery voltage is too low Check the battery, replace if necessary
Battery cable is loose, corroded Clean the battery and tighten connec-
tions
Starter fault Check the starter, replace if necessary
sary
Spark plug cable fault Check the spark plug cable, replace the
spark plug cable if necessary
The engine can Spark plug jump-spark gap is too Replace the spark plug
not be started large
impurities in fuel system fuel filter
Fuel pump fault Check the fuel pump and replace it if
necessary 15B
Timing belt jumping chain Reinstall or replace the timing toothed
belt
Air cleaner is blocked Replace the air cleaner and clean the
air cleaner housing
Idle speed stepper motor gets Clean the idle stepper motor and the
stuck throttle
Intake manifold leaks Check the intake manifold, the intake
Engine idling is
manifold gasket and the crankshaft
not stable
ventilation hose
Ignition coil fault Check related harness and replace the
ignition coil if necessary
Spark plug jump-spark pole gap Replace the spark plug
is too large
Insufficient en- impurities in fuel system fuel filter
gine power
Incorrect valve timing Reinstall the timing toothed belt and
adjust the timing
Cylinder lining leakage Replace cylinder gasket
15B-4 Engine Mechanism System(4W10/4W12) - Engine Mechanism

Cylinder pressure is too low Measure cylinder pressure, repair if
necessary
Throttle valve is not airtight. Check the valves and valve seats, re-
place if necessary
Three-way catalytic converter Replace with quality fuel, replace catalyt-
clogged ic converters
Spark plug cable resistance is Check spark plug cable resistance, re-
too large place if necessary
sary
Poor atomization of fuel injector Replace the fuel filter, cleaning the fuel
injector, replace if necessary
Obstructed exhaustion of ex- Check exhaust system
haust system
Inadequate intake by intake Check air inlet system
15B system
Ignition timing deviation Check knock sensor and other related
components
Engine Mechanism System(4W10/4W12) - Engine assembly 15B-5
Engine assembly
Replacement
Note
• Before removing the engine assembly, drain all engine fluids, and disconnect
the harness, pipe connector and other connections between the engine and the
body.
• Before disconnecting all harnesses and pipes, mark them properly to prevent
mismatching or missing harness and pipes during installation.
• Once a fitting is disconnected, seal up the opening to prevent foreign objects
from entering.
• All drained fluids must be collected and handled as required. Keep the site clean
and neat.
1. Recover A/C refrigerant. (See Chapter 61A Heating and A/C - Refrigerant,
Replacement)
15B
6. Drain transmission oil. (See Chapter 41B Transmission - Transmission Assembly,
Replacement )
8. Lift the driver seat.
9. Disconnect the battery negative cable and dismount the battery. (See20A Starting
and Charging(LJ465) - Battery, Replacement)
10 . Lift the passenger seat.
11 . Dismount the connector on right side of the engine compartment.
(a) Disconnect the engine ECU connector.
(b) Loosen the breathing pipe clamp on the upper
part of a carbon tube and break the
connection.
fpwx15b0200
15B-6 Engine Mechanism System(4W10/4W12) - Engine assembly

(a) Disconnect the engine ECU connector.
(b) Loosen the breathing pipe clamp on the upper
part of a carbon tube and break the
connection.
fpwx15b0201
12 . Dismount the intake hose between the air filter and the throttle.
(a) Loosen air filter side mounting clamps and
disconnect the inlet pipe connection.
(b) Disconnect the intake air temperature sensor
connector.
(c) Loosen crankcase intake pipe mounting
clamps and disconnect the intake pipe.
fpwx15b0202
(d) Loosen throttle intake side clamps and
15B disconnect the inlet pipe.

(a) Loosen air filter side mounting clamps and
disconnect the inlet pipe connection.
(b) Loosen crankcase intake pipe mounting
clamps and disconnect the intake pipe.
(c) Loosen throttle intake side clamps and
disconnect the inlet pipe.
fpwx15b0203
13 . Dismount the throttle cable adjustment

nut and disconnect it from the throttle.
Tool: 13mm wrench
fpwx15b0204
14 . Dismount 2 bolts of air conditioner

compressor high/low pressure pipelines
and disconnect tubing connections.
Tool: 13mm sleeve
fpwx15b0205
15 . Dismount generator terminal fixing nuts.

Tool: 13mm sleeve
fpwx15b0206
16 . Dismount the connecting accessory on 15B

left side of the engine compartment.
(a) Disconnect 2 engine harness connectors on
the left side of the engine compartment.
(b) Dismount the body grounding line bolts and
break the connection.
fpwx15b0207
17 . Disengage 5 retaining clips on the engine

compartment upper harness.
fpwx15b0208
18 . Loosen inlet pipe clips and disconnect the

inlet pipe connection.
Note
• First release oil pressure when

disconnecting an oil pipe.
• Seal the oil pipe connector after
disconnecting the pipe to prevent foreign
fpwx15b0209
matter from entering the pipe.
19 . Loosen the fixing bolt of battery positive

connection harness and disconnect the
harness connector.
Tool: 10mm sleeve
fpwx15b0210
20 . Disconnect the gear shift cable.

(a) Disassemble two split pins connecting the
upper gear shift cable and the transmission.
(b) Disassemble two clamps connecting the lower
gear shift cable and the transmission.
fpwx15b0211
15B 21 . Dismount the thermostat water pipe.

(a) Dismount mounting clamps on the pipe
between the thermostat and the water tank
(b) Dismount mounting clamps on the pipe
between the thermostat and the heater water
tank and break the connection.
fpwx15b0212
22 . Dismount the engine connection water

pipe.
(a) Dismount mounting clamps on the pipe
between the expansion tank and the engine
(b) Dismount mounting clamps on the pipe
between the water tank and the engine and
fpwx15b0213
(c) Dismount brake vacuum retaining clamps and
23 . Dismount the clutch cable.

(a) Dismount 2 fixing nuts of the clutch.
Tool: 10mm wrench
(b) Remove the clutch cable from the engine
bracket mounting hole.
fpwx15b0214
24 . Dismount 1 gearbox grounding line bolt

and disconnect the grounding line.
Tool: 13mm sleeve
fpwx15b0215
25 . Dismount the exhaust pipe. (See 16B Exhaust(4W10/4W12) - Exhaust Pipe, 15B
Replacement)
26 . Dismount the drive shaft. (See Chapter 34 Bridge and Drive Shaft - Drive Shaft
Assembly, Overhaul)
27 . Dismount the gearbox rear bracket nut.
Tool: 13mm sleeve
(a) Loosen the nut between the transmission rear
suspension and the frame.
(b) Adjust the jack height, pull out the bolt,
separate the transmission rear mounting
bracket.
fpwx15b0216
Note
Lower the vehicle to an appropriate height, hold
the bottom of the engine subframe and the
transmission with a hydraulic lifting device to
ensure safety and smoothness.
28 . Dismount fixing bolts of the engine left

mounting bracket and break the
connection.
Tool: 13mm sleeve
fpwx15b0217
29 . Dismount 4 fixing bolts of the engine right

mounting bracket and break the
connection.
Tool: 15mm sleeve
fpwx15b0218
30 . Slowly lower the engine and transmission assembly to completely separate them
from the frame.
Note
• Check whether the engine and gearbox are completely separated from the
vacuum hose, fuel and coolant hoses and electrical wires.
• Slowly lower the engine to an appropriate location, check again that all hoses
and electrical wires have been disconnected from the engine/gearbox.
31 . Separate the engine from the transmission assembly. (See Chapter 41B
15B Transmission - Transmission Assembly, Replacement )
32 . Remove the air intake manifold. (See 14B Intake(4W10/4W12) - Intake Manifold,
Replacement)
33 . Dismount the A/C compressor. (See Chapter 61 Heating and A/C - A/C
Compressor 4W10/4W12, Replacement)
34 . Dismount the generator. (See20B Starting and Charging(4W10/4W12) - Engine,
Overhaul)
35 . Disassemble the exhaust manifold. (See16B Exhaust(4W10/4W12) - Exhaust
Manifold, Replacement)
36 . Remove the related wiring harness connected to the engine.
37 . Install the exhaust manifold. (See16B Exhaust(4W10/4W12) - Exhaust Manifold,
Replacement)
38 . Install the engine. (See20B Starting and Charging(4W10/4W12) - Engine, Overhaul)
39 . Install the A/C compressor. (See Chapter 61 Heating and A/C - A/C Compressor
4W10/4W12, Replacement)
40 . Install the air intake manifold. (See 14B Intake(4W10/4W12) - Intake Manifold,
Replacement)
41 . Reset the related wiring harness connected to the engine.
42 . Install the engine and the transmission assembly. (See Chapter 41B
43 . Correctly position the engine and transmission assembly on the hydraulic lifting
device in an appropriate location underneath the vehicle.
44 . Lift the hydraulic lifting device until the lower engine mounting bracket and the
frame are properly engaged and the transmission rear suspension is in place.
Note
• Slowly lift the hydraulic lifting device, ensure that the engine and transmission
do not interfere with the frame during lifting.
• Adjust the position of the engine water pipe as well as the A/C piping and the
harness assembly to facilitate the engine installation.
45 . Install the engine right bracket and tighten

4 fixing bolts.
Tool: 15mm sleeve
(70±7N·m) Torque: 70 ± 7N•m
fpwx15b0219
46 . Install the engine left bracket and tighten

1 fixing bolt.
Tool: 13mm sleeve 15B
(70±7N·m)
fpwx15b0220
47 . Install the gearbox rear bracket and tighten

the nut.
Tool: 13mm sleeve
(70±7N·m)
fpwx15b0221
48 . Install the drive shaft. (See Chapter 34 Bridge and Drive Shaft - Drive Shaft
Assembly, Overhaul)
49 . Install the exhaust pipe. (See 16B Exhaust(4W10/4W12) - Exhaust Pipe,
Replacement)
50 . Install the gearbox to the body grounding

line and tighten 1 fixing bolt.
Torque: 9±1N•m
fpwx15b0222
51 . Mount the clutch cable from the engine

bracket mounting hole and tighten 2 nuts.
Tool: 10mm sleeve
Torque: 9±1N•m
(9±1N·m)
fpwx15b0223
15B 52 . Install the engine connection water pipe.

(a) Connect the expansion tank to the engine
pipeline and tighten clamps.
(b) Connect the water tank with the engine
pipeline and tighten mounting clamps.
(c) Connect the brake vacuum tube and tighten
clamps.
fpwx15b0224
53 . Install the thermostat connection water

pipe.
(a) Connect the thermostat to the water tank
pipeline and tighten clamps.
(b) Connect the thermostat to the heater water
tank pipeline and tighten clamps.
fpwx15b0225
54 . Install the gear shift cable.

(a) Install 2 cotter pins connecting the
transmission on the upper part of the shift
cable.
(b) Install 2 mounting clamps connecting the
transmission on the lower part of the shift
cable.
fpwx15b0226
55 . Tighten the fixing bolt of the battery

positive connection wiring harness and
connect the wiring harness connector.
(10±1N·m)
Tool: 10mm sleeve

Torque: 10±1N•m
fpwx15b0227
56 . Connect the injector rail inlet pipe and fix

inlet pipe snaps.
fpwx15b0228
57 . Install and tighten 5 harness fixing snaps 15B

on the upper part of the engine
compartment.
fpwx15b0229
58 . Install connection accessories on the left

side of the engine compartment.
(a) Connect 2 engine harness connectors on the
left side of the engine compartment.
(b) Install the body grounding line and tighten
bolts.
fpwx15b0230 Torque: 10±1N•m
59 . Install the generator terminal and fixing

the nut.
Tool: 13mm sleeve
Torque: 10±1N•m
(10±1N·m)
fpwx15b0231
(10±1N·m)
60 . Connect the high/low pressure pipeline of
an A/C compressor and tighten 2 fixing
bolts.
Tool: 13mm sleeve
Torque: 10±1N•m
fpwx15b0232
61 . Connect the throttle cable and tighten the

adjusting nut
Tool: 13mm wrench
(9±1N·m)
Torque: 9±1N•m
fpwx15b0233
15B 62 . Connect the air filter to the throttle connection intake hose.
(a) Connect the intake pipe on the air filter side
and tighten clamps.
(b) Connect the intake air temperature sensor
connector.
(c) Connect the crankcase intake pipe and tighten
clamps.
fpwx15b0235
(d) Connect the intake pipe on the throttle intake
side and tighten clamps.

(a) Connect the intake pipe on the air filter side
and tighten clamps.
(b) Connect the crankcase intake pipe and tighten
clamps.
(c) Connect the intake pipe on the throttle intake
side and tighten clamps.
fpwx15b0234
63 . Install the connection accessories on the right side of the engine compartment.

(a) Connect the engine ECU connector.
(b) Connect the breathing pipe at the upper part
of the carbon tube and tighten clamps.
fpwx15b0237

(a) Connect the engine ECU connector.
(b) Connect the breathing pipe at the upper part
of the carbon tube and tighten clamps.
fpwx15b0236
64 . Lay down the front passenger seat. 15B

65 . Install the battery and then connect the negative cable of the battery. (See20A
Starting and Charging(LJ465) - Battery, Replacement)
66 . Lay down the driver seat.
67 . Refill coolant. (See 17A Cooling(LJ465) - Coolant, Replacement)
68 . Refill transmission oil. (See Chapter 41A Transmission - Transmission Assembly,
Replacement )
70 . Fill A/C refrigerant. (See Chapter 61A Heating and A/C - Refrigerant, Replacement)
15B-16 Engine Mechanism System(4W10/4W12) - Timing Front Cover
Timing Front Cover

Replace
1. Dismount the ignition coil and the spark plug cable. (See19B Ignition
System(4W10/4W12) - Ignition Module/High-voltage Coil/Spark Plug, Overhaul)
2. Dismount 12 bolts of the valve cover and
remove the valve chamber cover.
Tool: 10mm sleeve
fpwx15b0001
3. Dismount 4 fixing bolts of the generator

bracket and remove the generator bracket.
Tool: 10mm sleeve
15B
fpwx15b0002
4. Dismount 1 fixing bolt of a dipstick tube

and remove the dipstick tube.
Tool: 10mm sleeve
fpwx15b0003
5. Dismount 1 fixing bolt of a crankshaft

pulley and remove the crankshaft pulley.
Tool: 17mm sleeve
fpwx15b0004
Engine Mechanism System(4W10/4W12) - Timing Front Cover 15B-17
6. Dismount 19 fixing bolts of the timing front

cover and remove the timing front cover.
Tool: 10mm sleeve
fpwx15b0005
7. Clean up the impurities on the timing front cover side.

8. Install the timing front cover to the correct
position and tighten 19 fixing bolts.
Tool: 10mm sleeve
Torque: 10 ± 2N•m 15B
(10±2N·m)
fpwx15b0006
9. Install the crankshaft pulley to the correct

position and tighten 1 fixing bolt.
Tool: 17mm sleeve
Torque: 150±5N•m
(150±5N·m)
fpwx15b0007
15B-18 Engine Mechanism System(4W10/4W12) - Timing Front Cover
10 . Install the dipstick tube to the correct

(10±2N·m) position and tighten 1 fixing bolt.
Tool: 10mm sleeve
fpwx15b0008
11 . Install the generator bracket to the correct

position and tighten 4 fixing bolts.
Tool: 10mm sleeve
Torque: 30±5N•m
(30±5N·m)
fpwx15b0009
15B 12 . Install the valve chamber cover to the

(10±2N·m) correct position and tighten 12 fixing bolts.
Tool: 10mm sleeve
13 . Install the ignition coil and the spark plug
cable. (See19B Ignition
System(4W10/4W12) - Ignition
fpwx15b0010
Module/High-voltage Coil/Spark Plug,
Overhaul)
Engine Mechanism System(4W10/4W12) - Timing Chain 15B-19
Timing Chain
Component Diagrams
1 7
8
2
11
9
2 12 10 15B
fpwx15b0301
1 Timing Chain 7 Intake camshaft component

2 Hexagonal flange face bolt - extra 8 Exhaust camshaft component
size range 9 Hexagonal flange face bolt - extra
3 Camshaft chain fixed guide rail size range
4 Hexagonal flange face bolt 10 Camshaft chain tensioner
5 Intake camshaft sprocket 11 Tension rail bolt
6 Exhaust camshaft sprocket 12 Tension rail
15B-20 Engine Mechanism System(4W10/4W12) - Timing Chain
Overhaul
1. Remove the valve chamber cover.
2. Dismount the timing front cover. (See15B Engine Mechanism System(4W10/4W12)
- Timing Front Cover, Replace)
3. Mark the direction of timing chain rotation
in order to confirm the installation
direction during installation.
fpwx15b0011
15B 4. Mark the engine timing symbol.
fpwx15b0012
5. Align with and mark the camshaft driving

wheel timing symbol.
fpwx15b0013
6. Align with and mark the crankshaft driving

wheel timing symbol.
fpwx15b0014
7. Insert the cotter pin into the locking hole

on the automatic tensioner and confirm
there is no tension.
fpwx15b0015
8. Dismount the automatic tensioner bolts 15B

and remove the automatic tensioner.
Tool: 10mm sleeve
1.2E4W1205000009
fpwx15b0016
9. Check the automatic tensioner.

(a) Measure the overhang of automatic tensioner,
replace the automatic tensioner if it does not
1-2E4W12050000009
meet the standard.
fpwx15b0017
(b) Disassemble the tensioner and check all parts

for wear or damage, replace if necessary.
1-2E4W12050000009
fpwx15b0018
10 . Dismount 3 fixing bolts of the timing chain

guide and remove the timing chain guide.
Tools: 12mm sleeve (left) / 10mm sleeve
(right)
fpwx15b0019
11 . Remove the timing chain and check it for

wear.
15B
fpwx15b0020
12 . Remove the crankshaft timing driving

wheel.
fpwx15b0027
13 . Dismount 6 fixing bolts of the camshaft

drive wheel and remove the driving wheel.
Tool: 10mm sleeve
fpwx15b0022
14 . Installation of automatic tensioner:

(a) If the automatic tensioner lever is in the extended position, retract it as specified below.
(b) Press the automatic tensioner using a vice

with soft jaw.
Note
Since there is cock overhang at the bottom of
1-2E4W12050000009
an automatic tensioner, you should insert a flat
bottom plate between the vise and the plug
screw to prevent direct contact between the two.
fpwx15b0023 (c) Slowly push in the lever with a vise until the
lever hole is aligned with the automatic
tensioner hole, then insert a pin into aligned
holes.
(d) Loosen the vise, remove the automatic
tensioner.
15 . Align camshaft timing marks.
15B
fpwx15b0024
16 . Install the camshaft drive wheel to the

correct position and tighten 6 bolts.
(35±3N·m)
Tool: 10mm sleeve
fpwx15b0025
17 . Align camshaft drive wheel timing marks.
fpwx15b0026
18 . Align crankshaft timing drive wheel marks,

then install crankshaft timing drive wheels.
fpwx15b0021
19 . Install a timing chain in accordance with

timing chain signed points.
Note
When installing a timing chain, do not move the
timing mark and 3 marked points of the timing
chain correspond with the crankshaft drive wheel
and the camshaft drive wheel.
15B
fpwx15b0028
20 . Install and tighten fixing bolts on the right

guide of timing chain.
Tool: 10mm sleeve
(10±2N·m) Torque: 10 ± 2N•m
fpwx15b0029
21 . Install and tighten fixing bolts on the left

guide of timing chain.
Tool: 10mm sleeve
(10±2N·m)
fpwx15b0030
22 . Press the timing chain tensioner to the

bayonet lock position and tighten 2 bolts.
Tool: 10mm sleeve
(13±1N·m)
Torque: 13±1N•m
1.2E4W1205000009
fpwx15b0031
23 . Install the engine timing front cover. (See15B Engine Mechanism

System(4W10/4W12) - Timing Front Cover, Replace)
24 . Mount an engine valve chamber cap.
15B
15B-26 Engine Mechanism System(4W10/4W12) - Valve Tappet and Camshaft
Valve Tappet and Camshaft

Valve Tappet Overhaul
1. Dismount 12 bolts of the valve cover and
remove the valve chamber cover.
Tool: 10mm sleeve
fpwx15b0032
2. Dismount 19 fixing bolts of the timing front

cover and remove the timing front cover.
Tool: 10mm sleeve
15B
fpwx15b0033
3. Dismount 20 fixing bolts of the camshaft

1 3 5 4 2 one by one in numerical order and remove
the camshaft shaft-cover.
1 3 5 4 2
Tool: 10mm sleeve
6 8 10 9 7
6 8 10 9 7
fpwx15b0034
4. Remove the camshaft.
fpwx15b0102
Engine Mechanism System(4W10/4W12) - Valve Tappet and Camshaft 15B-27
5. Remove the valve tappets and mark.
fpwx15b0035
6. Check the valve tappet.

(a) Check tappet clearance according to the label
inside the valve tappet.
366 (b) Check the tappet inner diameter, replace the
WL
it if there are any scratches or other damages.

130601
fpwx15b0036
7. Check and clean the valve tappet, replace it in time if damage is identified: 15B
Note
• Valve tappet is a precision component. Its surface should be free of dust and
foreign matter.
• There is a label inside the valve tappet, do not make mistake during installation.
• Clean valve tappets with clean diesel.
(a) Prepare 1 container and diesel. Pour enough

diesel into the container to completely
submerge the valve tappet.
(b) Place valve tappets in the container and clean
366
their outer surface
WL
30601 Note
Remove the hard deposit with a nylon brush.
fpwx15b0037
8. Install valve tappets in accordance with

marks made during dismounting.
fpwx15b0039
9. Install the camshaft in place.

Note
Fill in the right amount of oil during installation.
fpwx15b0040
10 . Install the camshaft shaft cover in

(13±1N·m)
4 2 1 3 5 dismounting order and tighten 20 fixing
bolts one by one in numerical order.
4 2 1 3 5
Tool: 10mm sleeve
Torque: 13±1N•m
10 8 6 7 9
10 8 6 7 9
fpwx15b0041
15B 11 . Confirm the valve clearance. Adjust valve

clearance if any difference to prevent the
valve clearance from becoming too large
or too small. Valve tappet has valve label
on the back, select the correct label when
adjusting valve tappets.
fpwx15b0042
12 . Install the timing front cover and tighten

19 fixing bolts.
Tool: 10mm sleeve
(13±1N·m)
Torque: 13±1N•m
fpwx15b0043
13 . Mount a new engine valve chamber cap

gasket
fpwx15b0044
14 . Install the engine valve cover and tighten

(10±2N·m) 12 fixing bolts.
Tool: 10mm sleeve
fpwx15b0045
15B
Camshaft Overhaul
1. Dismount the timing chain. (Refer to15B Engine Mechanism System(4W10/4W12)
- Timing Chain, Overhaul)
drive wheel and remove the driving wheel.
Tool: 10mm sleeve
fpwx15b0046

1 3 5 4 2 one by one in numerical order and remove
the camshaft shaft-cover.
1 3 5 4 2
6 8 10 9 7
15B
6 8 10 9 7
fpwx15b0100
4. Remove the camshaft.

(a) Check the bearing hole in the camshaft. Use
a lever indicator to check the inner diameter
of the bearing hole in the camshaft. If the
inner diameter of the hole exceeds its limit
value, replace the cylinder head.
Limit value of the bearing hole on the
fpwx15b0101 camshaft: φ23.00mm-φ23.021mm
5. Check the camshaft:

(a) Observe the camshaft axis surface for pitting, wear and crack. Once found, replace it
with a new camshaft.
(b) Use a micrometer to measure all the journal diameters. Use the measured value of
bearing hole's diameter to subtract its corresponding journal diameter and its D-value
is the journal clearance. If the journal clearance of the camshaft exceeds its limit value,
replace it.
Limit clearance value: 0.15 (0.082) mm
(c) Measure the cam height:

Name Standard Standard
value (4W12M) value (4W10M)
39.94 (39.93) 39.94 (39.93)
Intake cam
mm mm
15
10
39.40 (39.39) 39.40 (39.39)

Exhaust cam
fpwx15b0047
mm mm
6. Install the camshaft.
fpwx15b0098
7. Install the camshaft shaft cover in 15B

(13±1N·m)
4 2 1 3 5 dismounting order and tighten 20 fixing
4 2 1 3 5
Tool: 10mm sleeve
Torque: 13±1N•m
10 8 6 7 9
10 8 6 7 9
fpwx15b0099
8. Install the camshaft drive wheel to the

correct position and tighten 6 fixing bolts.
(35±3N·m)
Tool: 10mm sleeve
fpwx15b0048
9. Install the timing chain. (Refer to15B Engine Mechanism System(4W10/4W12) -

Timing Chain, Overhaul)
15B-32 Engine Mechanism System(4W10/4W12) - Cylinder Head and Valve

Component Diagrams
Valve Chamber Cap
3
1
2
8
4
5
15B 6
fpwx15b0305
1 Hexagon socket head cap screw 5 Crankcase ventilation hose (outlet)

2 Decorative plate 6 Steel strip spring clamp
3 Hexagonal flange face bolt - extra 7 Cylinder head cover components
size range 8 Oil refill cap components
4 PCV valve components
Engine Mechanism System(4W10/4W12) - Cylinder Head and Valve 15B-33
Cylinder Head
3
15B
6
4
fpwx15b0306
1 Hexagonal flange face bolt 2 4 Cylinder head components

2 Cylinder head cap gasket 1 5 Left lifting hook
3 Right lifting hook 1
6
5
10
15B
7
fpwx15b0300
1 Valve upper site of spring 6 Valve lock clamp

2 Valve tappet 7 Intake Valve
3 Valve spring 8 Cylinder head bolt
4 valve oil seal 9 Flat Washer
5 Exhaust Valve 10 Cylinder gasket components
Cylinder Head Overhaul

1. Dismount the timing chain. (See15B Engine Mechanism System(4W10/4W12) -
Timing Chain, Overhaul)
2. Dismount the valve tappet. (See15B Engine Mechanism System(4W10/4W12) -
Valve Tappet and Camshaft, Valve Tappet Overhaul)
3. Remove the camshaft. (See15B Engine Mechanism System(4W10/4W12) - Valve
Tappet and Camshaft, Camshaft Overhaul)
4. Dismount 10 fixing bolts of the cylinder
head one by one in numerical order and
1 3 5 4 2 remove the cylinder head.
Tool: T40
1 3 5 4 2
Note
When loosening cylinder head bolts, loosen them
evenly and gradually so that to apply even force
fpwx15b0049
on the cylinder head.
5. Remove and check the cylinder head gasket.

6. Clean the cylinder head assembly and check the cylinder head for cracks or 15B
serious damage, replace if necessary.
7. Check the flatness of cylinder head bottom
8
7
6
surface with a straightedge and a
9
clearance gauge, grind (grind the cylinder

10
1
2
3
4
5
6
7
8
9
20
1
head together with the cylinder block) or

2
3
4
5
6
7
8
9
30
1
2
replace it if there is excessive deformation.

3
4
5
6
7
8
9
40
1
2
3
4
5
6
7
Limit value of base plane flatness: 0.05

8
9
50
1
2
3
(0.03) mm
fpwx15b0050 Limit value of front end face flatness: 0.08
(0.05) mm
Limit value of exhaust face flatness: 0.05
(0.05) mm
Limit value of intake face flatness: 0.05
(0.05) mm
8. Check the cylinder head height and replace the head if the standards are not
met.
9. Install a new cylinder head gasket.
Danger
Properly install the cylinder head gasket, the cylinder gasket duct must match along
with the duct on the upper plane of the cylinder block, otherwise it will cause serious
engine damage
10 . Install the cylinder head components.
Note
Only fix the cylinder head assembly after installing a locating pin in place.
11 . Make sure the bolt length is within the

standard range before installing cylinder
head bolts.
fpwx15b0051
12 . Tighten 10 cylinder head component bolts

(70±3N·m) one by one in numerical order.
5 3 1 2 4
Tool: T40
Step 1: 15±3Nm
5 3 1 2 4
Step 2: 40±3Nm
15B Step 3: 70±3Nm
fpwx15b0052 Note
• Apply right amount of engine oil on

threaded parts of cylinder head bolts and
washers to facilitate screw tightening.
• If bolts are over-tightened, you should
completely loosen the bolts and then
retighten them.
13 . Install the camshaft. (See15B Engine Mechanism System(4W10/4W12) - Valve

Tappet and Camshaft, Camshaft Overhaul)
14 . Install the valve tappet. (See15B Engine Mechanism System(4W10/4W12) - Valve
Tappet and Camshaft, Valve Tappet Overhaul)
15 . Install the timing chain. (See15B Engine Mechanism System(4W10/4W12) - Timing
Chain, Overhaul)
Valve Overhaul
1. Remove the cylinder head. (See15B Engine Mechanism System(4W10/4W12) -
Valve Tappet and Camshaft, Camshaft Overhaul).
Note
Removed valve, valve spring and other parts should be put up with a label marked
with cylinder number and installation location and well stored for the correct installation
during assembly.
2. Dismount the valve locking spring with a

tool, remove the valve spring upper seat,
valve spring and valve spring gasket
respectively.
fpwx15b0054
3. Dismount the valve seal and remove the

valve. 15B
Note
The valve oil seal cannot be reused.
fpwx15b0055
4. Check the valve spring:

(a) Measure the valve spring free height, replace
it if it is less than the limiting value.
Limiting value: 43.49 - 43.65mm
(b) Measure the vertical height between the
spring centerline and the bottom, replace it if
it does not meet the criteria.
fpwx15b0056
Standard value: 1°
5. Check the valve:

(a) Check the valve working surface and the valve seat for contact seal. If the contact
seal is poor, reground them with a valve grinder. The valve seat contact surface must
be consistent with the valve working face center.
(b) Check the valve edge thickness, replace the

valve if the thickness is not as specified and
grind it with a valve grinder:
Valve edge Standard Limit value
thickness value
Air inlet 2.8mm 2.7 - 3.1mm
fpwx15b0057
Exhaust 2.45mm 2.35 - 2.75mm
(c) Check the valve total height, replace it if the

height is less than the limiting value:
Valve total Standard Limit value
height value
98.945 -
Air inlet 99.17mm
99.395mm
fpwx15b0058
99.785 -
Exhaust 100.01mm
100.235mm
15B
6. Check the valve stem diameter, replace
the valve if it exceeds the limiting value:
Diameter Standard Limit value
5
5
5
0 value
10
φ4.965 -
Air inlet φ 4.972 mm
φ4.979mm
fpwx15b0059 φ4.956 -
Exhaust φ 4.963 mm
φ4.970mm
7. Use an internal micrometer to measure the diameter of the valve duct, and then
decide whether the duct needs to be replaced or not. If the measured value is
out of the limit, replace by the following procedure:
Limit value of valve duct diameter: φ5.000 mm～φ5.057mm (φ5.000 mm -φ5.012
mm)
,
Note
Do not use a new valve duct which has the same size as the one removed.
(a) Heat the cylinder head and remove the valve seat.
(b) Press out the valve tube towards the cylinder head lower plane with a tool.
(c) Machine the valve tube hole of the cylinder head, so that the hole diameter reaches
the dimension of an enlarged valve duct.
(d) Install a new valve duct, press the valve duct

downward from cylinder head top surface until
its protruding amount meets the standard.
Note
• Press down the valve duct from cylinder

head top surface.
• The length of an intake valve duct and that
fpwx15b0060
of an exhaust valve duct is different.
(e) Insert a new valve after installing the valve duct and check the valve for smooth axial
movements.
8. Assemble the valve and measure the protruding height of valve stem between
the valve stem end and the valve spring seat.
9. Trim the valve seat:
(a) Check the clearance between valve duct and valve stem, if necessary, trim it after
replacing the valve duct.
(b) Trim the width and angle of a valve seat to specified values with a grinder.
(c) After trimming the valve seat, grind the valve and the valve seat in pairs with abrasive
15B
paste. Then check the valve stem projection height.
10 . Install the valve in accordance with marks made during the removal.
11 . Install the valve spring gasket.
12 . Install a new valve seal with tools.
fpwx15b0063
13 . Install the valve spring.

Note
When installing the valve spring, the end smeared with identification color should face
to the valve spring upper seat.
14 . Install the valve spring upper seat.
15 . Install the valve locker with tools.
fpwx15b0064
16 . Install the cylinder head. (See15B Engine Mechanism System(4W10/4W12) -

Valve Tappet and Camshaft, Camshaft Overhaul).
15B
Engine Mechanism System(4W10/4W12) - Piston and Connecting Rod Assembly 15B-41
Piston and Connecting Rod Assembly

Component Diagrams
3
5
6
4
7 15B
8
fpwx15b0304
1 First gas ring 5 Piston pin snap ring

2 Second gas ring 6 Piston pin
3 oil scraper ring 7 Connecting rod components
4 Piston 8 Bearing bush of the connecting rod
15B-42 Engine Mechanism System(4W10/4W12) - Piston and Connecting Rod Assembly
Overhaul
1. Mark the big end of connecting rod with a
cylinder number for correct assembly.
2
1
Note
Place the removed connecting rod, connecting
rod cap and connecting rod bearing according
to cylinder number to avoid confusion during
installation.
fpwx15b0065
2. Dismount 8 fixing bolts of connecting rod

3 2 4 cap one by one according to numeric
1
order.
5
1 2 3 4
Tool: 12mm sleeve
3 1 2 4
15B fpwx15b0066
3. Gently knock out the piston and the

connecting rod assembly with a wooden
or a plastic stick.
fpwx15b0067
4. Separate the connecting rod bearing.

5. Dismount the piston pin with a tool.
Note
Place the disassembled piston, piston pin and connecting rod away following the
cylinder number to avoid confusion during installation.
(a) Dismount bayonet locks on both ends of the

piston with special tools.
(b) Hold the piston forward mark upward, install
base of the piston pin.
fpwx15b0068
(c) Press out the piston pin with pressure.
fpwx15b0069
6. Dismount the first gas ring, the second

gas ring and the oil ring.
Note
• Clean up the carbon deposit on the piston

surface and in the air ring and the greasy
dirt in the oil ring.
• Be careful not to scratch the piston
fpwx15b0103
surface.
15B
7. Check the piston ring for damage, excessive wear and crack and replace it if
any. When replacing a piston, replace its piston ring all together.
8. Check the lateral clearance between a
piston ring and a piston ring groove, if too
large, replace the piston ring or replace
the piston and the piston ring.
fpwx15b0070
9. Insert the piston ring into the cylinder, and

use a thickness gauge to measure the
clearance. If the clearance exceeds the
limit value, replace the pistion ring. Clean
the cylinder hole and the piston ring, and
clear up the carbon deposit. End clearance
value:
Ring 1 standard value: 0.15～0.30 mm;
limit value: 0.7 mm
Ring 2 standard value: 0.30～0.45 mm;
limit value: 1.00 mm
fpwx15b0071
10 . Check the oil clearance of a crank pin with

a plastic gauge:
(a) Clean up the engine oil on rod journal and rod
bearing.
(b) Cut the plastic gauge to the same length as
the bearing width and then place it on the
crank pin, so that it is parallel to the shaft
centerline.
fpwx15b0072
(c) Carefully install the rod cover and tighten the
nut to the specified torque.
(d) Carefully remove the rod cover.
(e) Measure the width of widest part of a flattened

plastic wire with the ruler printed on a
packaging bag of a plastigauge to obtain the
clearance value.
15B
fpwx15b0073
11 . Install the piston pin:

(a) Assemble the piston forward mark and the rod forward mark in the same direction.
(b) Apply engine oil on the outside diameter of the piston pin.
(c) Insert the assembled piston pin, strut and duct components from the forward mark
side into a piston pin hole.
(d) Hold the piston forward mark upward, install

base of the piston pin and press it into the
piston pin.
(e) Install bayonet locks on both sides of the
piston.
fpwx15b0074
12 . After installing the piston pin, check

whether the piston can rotate freely
against the connecting rod or not.
fpwx15b0075
13 . Install the oil ring:

Note
There is no difference between topside and
underside for the oil ring blade and the main
ring.
(a) Put in the upper blade. When installing a
blade, simply press one end of the blade into
fpwx15b0076 the piston oil ring groove, then press the rest
of the blade with your thumb into the oil ring
groove as shown.
Note
Do not install the oil ring blade with a piston ring
plier as the blade may be broken when expended
by the piston ring plier.
(b) Install the lower blade by following the same
steps as (a).
(c) Confirm that the installed oil ring can rotate
freely.
15B
14 . Install the first gas ring and the second gas ring:
(a) Install the second gas ring with a piston ring
plier, then install the first gas ring.
Note
When installing the piston ring, put the
distinguishing mark upward, toward the top of
the piston.
fpwx15b0077
(b) The gas ring open end is labeled with

identification marks, the first gas ring: A1, the
second gas ring: A2.
A
A
A1
A2
fpwx15b0078
15 . Adjust the opening direction of the gas ring and the oil ring:
(a) Apply clean engine oil on the piston ring groove, the gas ring and the oil ring.
(b) Adjust the opening position of the gas ring

and the oil ring to the position shown.
1 5
Oil ring upper blade
1
opening
2 Piston pin position
6 2 Oil ring lower blade
3
opening
Collar and second
4
gas ring openings
4 3
First gas ring
5
fpwx15b0079
opening
Crankshaft belt
6
pulley side
16 . Rotate the crankshaft, so that the crank pin is in the central section of a cylinder.
17 . Before inserting the piston and the connecting rod assembly into a cylinder, the
15B connecting rod bolt should be furnished with an appropriate thread protective
device. Be careful not to bruise the crank pin.
18 . When installing the piston and the
connecting rod assembly, make sure the
E4W1203000002 arrow on the top of the piston faces to the
130801 timing chain side.
E4W1203000002
130801
fpwx15b0080
19 . Install the piston and the connecting rod

assembly with right piston ring
compression tool.
Note
• When installing the piston and connecting

rod assembly into the cylinder, be careful
not to bruise the crank pin with a
fpwx15b0081
connecting rod cap bolt.
• When installing the piston and rod
assembly, gently press the piston and the
connecting rod assembly with a wood or
plastic tool and avoid pressing vigorously,
otherwise the piston ring or crank pin may
be broken.
20 . Install the connecting rod cap according

to marks marked during dismounting. If
2
1
the link is a new part and without
combination marks, then install the upper
connecting rod bearing and the lower
connecting rod bearing groove on the
same side as shown.
fpwx15b0082
21 . Measure the axial clearance of connecting

rod big end with a clearance gauge.
fpwx15b0083
22 . Install the connecting rod nut: 15B

(a) Connecting rod bolts and nuts adopt a plastic range tightening method. Check a bolt
for stretch before re-using the bolt.
(b) Before tightening a nut, apply oil on the threaded portion of the nut and the seat surface.
(c) Tighten the nut on the bolt with your fingers, then alternately tighten the nut, so that
the connecting rod cap can be assembled correctly.
(d) Tighten the connecting rod nut.
Tool: 12mm sleeve
15B-48 Engine Mechanism System(4W10/4W12) - Crankshaft, Cylinder Block & Flywheel
Crankshaft, Cylinder Block & Flywheel

Component Diagrams
Crankshaft & Flywheel
1 2
3 4
15B 6
9
7
9
fpwx15b0303
1 Crankshaft damping pulley bolt 6 Flywheel components

2 Crankshaft damping pulley 7 Flywheel ring gear
3 Crankshaft chain wheel 8 Straight pin
4 Normal woodruff key 9 Flywheel bolt
5 Crankshaft
Engine Mechanism System(4W10/4W12) - Crankshaft, Cylinder Block & Flywheel 15B-49
Cylinder Block
4
1
8
1
2
7
6
7
10
9
5
15B
fpwx15b0302
1 Cylinder head locating sleeve 6 Main bearing bush

2 Cylinder block 7 Hexagonal flange face bolt - extra
3 Rear seal seat locating sleeve size range
4 Pump base generator mounting 8 Thrust bearing
bracket locating pin 9 Hexagonal flange face bolt - extra
5 Rear oil seal components size range
10 Cylinder block assembly
Overhaul
1. Dismount 6 fixing bolts of a flywheel one
by one according to numeric order and
remove the flywheel.
6
1 Tool: 13mm sleeve
4
3
2
5
fpwx15b0084
2. Dismount 6 fixing bolts of the crankshaft

rear seal and remove crankshaft rear oil
seal bolts.
Tool: 10mm sleeve
15B fpwx15b0085
3. Dismount 10 fixing bolts of the crankshaft

main bearing cap one by one in numerical
1 5 9 7 3
order and remove the crankshaft.
1 2 3 4 5 Tool: 14mm sleeve
2 6 10 8 4
fpwx15b0086
4. Remove the crankshaft and follow these steps to measure the crankshaft oil
film clearance with a plastic gauge:
(a) Check the wear extent of the crankshaft by
checking the cylindricities of different positions
on it. The cylindricity can show the uneven
wear extent of the crankshaft. If one of the
journals is excessively damaged or the
uneven wear extent exceeds its limit value,
grind the journal or replace the crankshaft.
Limit value of the spindle diameter: 0.007
fpwx15b0087
(0.005) mm
(b) Install the crankshaft.

(c) Cut off plastic gauge material with a length
equals to the bearing width and place it on
the crankshaft journal, so that it is parallel to
the crankshaft journal.
(d) Carefully install the crankshaft main bearing
cap and tighten bolts to the specified torque.
(e) Dismount crankshaft main bearing cap bolts,
fpwx15b0088
then carefully remove the crankshaft main
bearing cap.
(f) Measure the pressed part of the plastic gauge
material with the gauge printed on the plastic
gauge packaging material.
5. Remove the cylinder block assembly from the roll-over stand and check:
(a) Visually inspect the cylinder body for scratch, rust and other corrosions, or check for
cracks with testing agent. Trim or replace if there are obvious defects.
(b) Check the flatness of the top plane, the 15B

bottom plane and the front end plane of the
cylinder body by using the checker board and
the filler gauge. Make sure their surfaces have
no gasket particles or impurities.
Limit value of top plane flatness: 0.05
(0.03) mm
fpwx15b0089 Limit value of front end face flatness and
the bottom plane flatness: 0.08 (0.05) mm
(c) If the flatness of cylinder upper surface is too
large, you should adjust or replace it.
(d) Check the cylinder wall for scratches or other
injuries, trim or replace if there are obvious
scratches.
(e) Check the cylinder bore and cylindricity with

a cylinder gauge, if badly worn, trim it to a
larger size and replace the cylinder piston and
piston ring to fit the new size.
Project Standard Standard
value (4W12M) value (4W10M)
Cylinder bore 69.7(+0.01/+0.02)mm 68.5(+0.01/+0.02)mm
fpwx15b0090
(f) Measure the outer diameter of the piston to

be used in the thrust direction as shown.
(g) Calculate the boring size of cylinder bore
according to the piston outer diameter
measurement:
Boring size = piston outer diameter +
(clearance between the piston and the
fpwx15b0091 cylinder) -0.02mm (honing)
Note
If the cylinder needs to be bored, four cylinders
should be bored to the same size.
(h) Bore the diameter of each cylinder to the
boring size.
Note
Bore a cylinder in the following order in order to
avoid errors due to temperature rise: No.2 →
No.4 → No.1 → No.3
15B (i) Hone to the final cylinder diameter (piston
diameter + clearance between the piston and
the cylinder).
(j) Check the clearance between the piston and
the cylinder.
6. Install thrust bearing in accordance with

following items:
(a) Install a grooved bearing on the cylinder block
side.
(b) Install the groove-free bearing on the main
bearing cap side.
(c) Install the crankshaft thrust bearing at the third
fpwx15b0092
spindle bore of a cylinder body. Apply a little
oil on the thrust bearing surface to facilitate
the installation.
7. Install crankshaft main bearing cap bolts according to following items.

(a) Measure the bolt length before tightening
crankshaft main bearing cap bolts.
(b) Smear a little oil on the threaded portion of a
bolt and the seat surface.
fpwx15b0093
(c) Tighten 10 fixing bolts of the crankshaft main

(65±3N·m)
8 4 1 5 9
Tool: 14mm sleeve
1 2 3 4 5
7 3 2 6 10
fpwx15b0094
8. After installing the crankshaft main

bearing cap, confirm that crankshaft
rotates smoothly and check that the axial
clearance meets the standard value.
fpwx15b0095
9. Install the crankshaft rear end cap to the 15B

(10±2N·m) correct position and tighten 6 fixing bolts.
Tool: 10mm sleeve
Note
• Clear up the debris on the rear end cap

fpwx15b0096
surface after installing the crankshaft rear
end cap, be careful not to scratch the
contact surface.
• Apply sealant on the oil cap contact
surface.
• Make sure to install the rear end cap
quickly when the sealant is wet (≤15 min).
• After installation, keep lubricant and
coolant away from the sealing region for
about 1 hour.
10 . Install the flywheel in place, tighten 6 fixing

Tool: 13mm sleeve
6
1
4
Torque: 55±5N•m
3
2
5
(55±5N·m)
fpwx15b0097
15B
Exhaust(LJ465)
Exhaust Pipe.......................................16A-1
Precautions......................................16A-1
Replacement....................................16A-3
Exhaust Manifold................................16A-7
Replacement....................................16A-7
16A
16A
Exhaust(LJ465) - Exhaust Pipe 16A-1
Exhaust Pipe
Precautions
1. It is preferred to apply a little grease on the connecting surface before removing
the rubber lifting eye in order to realize successful removal and installation.
2. Replace the gasket with a new one and do not use the old gasket when installing
a exhaust pipe, otherwise it may easily lead to exhaust leakage.
3. As the exhaust pipe gasket would adhere to the exhaust pipe sealing surface
after long-term use, be sure to clean the sealing surface with a blade before
installing a new gasket to prevent leakage after installation.
16A
16A-2 Exhaust(LJ465) - Exhaust Pipe
Component Diagrams
16A
1 I-shaped hexagon nut 3 Muffler and lifting eye assembly

2 All-metal hexagon flange face lock
nut
Replacement
Note
The temperature of exhaust system is high when the engine is just turned off, do not
operate until the exhaust system is completely cooled.
3. Dismount the muffler assembly.
(a) Dismount 2 fixing nuts of the muffler.
Tool: 15mm sleeve
Note
Hold one end of the exhaust pipe with a bracket,

and then dismount the other end.
fpwx16a0001
(b) Dismount 1 rubber lifting eye on the rear end

of a muffler.
Note 16A
Since exhaust pipe gasket may adhere to both

ends of a muffler assembly after the long-term
use, you should clean the contact surface of
both ends with a blade after dismounting the
fpwx16a0002 muffler assembly and replace with a new exhaust
pipe gasket. So to prevent leakage after the
installation.
(c) Dismount 2 rubber lifting eyes on the front

end of a muffler.
fpwx16a0003
(d) Dismount and remove the muffler assembly.
fpwx16a0004
4. Check the muffler assembly.

(a) Beat or shake the muffler to check for abnormal noise due to internal fracture, if replace
the muffler if any.
(b) Check the muffler appearance for holes due to corrosion caused by water and gas
leakage, replace the muffler if any.
5. Dismount the three-way catalytic converter.
(a) Disconnect the rear oxygen sensor harness
connector.
Note
Hold one end of the way catalytic converter with

16A
a bracket and then dismount the other end
fpwx16a0005
(b) Dismount 3 fixing nuts connecting the front

end of a three-way catalytic converter with an
exhaust manifold.
Tool: 16mm sleeve
fpwx16a0006
6. Remove the rear oxygen sensor of a

three-way catalytic converter.
fpwx16a0007
7. Dismount the rear oxygen sensor. (See 11A Engine Control System(LJ465) -
Rear oxygen sensor, Overhaul )
8. Check the three-way catalytic converter.
Check the three-way catalytic converter.

Note
• Replace the exhaust pipe interface gasket during each reassembly.

• When installing an insulation gasket, be sure to avoid large gap or blockage
between the heat gasket and the exhaust pipe and do not interfere with each
exhaust pipe
• When mounting a fixing rubber, be sure to avoid up/down and left/right twists
or excessive stretches.
9. Install the rear oxygen sensor to the three-way catalytic converter assembly.
10 . Install the three-way catalytic converter assembly.
(a) Install and tighten 3 fixing nuts connecting a
three-way catalytic converter with an exhaust
manifold.
(50±5N·m)
Tool: 16mm sleeve
Torque: 50±5N•m
fpwx16a0008
16A
(b) Connect the rear oxygen sensor harness
connector.
fpwx16a0009
11 . Install the muffler assembly.

(a) Install 2 rubber lifting eyes on the front end of
a muffler.
fpwx16a0010
(b) Install 1 rubber lifting eye on the rear end of

a muffler.
fpwx16a0011
(c) Tighten 2 fixing nuts on the front end of a rear

muffler.
Tool: 15mm sleeve
Torque: 50±5N•m
(50±5N·m)
fpwx16a0012

(a) Confirm the clearance between the exhaust pipe tail section and the rear bumper is
16A uniform.
(b) When the engine is running, check the exhaust pipe joints for leaks and abnormal
sound.
(c) Make sure the mounting bracket and the fixing rubber have been installed correctly
without excessive force. Improper installation may result in excessive noise and
vibration.
Exhaust(LJ465) - Exhaust Manifold 16A-7
Exhaust Manifold
Replacement
Note
As a high-temperature part, the exhaust manifold should only be operated after
complete cooling.
3. Dismount the three-way catalytic converter assembly. (See 16A Exhaust(LJ465)
- Exhaust Pipe, Replacement)
Note
Gaskets on the front and rear ends of the three-way catalytic converter are different,
do not be confused.
5. Dismount the front oxygen sensor. (See11A Engine Control System(LJ465) -
Front oxygen sensor, Overhaul)
6. Dismount and remove the exhaust manifold heat shield.
(a) Dismount 5 bolts on the exhaust manifold
upper heat shield.
Tool: 10mm sleeve 16A
fpwx16a0013
(b) Dismount 3 nuts on the exhaust manifold

lower heat shield.
Tool: 10mm sleeve
Note
As exhaust manifold heat shield bolts are

exposed to long term high-temperature or
fpwx16a0014
corroded, be cautious during dismounting to
avoid twisting them off.
(c) Remove the exhaust manifold heat shield.
7. Dismount the exhaust manifold assembly.

16A-8 Exhaust(LJ465) - Exhaust Manifold
(a) Dismount 8 mounting nuts of the exhaust

manifold.
Tool: 13mm sleeve
Note
Nuts on the exhaust manifold of a long millage

vehicle tend to rust, be sure to use rust cleaning
fpwx16a0015
spray and carefully loosen these nuts.
(b) Remove the exhaust manifold.

Note
• Check the component throughout for

damage or cracks.
• Check the flatness of exhaust manifold
and cylinder head mounting surface with
a ruler and a thickness gauge.
fpwx16a0016
Standard value: 0.15mm or lower
Limit: 0.20mm
• Clear out impurities on the contact surface
16A of the exhaust manifold and the cylinder
head.
8. Install the front oxygen sensor on the exhaust manifold.

9. Install a new exhaust manifold gasket.
Note
Otherwise, apply exhaust pipe sealant evenly on
the contact surface as needed in order to prevent
exhaust pipe leakage.
fpwx16a0017
10 . Install the exhaust manifold.

(a) Install 8 fixing nuts of the exhaust manifold.
Tool: 13mm sleeve
(50±5N·m) Torque: 50±5N•m
fpwx16a0018
Exhaust(LJ465) - Exhaust Manifold 16A-9
Note
• Apply antirust grease on nuts for easy

disassembly by next time.
• When installing nuts, tighten exhaust
manifold nuts evenly by following the
method of tightening from the middle to
both sides diagonally.
11 . Install the exhaust manifold heat shield.

(a) Install 3 fixing nuts on the exhaust manifold
lower heat shield.
Tool: 10mm sleeve
Torque: 10±1N•m
(10±1N·m)
fpwx16a0014
(b) Install 5 bolts on the exhaust manifold upper

heat shield. 16A
Tool: 10mm sleeve

(10±1N·m)
Torque: 10±1N•m
fpwx16a0013
12 . Install the catalytic converter to the exhaust manifold. (See16A Exhaust(LJ465)

- Exhaust Pipe, Replacement
(a) Confirm that the exhaust manifold and the cylinder head and the three-way catalytic
converter section are mounted in place.
(b) When the engine is running, check the exhaust manifold joints for leaks and abnormal
sound.
16A-10 Exhaust(LJ465) - Exhaust Manifold
16A
Exhaust(4W10/4W12)
Exhaust Pipe.......................................16B-1
Precautions......................................16B-1
Replacement....................................16B-2
Exhaust Manifold................................16B-6
Replacement....................................16B-7
16B
16B
Exhaust(4W10/4W12) - Exhaust Pipe 16B-1
Exhaust Pipe
Precautions
1. It is preferred to apply a little grease on the connecting surface before removing
the rubber lifting eye in order to realize successful removal and installation.
2. Replace the gasket with a new one and do not use the old gasket when installing
a exhaust pipe, otherwise it may easily lead to exhaust leakage.
3. As the exhaust pipe gasket would adhere to the exhaust pipe sealing surface
after long-term use, be sure to clean the sealing surface with a blade before
installing a new gasket to prevent leakage after installation.
16B
16B-2 Exhaust(4W10/4W12) - Exhaust Pipe
Replacement
Note
The temperature of exhaust system is high when the engine is just turned off, do not
operate until the exhaust system is completely cooled.
3. Dismount the muffler assembly.
(a) Dismount 2 fixing nuts of the muffler.
Tool: 15mm sleeve
Note
Hold one end of the exhaust pipe with a bracket,

and then dismount the other end.
fpwx16B0001
(b) Dismount 1 rubber lifting eye on the rear end

of a muffler.
Note
16B Since exhaust pipe gasket may adhere to both

ends of a muffler assembly after the long-term
use, you should clean the contact surface of
both ends with a blade after dismounting the
fpwx16B0002 muffler assembly and replace with a new exhaust
pipe gasket. So to prevent leakage after the
installation.
(c) Dismount 2 rubber lifting eyes on the front

end of a muffler.
fpwx16B0003
(d) Dismount and remove the muffler assembly.
fpwx16B0004
4. Check the muffler assembly.

(a) Beat or shake the muffler to check for abnormal noise due to internal fracture, if replace
the muffler if any.
(b) Check the muffler appearance for holes due to corrosion caused by water and gas
leakage, replace the muffler if any.
5. Dismount the three-way catalytic converter.
(a) Disconnect the rear oxygen sensor harness
connector.
Note
Hold one end of the way catalytic converter with

a bracket and then dismount the other end
16B
fpwx16B0005
(b) Dismount the front oxygen sensor.
fpwx16B0006
(c) Dismount 3 fixing nuts between the three-way

catalytic converter front end and an exhaust
manifold.
Tool: 16mm sleeve
fpwx16B0007
16B-4 Exhaust(4W10/4W12) - Exhaust Pipe
7. Check the three-way catalytic converter.

(a) Gently tap the catalytic converter for abnormal
sound resulting from looseness, replace the
catalytic converter if any.
(b) Check the fluctuation range of rear oxygen
sensor with a diagnostic unit, it may increase
if the three-way catalytic converter is
damaged.
fpwx16B0008
Note
• Replace the exhaust pipe interface gasket

during each reassembly.
• When installing an insulation gasket, be
sure to avoid large gap or blockage
between the heat gasket and the exhaust
pipe and do not interfere with each
exhaust pipe
• When mounting a fixing rubber, be sure
to avoid up/down and left/right twists or
excessive stretches.
8. Install the three-way catalytic converter

assembly.
16B
(a) Install and tighten 3 fixing nuts between the
(50±5N·m)
three-way catalytic converter and the exhaust
manifold.
Tool: 16mm sleeve
Torque: 50±5N•m
fpwx16B0009
(b) Install the rear oxygen sensor.
(25±3N·m)
fpwx16B0010
(c) Install the front oxygen sensor.
(25±3N·m)
fpwx16B0011
9. Install the muffler assembly.

(a) Install 2 rubber lifting eyes on the front end of
a muffler.
fpwx16B0012
(b) Install 1 rubber lifting eye on the rear end of

a muffler.
16B
fpwx16a0011
(c) Tighten 2 fixing nuts on the front end of a rear

muffler.
Tool: 16mm sleeve
Torque: 50±5N•m
(50±5N·m)
fpwx16B0014

(a) Confirm the clearance between the exhaust pipe tail section and the rear bumper is
uniform.
(b) When the engine is running, check the exhaust pipe joints for leaks and abnormal
sound.
(c) Make sure the mounting bracket and the fixing rubber have been installed correctly
without excessive force. Improper installation may result in excessive noise and
vibration.
16B-6 Exhaust(4W10/4W12) - Exhaust Manifold
Exhaust Manifold
Component Diagrams
6
16B
fpwx16b0300
1 Hexagonal flange face bolt - extra 5 Exhaust manifold components

size range 6 Lower heat shield components
2 Upper heat shield 7 Hexagonal flange face nut
3 Stud
4 Exhaust manifold gasket
Exhaust(4W10/4W12) - Exhaust Manifold 16B-7
Replacement
Note
As a high-temperature part, the exhaust manifold should only be operated after

complete cooling.
3. Dismount the three-way catalytic converter assembly. (See16B
Exhaust(4W10/4W12) - Exhaust Pipe, Replacement)
Note
Gaskets on the front and rear ends of the three-way catalytic converter are different,
do not be confused.
4. Dismount the exhaust manifold heat

shield.
(a) Dismount 5 bolts on the exhaust manifold
upper heat shield.
Tool: 10mm sleeve
fpwx16B0015
16B
(b) Dismount 3 bolts on the exhaust manifold

lower heat shield.
Tool: 10mm sleeve
Note
As exhaust manifold heat shield bolts are

exposed to long term high-temperature or
fpwx16B0016
corroded, be cautious during dismounting to
avoid twisting them off.
5. Disassemble the exhaust manifold.

(a) Dismount 9 mounting nuts of the exhaust
manifold.
Tool: 13mm sleeve
Note
Nuts on the exhaust manifold of a long millage

fpwx16B0017 vehicle tend to rust, be sure to use rust cleaning
spray and carefully loosen these nuts.
(b) Remove the exhaust manifold.

Note
• Check the component throughout for

damage or cracks.
• Check the flatness of exhaust manifold
and cylinder head mounting surface with
a ruler and a thickness gauge.
fpwx16B0018
Standard value: 0.15mm or lower
Limit: 0.20mm
• Clear out impurities on the contact surface
of the exhaust manifold and the cylinder
head.
6. Install a new exhaust manifold gasket.

Note
Otherwise, apply exhaust pipe sealant evenly on
the contact surface as needed in order to prevent
exhaust pipe leakage.
fpwx16B0019
16B
7. Install the exhaust manifold.

(a) Install 9 fixing nuts of the exhaust manifold.
(50±5N·m)
Tool: 13mm sleeve
Torque: 50±5N•m
Note
• Apply antirust grease on nuts for easy

fpwx16B0020
disassembly by next time.
• When installing nuts, tighten exhaust
manifold nuts evenly by following the
method of tightening from the middle to
both sides diagonally.
8. Install the exhaust manifold heat shield.

(a) Install 3 bolts on the exhaust manifold lower
heat shield.
Torque: 10±1N•m
fpwx16B0021
Exhaust(4W10/4W12) - Exhaust Manifold 16B-9
(b) Install 5 bolts on the exhaust manifold upper

heat shield.
Tool: 10mm sleeve
(10±1N·m)
Torque: 10±1N•m
fpwx16B0022
9. Install the catalytic converter to the exhaust manifold. (See16B

Exhaust(4W10/4W12) - Exhaust Pipe, Replacement)
(a) Confirm that the exhaust manifold and the cylinder head and the three-way catalytic
converter section are mounted in place.
(b) When the engine is running, check the exhaust manifold joints for leaks and abnormal
sound.
16B
16B
Cooling(LJ465)
Cooling System..................................17A-1
Precautions......................................17A-1
Check on Vehicle..............................17A-4
Coolant................................................17A-6
Replacement....................................17A-6
Expansion tank...................................17A-8
Replacement....................................17A-8
Electronic Fan Assembly...................17A-9
Overhaul...........................................17A-9
Radiator.............................................17A-12
Replacement..................................17A-12
Thermostat........................................17A-14
Overhaul.........................................17A-14
Water Pump......................................17A-17
Overhaul.........................................17A-17
17A
17A
Cooling(LJ465) - Cooling System 17A-1
Cooling System
Precautions
1. Collect the residual coolant with a special container when disconnecting cooling
system pipelines. If not continue to use, dispose it according to regulations.
2. When disconnecting the cooling system piping, do not let debris from entering
the cooling system piping, as this may damage the cooling system and the
engine.
3. When disconnecting the cooling system pipe joints, you must seal the mouth
of the pipe with a special blocking cap to prevent dirt or debris from entering.
4. Since coolant is toxic , if not to be used any more, it should be kept away from
children and pets and disposed in accordance with regulations.
5. Do not open the radiator cover from a hot engine. Do not remove the pressure
cover until coolant temperature drops below 50℃ [120℉]. Otherwise, hot coolant
or steam may lead to personal injury.
6. After filling coolant, make sure the engine cooling system is exhausted to
discharge the cooling air in the system, otherwise it could cause engine
overheating.
7. Use coolant specified by Foton, do not use only water as coolant. Use water as
the only coolant may damage the engine due to corrosion.
8. Clean the radiator exterior regularly to prevent mud or dust deposition which
may affect the heat dissipation of the radiator.
17A
17A-2 Cooling(LJ465) - Cooling System
Component Diagrams
20
14
15 19
16
13
4 6 17
12
6
22
11 18 21
3
5
3 10
8
9
2
7
1
fpwx17a0042
17A
1 Radiator bushing 12 Three Links
2 Radiator assembly 13 Filling hose 1
3 Radiator bushing 14 Expansion tank to radiator hose 1
4 Support above radiator 15 Hose double pipe clamp 1
5 Support above radiator (left) 16 Expansion tank to engine hose 2
6 Components of hexagon headed 17 Engine water inlet hose 1
bolt, spring washer and flat washer 18 Hexagon headed bolt
7 Electronic Fan Assembly 19 Pump pulley
8 Radiator water outlet hose 1 20 Water pump assembly
9 Radiator water inlet hose 1 21 Hexagon headed bolt
10 Engine water hard pipe assembly 1 22 Water pump pad
11 Filling hose 2


17A Cooling(LJ465) - Coolant, Replace-
1. Coolant (missing or leaking)
ment
2. Coolant (does not meet 17A Cooling(LJ465) - Coolant, Replace-
specifications) ment
17A Cooling(LJ465) - Thermostat,
3. Thermostat (fault)
Overhaul
Engine: Over-
heated water 4. Engine (rough operation) —
17A Cooling(LJ465) - Cooling System,
5. Radiator (poor cooling)
Precautions
17A Cooling(LJ465) - Electronic Fan
6. Electronic fan (not working)
Assembly, Overhaul
7. Cooling pipeline (blocked) —
17A Cooling(LJ465) - Radiator, Replace-
1. Radiator
ment
2. Cooling Pipeline —
Engine Coolant 17A
Leaking 17A Cooling(LJ465) - Water Pump,
3. Water Pump
Overhaul
17A Cooling(LJ465) - Expansion tank,
4. Expansion Tank
Replacement
17A Cooling(LJ465) - Electronic Fan
1. Electronic Fan
Assembly, Overhaul
Abnormal En-
17A Cooling(LJ465) - Water Pump,
gine Sound 2. Water Pump
Overhaul
17A-4 Cooling(LJ465) - Cooling System
Check on Vehicle
1. Check coolant for normal consumption.
2. Check cooling system for leakage if the consumption is abnormal.
Danger
To avoid burns, do not open the expansion tank pressure cap when the engine and
the radiator are hot, as the liquid and vapor can spray out under pressure.
(a) Fill radiator coolant, mount a radiator cap

detector.
(b) Start and heat the engine.
(c) Pressurize to standard pressure, then check
that the pressure is not reduced.
Note
If the pressure drops, check the hose, radiator
fpwx17a0033 or water pump for leaks. If you do not find an
external leak, check the heater core, cylinder
head and cylinder block.
3. Check the engine coolant level.

(a) When the engine is cold, visually inspect that
the coolant level in the expansion tank is
between the LOW (minimum) and FULL
(maximum) lines.
FULL (b) If the engine coolant level is too low, check
17A
the cooling system for leaks and add "Fukuda
LOW Private Life Coolant" or similar high-quality
ethylene glycol coolant which is free of
fpwx17a0034
silicate, amine, nitrite, borate and based on
long-term organic acid mixture technology to
FULL (highest) line.
Note
Never use only water as coolant.
4. Check the quality of engine coolant.

Danger
Do not open the pressure cap when the engine is heat. Do not open the radiator cover
until the engine cools down below 50℃. Otherwise, hot coolant or steam may lead to
personal injury.
(a) Open the expansion tank cap.
(b) Place a container under the radiator drain valve opening to contain discharged coolant.
(c) Loosen the radiator drain valve to discharge a small amount of engine coolant and
check around the drain valve for excessive corrosion or scale deposits. Meanwhile,
the coolant can not contain oil. If too much dirt, clean the cooling system and replace
the coolant.
(d) Install the radiator drain valve and check the coolant level in the expansion tank, add
coolant to the specified level if necessary. Check the radiator fin for blocking.
(e) If the heat fin is blocked, wash it with high-pressure water jet or a steam cleaning
machine and blow it dry with compressed air.
Note
• Radiator fin is susceptible to damage if cleaning distance between a steam

cleaning machine or high pressure squirt gun and radiator cores is too small,
be sure to maintain an appropriate cleaning distance.
• Be careful not to spray water directly onto the electronic components.
5. Inspect the cooling fan.

(a) Disconnect the electronic fan connector.
(b) Connect the battery and the ammeter to connectors.
(c) The electronic fan rotates smoothly, then check ammeter readings.
(d) Reconnect electronic fan connectors.
(e) There is no other abnormal sound beside the fan noise when the fan is running at high
speed.
6. Check the water temperature sensor
(a) Mounted on the intake manifold of circulating water passage, it provides coolant
temperature signals for correcting fuel injection amount and ignition timing.
(b) When necessary, the sensor can be cleaned with isopropanol and dried by air.
Note
Do not soak the sensor with isopropanol for more than one minute to prevent cleaning
17A
liquid from entering sensor interior!
Graphics
fpwx17a0043
Working voltage: 5 VDC

Limit temperature: 140℃ (only accumulated 1 hour)
Parameters
Sealing pressure: 145 kPa
At room temperature 20℃, the resistance value is 3511Ω ±
2.6%
17A-6 Cooling(LJ465) - Coolant
Coolant
Replacement
Danger
personal injury.
1. Cool the engine to normal ambient temperature.
2. Open the the engine cover.
3. Unscrew the expansion tank pressure cap
to release the pressure.
Danger
Wrap the expansion tank pressure cap with a
thick cloth and unscrew it carefully. Unscrew the
cap for 1/4 circle to release the pressure inside
the expansion tank. Then unscrew the cap
fpwx17a0001 completely.

5. Unscrew the drain valve to discharge the
coolant.
Danger
17A As coolant is corrosive, collect residual coolant
with a special container. If not continue to use,
dispose it according to regulations.
fpwx17a0002
6. Check coolant.
(a) Check the discharged engine coolant for rust, corrosion or discoloration.
(b) Clean the engine cooling system if contaminated.
7. Clean the cooling system.
(a) Install the radiator drain valve.
Note
Be sure to clean the radiator drain valve and install a new O-ring.
(b) Add water in the expansion tank to normal height.
(c) Run the engine to warm it up to normal operating temperature.
(d) Accelerate the engine speed under no-load condition for two or three times.
(e) Turn off the engine and wait for it to cool down.
(f) Drain the cooling water in the system.
(g) Repeat the procedure until the radiator begins to drain clear water.
9. Add engine coolant.
Cooling(LJ465) - Coolant 17A-7

(b) Slowly inject Fukuda ultra-long-acting coolant into an expansion tank.
(c) Press the inlet and outlet water hoses of a radiator with your hand for several times
and check the coolant level. If the coolant level is low, you need to add coolant.
(d) Install the expansion tank pressure cap.
(e) Start the engine and warm it up until the fan runs at high speed.
(f) Switch off the engine and wait until engine coolant is cooled.
(g) Check that coolant in the expansion tank is at the specified level. Add coolant to the
specified level if necessary.
Note
Air in a cooling system is automatically vented via an expansion tank, thus no venting
operation is required.
10 . Close the cover.
17A
17A-8 Cooling(LJ465) - Expansion tank
Expansion tank
Replacement
1. Drain the engine coolant. (See17A Cooling(LJ465) - Coolant, Replacement)
2. Dismount the expansion tank.
(a) Slowly unscrew the expansion tank pressure
cap to relieve pressure.
(b) Remove expansion tank breathing hose
clamps and disconnect the breathing hose.
Note
Check water pipes for cracks or marks of aging,
replace as needed.
fpwx17a0003
(c) Dismount water replenishing hose clamps on

the lower side of an expansion tank and
disconnect the water replenishing hose.
(d) Put it up in arrow direction and remove the
expansion tank.
Note
fpwx17a0004 replace as needed.
17A 3. Install the expansion tank.

(a) Install the expansion tank downward in
accordance with arrow direction.
(b) Connect a water replenishing hose and install
water replenishing hose clamps.
fpwx17a0005
(c) Connect expansion tank breathing hose and

mount retaining clamps.
fpwx17a0006
4. Check after the installation to make sure that coolant level is added to the
standard level, water level indicated by meter is correct and there is no coolant
leakage.
Cooling(LJ465) - Electronic Fan Assembly 17A-9
Electronic Fan Assembly

Overhaul
3. Disconnect the electronic fan assembly
connector.
fpwx17a0007
4. Dismount 2 fixing bolts of an electronic

fan bracket.
Tool: 10mm sleeve
fpwx17a0008
5. Pull out the electronic fan from the lower 17A

bracket holder.
fpwx17a0009
6. Remove the electric fan assembly.

7. Dismount the electronic fan motor.
(a) Dismount 1 fixing nut in the middle of the
electronic fan.
Tool: 8mm sleeve
fpwx17a0010
17A-10 Cooling(LJ465) - Electronic Fan Assembly
(b) Dismount 3 fixing nuts of the electronic fan

motor.
Tool: 10mm sleeve
(c) Remove the electronic fan motor.
fpwx17a0011
8. Check the electronic fan.

(a) Check resistance between two pins of electronic fan connectors with an ohmmeter.
(b) Visually check electronic fan blades for deficiency or damage.
(c) Fan blades should rotate smoothly without any blockage as you manually rotate the
electronic fan.
9. Install an electronic fan.
(a) Install the electronic fan motor in place and
(10±1N·m) tighten 3 retaining nuts.
Tool: 10mm sleeve
Torque: 10±1N•m
fpwx17a0012
17A
(b) Install the electronic fan and tighten 1
retaining nut in the middle of the fan.
Tool: 8mm sleeve
Torque: 10±1N•m
(10±1N·m)
fpwx17a0013
10 . Install an electronic fan.

(a) Assemble the electronic fan with the lower
bracket in arrow direction.
fpwx17a0014
Cooling(LJ465) - Electronic Fan Assembly 17A-11
(b) Install the electronic fan bracket and tighten

2 retaining nuts.
Tool: 10mm sleeve
Torque: 10±1N•m
(10±1N·m)
fpwx17a0015
11 . Connect the electronic fan assembly

connector.
fpwx17a0016
12 . Check and start the vehicle after the installation to make sure that the electronic
fan works properly and free of abnormal sound when the engine temperature is
high and the A/C is turned on.
17A
17A-12 Cooling(LJ465) - Radiator
Radiator
Replacement
Danger
personal injury.
1. Drain the coolant. (See17A Cooling(LJ465) - Coolant, Replacement)
2. Dismount the electronic fan. (See 17A Cooling(LJ465) - Electronic Fan Assembly,
Overhaul)
3. Dismount the radiator water pipe.
(a) Loosen pipe clamps between the radiator and
the secondary tank.
(b) Loosen radiator upper pipe clamps.
(c) Disengage the radiator upper pipe and the
expansion tank breathing hose.
Note
fpwx17a0017 replace as needed.
(d) Loosen radiator lower pipe clamps.

(e) Disengage the radiator lower pipe.
Note
17A
replace as needed.
fpwx17a0018
4. Dismount 2 fixing bolts of a radiator

bracket.
Tool: 10mm sleeve
fpwx17a0019
5. Slightly lift the radiator upward in vertical direction, then remove the radiator.
Note
Do not lose radiator lower pads and check radiator mounting bracket rubber pads and
radiator lower rubber pads for signs of damage, replace as needed.
Cooling(LJ465) - Radiator 17A-13
6. Install the radiator.

Note
Before installing the radiator, make sure that
radiator lower rubber pads have been placed in
place.
fpwx17a0020
7. Install the radiator bracket and tighten 2

fixing bolts.
Tool: 10mm sleeve
Torque: 10±1N•m
(10±1N·m)
fpwx17a0021
8. Install the radiator pipe.

(a) Connecting the radiator lower pipe and
mounting retaining clamps.
17A
fpwx17a0022
(b) Connect the radiator upper pipe and the

expansion tank breathing hose.
(c) Install pipe clamps between the radiator and
the expansion tank.
(d) Install radiator upper pipe clamps.
fpwx17a0023
9. Install an electronic fan. (See 17A Cooling(LJ465) - Electronic Fan Assembly,

Overhaul)
10 . Refill coolant. (See17A Cooling(LJ465) - Coolant, Replacement)
17A-14 Cooling(LJ465) - Thermostat
Thermostat
Overhaul
Danger
personal injury.
3. Turn over the driver seat.
(b) Flip and turn over the driver seat.
fpwx17a0024
4. Dismount the thermostat housing.

(a) Loosen engine outlet pipe clamps and
disengage the pipe.
(b) Dismount 2 fixing bolts on the thermostat
housing.
17A
Tool: 13mm wrench
Note
fpwx17a0025
replace as needed.
5. Remove the thermostat.
fpwx17a0026
Cooling(LJ465) - Thermostat 17A-15
6. Check the thermostat.

(a) The thermostat is marked with valve opening
temperature.
82 C
82 C
fpwx17a0027
(b) Place the thermostat in water and gradually

increase water temperature.
(c) Check valve opening temperature.
Valve opening temperature: 82 ℃
Note
If valve opening temperature is not normal,
replace the thermostat.
fpwx17a0028
(d) Check the valve lift.

Standard value of valve lift: 8mm
Note
Replace the thermostat if valve lift is not normal.
• Check that the valve can fully close when 17A
the thermostat is at a low temperature.
fpwx17a0029 • Otherwise, replace the thermostat.
7. Install the thermostat.

Note
Replace the thermostat gasket with a new one
when dismounting each thermostat.
fpwx17a0030
(a) Install the thermostat and the seal.

Note
Make sure the seal is properly engaged with the
thermostat and tightly fitted to the thermostat
seat plane.
fpwx17a0031
17A-16 Cooling(LJ465) - Thermostat
(b) Install the thermostat housing and tighten the

two fixing bolts.
Tool: 13mm wrench
Torque: 10±1N•m
(10±1N·m)
(c) Connect the engine upper water pipe and
install clamps.
fpwx17a0032
8. Refill coolant. (See17A Cooling(LJ465) - Coolant, Replacement)

9. Heat the vehicle up for some time after installing the thermostat until the
electronic fan operates at a high speed, check whether the water temperature
of each radiator is normal or not, then check every connecting component for
coolant leakage.
10 . Turn down the driver seat and lock the fixing buckle of driver seat.
17A
Cooling(LJ465) - Water Pump 17A-17
Water Pump
Overhaul
Danger
personal injury.
2. Dismount the generator belt. (See 20A Starting and Charging(LJ465) - Engine,
Overhaul)
3. Dismount the compressor belt. (See Chapter 61A Heating and A/C - A/C
Compressor, Replacement)
4. Lift the vehicle and dismount 4 fixing bolts
of the water pump assembly belt drive
wheel.
Tool: 10mm sleeve
fpwx17a0035
5. Dismount the engine timing belt front cover. (See15A Engine Mechanism
System(LJ465) - Timing Belt Front Cover, Replacement)
6. Dismount the timing belt. (See15A Engine Mechanism System(LJ465) - Timing 17A
Belt, Overhaul)
7. Remove the water pump assembly gasket.
fpwx17a0036
8. Remove the water pump.

(a) Dismount water pump bolts and nuts.
Tool: 10mm sleeve
(b) Remove the water pump.
fpwx17a0037
17A-18 Cooling(LJ465) - Water Pump
9. Remove the water pump seal.

(a) Clean the contact surface of water pump and
engine block with a scraper.
Note
Carefully remove adhesive material, do not
damage the contact surface of water pump and
engine block.
fpwx17a0038
10 . Check the water pump.

(a) The pump should be rotated smoothly without catching.
(b) Water pump rotation shaft is free of gaps, no abnormal sound when rotated.
(c) No signs of coolant leakage around the water pump.
11 . Install the water pump.
(a) Install the water pump gasket, smear the contact surface with engine oil pan sealant
if necessary to prevent coolant leakage.
Note
When installing a water pump with sealant, you need to wait for 15 minutes before
adding coolant.
(b) Install the water pump in place and tighten

bolts and nuts.
(10±1N·m)
Tool: 10mm sleeve
17A
Torque: 10±1N•m
fpwx17a0039
12 . Install the water pump assembly gasket.
fpwx17a0040
Overhaul)
14 . Install the engine timing belt front cover. (See15A Engine Mechanism
System(LJ465) - Timing Belt Front Cover, Replacement)
Cooling(LJ465) - Water Pump 17A-19
15 . Install water pump assembly belt drive

wheel and tighten 4 bolts.
Tool: 10mm sleeve
Torque: 10±1N•m
(10±1N·m)
fpwx17a0041
16 . Install the compressor belt. (See Chapter 61A Heating and A/C - A/C Compressor,
Replacement)
17 . Install the generator belt. (See 20A Starting and Charging(LJ465) - Engine,
Overhaul)
18 . Add coolant. (See 17A Cooling(LJ465) - Coolant, Replacement)
19 . Heat the vehicle up for some time after replacing the water pump until the
electronic fan operates at a high speed, then check every component for coolant
leakage.
17A
17A-20 Cooling(LJ465) - Water Pump
17A
Cooling(4W10/4W12)
Cooling System..................................17B-1
Precautions......................................17B-1
Check on Vehicle..............................17B-5
Coolant................................................17B-7
Replacement....................................17B-7
Expansion tank...................................17B-9
Replacement....................................17B-9
Electronic Fan Assembly.................17B-11
Overhaul.........................................17B-11
Radiator.............................................17B-14
Replacement..................................17B-14
Thermostat........................................17B-16
Overhaul.........................................17B-16
Water Pump......................................17B-19
Overhaul.........................................17B-19
17B
17B
Cooling(4W10/4W12) - Cooling System 17B-1
Cooling System
Precautions
1. Collect the residual coolant with a special container when disconnecting cooling
system pipelines. If not continue to use, dispose it according to regulations.
2. When disconnecting the cooling system piping, do not let debris from entering
the cooling system piping, as this may damage the cooling system and the
engine.
3. When disconnecting the cooling system pipe joints, you must seal the mouth
of the pipe with a special blocking cap to prevent dirt or debris from entering.
4. Since coolant is toxic , if not to be used any more, it should be kept away from
children and pets and disposed in accordance with regulations.
5. Do not open the radiator cover from a hot engine. Do not remove the pressure
cover until coolant temperature drops below 50℃ [120℉]. Otherwise, hot coolant
or steam may lead to personal injury.
6. After filling coolant, make sure the engine cooling system is exhausted to
discharge the cooling air in the system, otherwise it could cause engine
overheating.
7. Use coolant specified by Foton, do not use only water as coolant. Use water as
the only coolant may damage the engine due to corrosion.
8. Clean the radiator exterior regularly to prevent mud or dust deposition which
may affect the heat dissipation of the radiator.
17B
17B-2 Cooling(4W10/4W12) - Cooling System
Component Diagrams
4
3
1
4
2
5
fpwx17b0300
1 Radiator bushing 4 Components of hexagon headed

17B 2 Radiator assembly bolt, spring washer and flat washer
3 Support above radiator 5 Electronic fan assembly
3 4
10
11
5
2
12
6
9
13
fpwx17b0301
1 Radiator assembly 8 Expansion tank to engine hose

2 Radiator outlet hose 9 Engine water hard pipe assembly
3 Expansion tank to radiator hose 10 Expansion tank to engine hose 2
4 Expansion tank assembly 11 Engine water inlet hose 17B
5 Filling hose 12 Engine water outlet hose
6 Radiator water inlet hose 13 Water pump component
7 Filling hose 2


17B Cooling(4W10/4W12) - Coolant,
1. Coolant (missing or leaking)
Replacement
2. Coolant (does not meet 17B Cooling(4W10/4W12) - Coolant,
specifications) Replacement
17B Cooling(4W10/4W12) - Thermostat,
3. Thermostat (fault)
Overhaul
Engine: Over-
heated water 4. Engine (rough operation) —
17B Cooling(4W10/4W12) - Cooling
5. Radiator (poor cooling)
System, Precautions
17B Cooling(4W10/4W12) - Electronic
6. Electronic fan (not working)
Fan Assembly, Overhaul
7. Cooling pipeline (blocked) —
17B Cooling(4W10/4W12) - Radiator,
1. Radiator
Replacement
Engine Coolant
Leaking 17B Cooling(4W10/4W12) - Water Pump,
3. Water Pump
17B Overhaul
17B Cooling(4W10/4W12) - Expansion
4. Expansion Tank
tank, Replacement
17B Cooling(4W10/4W12) - Electronic
1. Electronic Fan
Fan Assembly, Overhaul
Abnormal En-
17B Cooling(4W10/4W12) - Water Pump,
gine Sound 2. Water Pump
Overhaul
Check on Vehicle
1. Check coolant for normal consumption.
2. Check cooling system for leakage if the consumption is abnormal.
Danger
To avoid burns, do not open the expansion tank pressure cap when the engine and
the radiator are hot, as the liquid and vapor can spray out under pressure.
(a) Fill radiator coolant, mount a radiator cap

detector.
(b) Start and heat the engine.
(c) Pressurize to standard pressure, then check
that the pressure is not reduced.
Note
If the pressure drops, check the hose, radiator
fpwx17b0033 or water pump for leaks. If you do not find an
external leak, check the heater core, cylinder
head and cylinder block.
3. Check the engine coolant level in the expansion tank.

(a) When the engine is cold, visually inspect that
the coolant level in the expansion tank is
between the LOW (minimum) and FULL
(maximum) lines.
FULL (b) If the engine coolant level is too low, check
the cooling system for leaks and add "Foton
LOW Private Life Coolant" or similar high-quality 17B
ethylene glycol coolant which is free of
fpwx17b0034
silicate, amine, nitrite, borate and based on
long-term organic acid mixture technology to
FULL (highest) line.
Note
Never use only water as coolant.
4. Check the quality of engine coolant.

Danger
personal injury.
(a) Open the expansion tank cap.
(b) Place a container under the radiator drain valve opening to contain discharged coolant.
(c) Loosen the radiator drain valve to discharge a small amount of engine coolant and
check around the drain valve for excessive corrosion or scale deposits. Meanwhile,
the coolant can not contain oil. If too much dirt, clean the cooling system and replace
the coolant.
(d) Install the radiator drain valve and check the coolant level in the expansion tank, add
coolant to the specified level if necessary. Check the radiator fin for blocking.
5. If the heat fin is blocked, wash it with high-pressure water jet or a steam cleaning
machine and blow it dry with compressed air.
Note
• Radiator fin is susceptible to damage if cleaning distance between a steam

cleaning machine or high pressure squirt gun and radiator cores is too small,
be sure to maintain an appropriate cleaning distance.
• Be careful not to spray water directly onto the electronic components.
6. Inspect the cooling fan.

(a) Disconnect the electronic fan connector.
(b) Connect the battery and the ammeter to connectors.
(c) The electronic fan rotates smoothly, then check ammeter readings.
(d) Reconnect electronic fan connectors.
(e) There is no other abnormal sound beside the fan noise when the fan is running at high
speed.
17B
Cooling(4W10/4W12) - Coolant 17B-7
Coolant
Replacement
Danger
personal injury.
1. Cool the engine to normal ambient temperature.
3. Unscrew the expansion tank pressure cap
to release the pressure.
Danger
Wrap the expansion tank pressure cap with a
thick cloth and unscrew it carefully. Unscrew the
cap for 1/4 circle to release the pressure inside
the expansion tank. Then unscrew the cap
fpwx17b0035 completely.

5. Unscrew the drain valve to discharge the
coolant.
Danger
As coolant is corrosive, collect residual coolant
with a special container. If not continue to use,
dispose it according to regulations. 17B
fpwx17b0036
6. Check coolant.
(a) Check the discharged engine coolant for rust, corrosion or discoloration.
(b) Clean the engine cooling system if contaminated.
7. Clean the cooling system.
Note
Be sure to clean the radiator drain valve and install a new O-ring.
(b) Add water in the expansion tank to normal height.
(c) Run the engine to warm it up to normal operating temperature.
(d) Accelerate the engine speed under no-load condition for two or three times.
(e) Turn off the engine and wait for it to cool down.
(f) Drain the cooling water in the system.
(g) Repeat the procedure until the radiator begins to drain clear water.
9. Add engine coolant.
17B-8 Cooling(4W10/4W12) - Coolant

(b) Slowly inject Foton ultra-long-acting coolant into an expansion tank.
(c) Press the inlet and outlet water hoses of a radiator with your hand for several times
and check the coolant level. If the coolant level is low, you need to add coolant.
(d) Install the expansion tank pressure cap.
(e) Start the engine and warm it up until the fan runs at high speed.
(f) Switch off the engine and wait until engine coolant is cooled.
(g) Check that coolant in the expansion tank is at the specified level. Add coolant to the
specified level if necessary.
Note
Air in a cooling system is automatically vented via an expansion tank, thus no venting
operation is required.
17B
Cooling(4W10/4W12) - Expansion tank 17B-9
Expansion tank
Replacement
1. Drain the engine coolant. (See 17B Cooling(4W10/4W12) - Coolant, Replacement)
2. Dismount the expansion tank.
(a) Slowly unscrew the expansion tank pressure
cap to relieve pressure.
Note
is heating. Do not open the radiator cover until
the engine cools down below 50℃. Otherwise,
hot coolant or steam may lead to personal injury.
fpwx17b0001
(b) Remove connecting pipe mounting clamps
between the expansion tank and the tank and
(c) Remove connecting pipe mounting clamps
between the expansion tank and the
thermostat and break the connection.
Note
replace as needed.
(d) Dismount fixing clamps of lower water pipe

at lower portion of the expansion tank,
disconnect the lower water pipe.
(e) Remove the expansion tank in arrow direction. 17B
Note
replace as needed.
fpwx17b0002
3. Install the expansion tank.

(a) Install the expansion tank to the mounting
bracket in arrow direction.
(b) Connect the expansion tank pipe and tighten
clamps.
fpwx17b0003
17B-10 Cooling(4W10/4W12) - Expansion tank
(c) Connect the expansion tank to the thermostat

pipe and tighten clamps.
(d) Connect the expansion tank to the tank upper
pipe and tighten mounting clamps.
fpwx17b0004
4. Check after the installation to make sure that coolant level is added to the
standard level, water level indicated by meter is correct and there is no coolant
leakage.
17B
Cooling(4W10/4W12) - Electronic Fan Assembly 17B-11
Electronic Fan Assembly

Overhaul
3. Disconnect the electronic fan assembly
connector.
fpwx17b0005
4. Dismount the electronic fan assembly.

(a) Dismount the expansion tank. (Refer to17B Cooling(4W10/4W12) - Expansion tank,
Replacement)
(b) Dismount the radiator upper water pipe.

• Loosen cooling upper water pipe
mounting clamps and disconnect the
upper water pipe.
• Loosen mounting clamps between the
cooling upper water pipe and the tank
pipe and disconnect the water pipe.
fpwx17b0037
17B
(c) Dismount 2 fixing bolts of the electronic fan

assembly and remove the electronic fan
assembly in arrow direction.
Tool: 10mm sleeve
fpwx17b0006
5. Dismount the electronic fan motor.

17B-12 Cooling(4W10/4W12) - Electronic Fan Assembly
(a) Remove 1 retaining nut of the electronic fan

impeller assembly.
Tool: 10mm sleeve
fpwx17b0007
(b) Turn over the electronic fan assembly.

(c) Dismount 3 fixing nuts of the electronic fan
motor.
Tool: 10mm sleeve
(d) Remove the electronic fan motor.
fpwx17b0008
6. Check the electronic fan.

(a) Check resistance between two pins of electronic fan connectors with an ohmmeter.
(b) Visually check electronic fan blades for deficiency or damage.
(c) Fan blades should rotate smoothly without any blockage as you manually rotate the
electronic fan.
7. Install the electronic fan motor.
(a) Install the electronic fan motor in place and
17B tighten 3 retaining nuts.
Tool: 10mm sleeve
Torque: 10±1N•m
(10±1N·m)
fpwx17b0009
(b) Turn over the electronic fan assembly.

(c) Install the electronic fan blade wheel and
tighten 1 retaining nut in the middle of the
wheel.
Torque: 10±1N•m
fpwx17b0010
8. Install the electronic fan assembly.

Cooling(4W10/4W12) - Electronic Fan Assembly 17B-13
(a) Install the electronic fan to the correct position

in arrow direction and tighten 2 bolts.
Tool: 10mm sleeve
Torque: 10±1N•m
(10±1N·m)
fpwx17b0011
(b) Install the radiator upper pipe.

(a) Connect the cooling upper water pipe and
tighten mounting clamps.
(b) Connect the expansion tank to the tank pipe
and tighten mounting clamps.
fpwx17b0038
(c) Install the expansion tank. (Refer to17B Cooling(4W10/4W12) - Expansion tank,
Replacement)
9. Connect the electronic fan assembly
connector.
17B
fpwx17b0012
10 . Check and start the vehicle after the installation to make sure that the electronic
fan works properly and free of abnormal sound when the engine temperature is
high and the A/C is turned on.
17B-14 Cooling(4W10/4W12) - Radiator
Radiator
Replacement
Danger
personal injury.
1. Drain the coolant. (See17B Cooling(4W10/4W12) - Coolant, Replacement)
2. Dismount the expansion tank. (See17B Cooling(4W10/4W12) - Expansion tank,
Replacement)
3. Dismount the electronic fan. (See 17B Cooling(4W10/4W12) - Electronic Fan
Assembly, Overhaul)
4. Loosen radiator lower pipe mounting
clamps and disconnect the water pipe.
Note
replace as needed.
fpwx17b0013
5. Dismount the upper water pipe of the

radiator.
(a) Loosen cooling upper water pipe mounting
clamps and disconnect the upper water pipe.
17B (b) Loosen mounting clamps between the cooling
upper water pipe and the tank pipe and
disconnect the water pipe.
fpwx17b0014
6. Dismount 2 fixing bolts of a radiator

bracket.
Tool: 10mm sleeve
7. Slightly lift the radiator upward in vertical
direction, then remove the radiator.
Note
Do not lose radiator lower pads and check
fpwx17b0016
radiator mounting bracket rubber pads and
radiator lower rubber pads for signs of damage,
replace as needed.
Cooling(4W10/4W12) - Radiator 17B-15
8. Install the radiator in place.

(10±1N·m)
Note
Before installing the radiator, make sure that
radiator lower rubber pads have been placed in
place.
9. Install the radiator bracket and tighten 2
fixing bolts.
fpwx17b0016
Tool: 10mm sleeve
Torque: 10±1N•m
10 . Install the upper pipe of the radiator.

(a) Connect the cooling upper water pipe and
tighten mounting clamps.
(b) Connect the expansion tank to the tank pipe
fpwx17b0017
11 . Connecting the radiator lower pipe and

tightening retaining clamps.
17B
fpwx17b0018
12 . Install an electronic fan. (See 17B Cooling(4W10/4W12) - Electronic Fan Assembly,

Overhaul)
13 . Install the expansion tank. (See17B Cooling(4W10/4W12) - Expansion tank,
Replacement)
14 . Refill coolant. (See 17B Cooling(4W10/4W12) - Coolant, Replacement)
17B-16 Cooling(4W10/4W12) - Thermostat
Thermostat
Overhaul
Danger
personal injury.
2. Drain the coolant. (See 17B Cooling(4W10/4W12) - Coolant, Replacement)
4. Loosen thermostat connection pipe
mounting clamps and disconnect the water
pipe.
fpwx17b0019
5. Dismount 2 fixing bolts on the thermostat

housing.
Tool: 10mm sleeve
17B
fpwx17b0020
6. Take out the thermostat.
fpwx17b0021
Cooling(4W10/4W12) - Thermostat 17B-17
7. Check the thermostat.

(a) The thermostat is marked with valve opening
temperature.
87°C
fpwx17b0025
(b) Place the thermostat in water and gradually

increase water temperature.
(c) Check valve opening temperature.
Valve opening temperature: 87℃
Note
If valve opening temperature is not normal,
replace the thermostat.
fpwx17b0026
(d) Check the valve lift.

Standard value of valve lift: 8mm
Note
Replace the thermostat if valve lift is not normal.
• Check that the valve can fully close when
the thermostat is at low temperature
fpwx17b0027 (below 87℃). 17B
• Otherwise, replace the thermostat.
8. Install the thermostat.

(a) Install the thermostat gasket.
Note
Replace the thermostat seal with a new one when
dismounting each thermostat.
fpwx17b0028
17B-18 Cooling(4W10/4W12) - Thermostat
(b) Install the thermostat in place.

Note
When installing the thermostat, make sure the
seal is properly engaged with the thermostat and
tightly fitted to the thermostat seat plane.
fpwx17b0022
(c) Install the thermostat housing and tighten 2

fixing bolts.
Tool: 10mm sleeve
(10±2N·m)
fpwx17b0023
9. Connect the thermostat connection pipe

17B fpwx17b0024

11 . Refill coolant. (See 17B Cooling(4W10/4W12) - Coolant, Replacement)
12 . Heat the vehicle up for some time after installing the thermostat until the
electronic fan operates at a high speed, check whether the water temperature
of each radiator is normal or not, then check every connecting component for
coolant leakage.
Cooling(4W10/4W12) - Water Pump 17B-19
Water Pump
Overhaul
Danger
personal injury.
2. Drain the coolant. (See 17B Cooling(4W10/4W12) - Coolant, Replacement)
3. Loosen the front passenger seat fixing buckle, flip the front passenger seat.
4. Dismount the generator assembly. (See 20A Starting and Charging(LJ465) -
Engine, Overhaul)
5. Remove 5 fixing bolts of the water pump
assembly.
Tool: 10mm sleeve
fpwx17b0029
17B
6. Remove the water pump.
fpwx17b0030
7. Remove the water pump seal.

(a) Clean the contact surface of water pump and
engine block with a scraper.
Note
Carefully remove adhesive material, do not
damage the contact surface of water pump and
engine block.
fpwx17b0031
8. Check the water pump.

17B-20 Cooling(4W10/4W12) - Water Pump
(a) The pump should be rotated smoothly without catching.

(b) Water pump rotation shaft is free of gaps, no abnormal sound when rotated.
(c) No signs of coolant leakage around the water pump.
9. Install the water pump.
(a) Install the water pump gasket, smear the contact surface with engine oil pan sealant
if necessary to prevent coolant leakage.
Note
When installing a water pump with sealant, you need to wait for 15 minutes before
adding coolant.
(b) Install the water pump in place and tighten 5

fixing bolts.
Tool: 10mm sleeve
(30±2N·m)
fpwx17b0032
10 . Install the generator assembly (See 20A Starting and Charging(LJ465) - Engine,
17B
Overhaul)
12 . Turn down the front passenger seat and lock the seat fixing buckle.
13 . Add coolant. (See 17B Cooling(4W10/4W12) - Coolant, Replacement)
14 . Heat the vehicle up for some time after replacing the water pump until the
electronic fan operates at a high speed, then check every component for coolant
leakage.
Lubrication System(LJ465)
Lubrication System............................18A-1
Precautions......................................18A-1
Engine Oil............................................18A-2
Replacement....................................18A-2
Oil Filter...............................................18A-5
Replacement....................................18A-5
Oil pan.................................................18A-7
Replacement....................................18A-7
Engine Oil Pump...............................18A-10
Overhaul.........................................18A-10
18A
18A
Lubrication System(LJ465) - Lubrication System 18A-1
Lubrication System
Precautions
Note
Prolonged and repeated contact with mineral oil can cause the removal of skin oil
resulting in dry skin, allergies and dermatitis. Moreover, used engine oil contains
potentially harmful contaminants that may cause skin cancer. Therefore you should
be provided with proper skin protection methods and cleaning equipment.
1. Try not to contact with engine oil on long-term and repeated basis, used engine
oil in particular.
2. Wear protective clothing, including waterproof work gloves.
3. Avoid contamination of clothing, especially underwear containing oil.
4. Do not put rag contaminated with oil into pocket.
5. Do not wear heavily contaminated clothing and socks soaked by oil. Work pants
must be cleaned regularly and kept separately from personal clothings.
6. Be sure to wear goggles, i.e. chemical goggles or face shield, to prevent eyes
from coming into contact with engine oil. In addition, eye cleaning devices must
be prepared.
7. Wounds must be dealt with and wrapped immediately.
8. Clean with soap and clean water regularly, especially before meals, and make
sure that all oil has been cleared (you can also use skin cleansers and nail brush
to assist the cleaning). After cleaning, it is recommended to replace natural skin
oil with cotton suet.
9. Don't wash your skin with petroleum/gasoline, kerosene, diesel, engine oil,
thinner or solvent.
10 . Smear cream before work to help skin cleaning after work.
11 . Consult a doctor immediately if your skin appears abnormal.
18A
18A-2 Lubrication System(LJ465) - Engine Oil
Engine Oil
Replacement
1. Start the engine and allow the engine to reach warm-up state.
2. Turn off the engine and wait for 10 minutes.
(b) Flip the driver seat.
fpwx18a0029
4. Unscrew the engine oil filler cap.
N
E
OIE E
OP
ENGIN
fpwx18a0001

6. Dismount oil pan drain bolts and drain
engine oil.
18A Tool: 15mm sleeve
Note
• Engine oil is very hot, be careful not to be

burnt.
fpwx18a0002 • Prolonged and repeated contact with used
engine oil may cause skin cancer;
therefore, you should avoid the direct
contact of used oil with skin. If contact
was made, thoroughly clean with soap or
detergent as soon as possible.
• Collect waste oil with a specified container
and dispose according to provisions.
Lubrication System(LJ465) - Engine Oil 18A-3
7. Replace with a new oil drain plug gasket

and tighten bolts.
Tool: 15mm sleeve
Torque: 30～35N•m
(30~35N·m)
fpwx18a0003

9. Add a fixed mount of oil.
Engine oil: 3.3L
Note
When the ambient temperature is above -20℃, use SF15W / 40 gasoline engine oil;
GB11121-2006 (APISGSAE15W40 gasoline engine oil). When the ambient temperature
is below -20℃, use SF5W / 30 gasoline engine oil GB11121-2006 (APISGSAE5W30
gasoline engine oil).
10 . Install the engine oil filler cap.

11 . Park the vehicle on level ground and start
N
the engine to heat the vehicle. And check
E
E
OP
around the oil drain plug and oil filter for

ENGIN
OIE
oil leakage.
12 . Turn off the engine and wait for 10
minutes.
fpwx18a0004
18A
13 . Check the height of engine oil level.
(a) Pull out the dipstick and wipe it clean.
(b) Insert the dipstick and confirm the engine oil
MAX MIN
level is within the scope as shown.
fpwx18a0005
18A-4 Lubrication System(LJ465) - Engine Oil
14 . Turn down the driver seat, lock the fixing

buckle of driver seat.
fpwx18a0030
18A
Lubrication System(LJ465) - Oil Filter 18A-5
Oil Filter
Replacement
5. Discharge engine oil. (See 18A Lubrication
System(LJ465) - Engine Oil, Replacement)
fpwx18a0031
Note
Oil filter is generally replaced along with engine
oil to avoid oil contamination that affects the
engine operation.
6. Dismount the oil filter with special tools.
fpwx18a0006
7. Clear out foreign matters adhering to the mounting surface of an oil cleaner.
8. Apply engine oil on the new oil filter seal 18A
surface.
fpwx18a0007
9. Screw on the oil filter by hand until the

O-ring contact surface comes into contact
with filter bracket contact surface, then
(12~16N·m)
tighten the filter to the specified torque
with a tool.
fpwx18a0008
18A-6 Lubrication System(LJ465) - Oil Filter
10 . Install the oil drain plug.

Tool: 15mm sleeve
12 . Open the engine oil filler cap to fill engine oil to the required level.
14 . Park the vehicle on level ground and start the engine to heat the vehicle.
15 . Check and make sure oil filter is free of oil leakage.
16 . Turn off the engine and wait for 10 minutes.
17 . Pull out the dipstick to check that oil level is within specified range.
18 . Turn down the main engine cover and lock the fixing buckle of driver seat.
18A
Lubrication System(LJ465) - Oil pan 18A-7
Oil pan
Replacement
fpwx18a0032
2. Open the engine oil filler cap.

6. Unplug the dipstick.
7. Dismount the engine oil dipstick pipe.
(a) Dismount engine oil dipstick pipe bolts.
Tool: 13mm sleeve
(b) Pull out the dipstick pipe.
Note
Check the seal on the bottom of dipstick pipe
fpwx18a0009
for damage or aging and replace as needed.

18A
9. Remove the oil tray.
(a) Dismount 2 bolts on the transmission front
cover.
Tool: 10mm socket
(b) Dismount the front cover.
fpwx180010
18A-8 Lubrication System(LJ465) - Oil pan
(d) Dismount 18 bolts of the engine oil pan.

Tool: 10mm socket
fpwx180011
(e) Insert an appropriate tool between the cylinder

block and the oil pan by tapping it with a
hammer and dismount the oil pan.
Note
Do not forcibly dismount the oil pan with a

screwdriver, otherwise the oil pan contact
surface may deform, thus affecting the leak
fpwx180012
tightness.
10 . Clean the contact surface between the cylinder block and the engine oil pan.
11 . Apply sealant to the oil pan flange.
Note
Bolt holes must be encircled with round strip
sealant. When apply sealant on the edge of hole
mounted with a bolt, you should apply along the
hole circle to prevent oil leakage at the hole.
18A fpwx180014
12 . Install the oil pan.
(7~9N·m)
(a) Install the sump oil pan and tighten 18 fixing
bolts.
Tool: 10mm sleeve
Note
Install the oil pan quickly while the sealant is not
fpwx180033
dry (within 15 minutes). Keep the sealant away
from oil for about an hour after the installation.
Lubrication System(LJ465) - Oil pan 18A-9
(b) Install the transmission front cover and tighten

2 fixing bolts.
Tool: 10mm socket
Torque: 7～9N•m
(7~9N·m)
fpwx180016
13 . Install the dipstick pipe and tighten 2 fixing

bolts.
Tool: 13mm socket
Torque: 9 - 12N•m
(9~12N·m)
fpwx180017

15 . Insert the oil dipstick.
19 . Check to make sure the oil pan is free of oil leakage.
18A
18A-10 Lubrication System(LJ465) - Engine Oil Pump
Engine Oil Pump

Overhaul
Belt, Overhaul)
6. Remove 2 bolts of an oil strainer and
remove the oil strainer.
Tool: 10mm socket
fpwx180018
7. Unscrew the engine oil pressure switch.
fpwx180019
18A 8. Dismount 8 bolts of the engine oil pump.

Tool: 10mm socket
fpwx180020
9. Remove the engine oil pump and check.

(a) Check oil holes and oil ducts for blocking, clean if necessary.
(b) Check the front cover for cracks or other damages, replace if necessary.
(c) Check the oil seal lip for wear or damage, replace if necessary.
Lubrication System(LJ465) - Engine Oil Pump 18A-11
10 . Dismount 6 fixing screws of the oil pump

cover.
fpwx180021
11 . Check the engine oil pump gear.

(a) Measure the gear backlash with a surface
gauge and a thickness gauge.
(b) Install the oil pump gear on the front cover,
then rotate the gear and check that it can
rotate smoothly without looseness.
(c) Confirm the contact surface between the front
fpwx180022
cover and the oil pump cover gear surface is
free of ridge wear.
12 . Replace the oil pump seal with special

tools.
fpwx180023
18A
13 . Install the oil pump cover and tighten 6
screws.
fpwx180024
14 . Install the oil pump front cover gasket.
fpwx180025
18A-12 Lubrication System(LJ465) - Engine Oil Pump
15 . Install the oil pump and tighten 8 bolts.

Tool: 10mm socket
(9~12N·m) Torque: 9 - 12N•m
fpwx180026
16 . Install the engine oil pressure switch.

Clear up the greasy dirt on engine oil pressure
switch threads and smear a little sealant.
fpwx180027
(7~9N·m)
17 . Install the oil strainer and tighten 2 fixing
bolts.
Tool: 10mm socket
Torque: 7～9N•m
fpwx180028
18A 18 . Install the timing belt. (See15A Engine Mechanism System(LJ465) - Timing Belt,
Overhaul)
Lubrication System(4W10/4W12)
Lubrication System............................18B-1
Precautions......................................18B-1
Engine Oil............................................18B-3
Replacement....................................18B-3
Oil Filter...............................................18B-5
Replacement....................................18B-5
Oil pan.................................................18B-7
Replacement....................................18B-7
Engine Oil Pump...............................18B-10
Overhaul.........................................18B-10
18B
18B
Lubrication System(4W10/4W12) - Lubrication System 18B-1
Lubrication System
Precautions
Note
Prolonged and repeated contact with mineral oil can cause the removal of skin oil
resulting in dry skin, allergies and dermatitis. Moreover, used engine oil contains
potentially harmful contaminants that may cause skin cancer. Therefore you should
be provided with proper skin protection methods and cleaning equipment.
1. Try not to contact with engine oil on long-term and repeated basis, used engine
oil in particular.
2. Wear protective clothing, including waterproof work gloves.
3. Avoid contamination of clothing, especially underwear containing oil.
4. Do not put rag contaminated with oil into pocket.
5. Do not wear heavily contaminated clothing and socks soaked by oil. Work pants
must be cleaned regularly and kept separately from personal clothings.
6. Be sure to wear goggles, i.e. chemical goggles or face shield, to prevent eyes
from coming into contact with engine oil. In addition, eye cleaning devices must
be prepared.
7. Wounds must be dealt with and wrapped immediately.
8. Clean with soap and clean water regularly, especially before meals, and make
sure that all oil has been cleared (you can also use skin cleansers and nail brush
to assist the cleaning). After cleaning, it is recommended to replace natural skin
oil with cotton suet.
9. Don't wash your skin with petroleum/gasoline, kerosene, diesel, engine oil,
thinner or solvent.
10 . Smear cream before work to help skin cleaning after work.
11 . Consult a doctor immediately if your skin appears abnormal.
18B
18B-2 Lubrication System(4W10/4W12) - Lubrication System
Component Diagrams
13
3
3
12
4
7
8 11
2 6
10 9
fpwx18b0300
1 Engine oil dipstick assembly 8 Timing chain cover pipe clamp

2 Oil dipstick assembly (right)
3 Hexagonal flange face bolt - extra 9 Backing sheet
size range 10 Hexagonal flange face bolt
4 Hexagonal flange face bolt 11 Oil pump timing chain cover oil seal
5 Timing chain cover pipe clamp (left) assembly
18B
6 Hexagonal flange face bolt - extra 12 Hexagonal flange face bolt — extra
size range size range
7 Hexagonal flange face bolt 13 Oil strainer assembly
Lubrication System(4W10/4W12) - Engine Oil 18B-3
Engine Oil
Replacement
2. Turn off the engine and wait for 10 minutes.
fpwx18b0001

6. Dismount oil pan drain bolts and drain
engine oil.
Tool: 15mm sleeve
Note
• Engine oil is very hot, be careful not to be

burnt.
fpwx18B0002 • Prolonged and repeated contact with used
engine oil may cause skin cancer;
therefore, you should avoid the direct
contact of used oil with skin. If contact
was made, thoroughly clean with soap or
detergent as soon as possible.
18B
• Collect waste oil with a specified container
and dispose according to provisions.
7. Replace with a new oil drain plug gasket

and tighten bolts.
Tool: 15mm sleeve
(25～30N·m)
fpwx18B0003

9. Add a fixed mount of oil.
Engine oil: 2.7L
18B-4 Lubrication System(4W10/4W12) - Engine Oil
Note
When the ambient temperature is above -20℃, use SF15W / 40 gasoline engine oil;
GB11121-2006 (APISGSAE15W40 gasoline engine oil). When the ambient temperature
is below -20℃, use SF5W / 30 gasoline engine oil GB11121-2006 (APISGSAE5W30
gasoline engine oil).

11 . Park the vehicle on level ground and start the engine to heat the vehicle. And
check around the oil drain plug and oil filter for oil leakage.
13 . Check the height of engine oil level.
(a) Pull out the dipstick and wipe it clean.
(b) Insert the dipstick and confirm the engine oil
level is within the scope as shown.
MAX MIN
fpwx18a0005
14 . Turn down the driver seat, lock the fixing buckle of driver seat.
18B
Lubrication System(4W10/4W12) - Oil Filter 18B-5
Oil Filter
Replacement
5. Discharge engine oil. (See 18B Lubrication System(4W10/4W12) - Engine Oil,
Replacement)
Note
Oil filter is generally replaced along with engine oil to avoid oil contamination that
affects the engine operation.
6. Dismount the oil filter with special tools.
fpwx18B0005
7. Clear out foreign matters adhering to the mounting surface of an oil cleaner.
8. Apply engine oil on the new oil filter seal
surface.
18B
fpwx18B0006
9. Screw on the oil filter by hand until the

O-ring contact surface comes into contact
with filter bracket contact surface, then
tighten the filter to the specified torque
(14±2N·m) with a tool.
fpwx18B0007
10 . Install the oil drain plug. (See 18B Lubrication System(4W10/4W12) - Engine Oil,
Replacement)
18B-6 Lubrication System(4W10/4W12) - Oil Filter

15 . Check and make sure oil filter is free of oil leakage.
18B
Lubrication System(4W10/4W12) - Oil pan 18B-7
Oil pan
Replacement
2. Open the engine oil filler cap.
4. Drain engine oil. (See 18B Lubrication System(4W10/4W12) - Engine Oil,
Replacement)
6. Unplug the dipstick.
7. Dismount the engine oil dipstick pipe.
(a) Dismount engine oil dipstick pipe bolts.
Tool: 13mm sleeve
(b) Pull out the dipstick pipe.
Note
Check the seal on the bottom of dipstick pipe

for damage or aging and replace as needed.
fpwx18B0008

9. Remove the oil tray.
(a) Dismount 3 fixing bolts and bolts on the
transmission front cover.
Tool: 10mm socket
(b) Dismount the front cover.
18B
fpwx18B0009
(c) Dismount fixing bolts on the rear part of

engine oil pan.
Tool: 10mm socket
fpwx18B0010
18B-8 Lubrication System(4W10/4W12) - Oil pan
(d) Dismount fixing bolts on the right side of

engine oil pan.
Tool: 10mm socket
fpwx18B0011
(e) Dismount fixing bolts on the left side of engine

oil pan.
Tool: 10mm socket
fpwx18B0012
(f) Insert an appropriate tool between the cylinder

block and the oil pan by tapping it with a
hammer and dismount the oil pan.
Note
Do not forcibly dismount the oil pan with a
screwdriver, otherwise the oil pan contact
surface may deform, thus affecting the leak
fpwx18B0013 tightness.
10 . Clean the contact surface between the cylinder block and the engine oil pan.
11 . Apply sealant in the shape of continuous
18B
round strip with 4 mm diameter to the oil
pan flange.
Note
Bolt holes must be encircled with round strip
sealant. When apply sealant on the edge of hole
mounted with a bolt, you should apply along the
fpwx18B0014 hole circle to prevent oil leakage at the hole.
Lubrication System(4W10/4W12) - Oil pan 18B-9
12 . Install the oil pan.

(a) Install the oil pan and fixing bolts, tighten oil
pan fixing bolts one by one in numeric order.
Tool: 10mm socket
(7±1N·m)
Torque: 7 ± 1 N • m
Note
fpwx18B0015 Install the oil pan quickly while the sealant is not
dry (within 15 minutes). Keep the sealant away
from oil for about an hour after the installation.
(b) Install the transmission front cover and fixing

bolts.
(10±1N·m) Tool: 10mm socket
fpwx18B0016
13 . Install the dipstick pipe and fixing bolts.

Tool: 10mm socket
(7±1N·m)
fpwx18B0017
14 . Lower the vehicle. 18B

15 . Refill engine oil. (Refer to18B Lubrication System(4W10/4W12) - Engine Oil,
Replacement)
16 . Insert the oil dipstick.
20 . Check to make sure the oil pan is free of oil leakage.
18B-10 Lubrication System(4W10/4W12) - Engine Oil Pump
Engine Oil Pump

Overhaul
3. Drain engine oil. (See 18B Lubrication System(4W10/4W12) - Engine Oil,
Replacement)
4. Remove the oil tray. (See 18B Lubrication System(4W10/4W12) - Oil pan,
Replacement)
5. Dismount the water pump and the crankshaft pulley. ( Refer to15B Engine
Mechanism System(4W10/4W12) - Timing Front Cover, Replace )
6. Dismount oil strainer fixing bolts and nuts,
remove the oil strainer.
Tool: 10mm sleeve.
fpwx18B0018
7. Dismount the fixing bolt which mounts the

timing chain cover oil pump assembly on
the engine.
Tool: 10mm sleeve.
fpwx18B0019
18B 8. Dismount oil pump assembly mounting

screws, remove the oil pump assembly.
fpwx18B0020
9. Check the oil pump assembly.

(a) Check oil holes and oil ducts for blocking, clean if necessary.
(b) Check the front cover for cracks or other damages, replace if necessary.
(c) Check the oil seal lip for wear or damage, replace if necessary.
Lubrication System(4W10/4W12) - Engine Oil Pump 18B-11
10 . Install the oil pump assembly.

Install retaining screws of the oil pump
assembly.
fpwx18B0021
11 . Install the fixing bolt which mounts the

timing chain cover oil pump assembly on
the engine.
(23±2N·m)
Tool: 10mm sleeve
fpwx18B0022
12 . Install the oil strainer and its fixing bolts

(10±1N·m)
Tool: 10mm sleeve
Torque: 10±1N•m
fpwx18B0023
13 . Install the oil pan. (See 18B Lubrication System(4W10/4W12) - Oil pan,
Replacement)
14 . Install the water pump and the crankshaft pulley. ( Refer to15B Engine Mechanism 18B
System(4W10/4W12) - Timing Front Cover, Replace )
16 . Refill engine oil. (See 18B Lubrication System(4W10/4W12) - Engine Oil,
Replacement)
17 . Turn down the seat, lock the fixing buckle of driver seat.
18B-12 Lubrication System(4W10/4W12) - Engine Oil Pump
18B
Ignition System(LJ465)
The Ignition System...........................19A-1
Precautions......................................19A-1
Component Specification.................19A-3
Ignition Module/High-voltage Coil/Spark
Plug......................................................19A-4
Overhaul...........................................19A-4
19A
19A
Ignition System(LJ465) - The Ignition System 19A-1
The Ignition System

Precautions
3. Before dismounting electrical components, you must switch off all electrical
appliances and ignition switches, disconnect the negative battery cable,
otherwise electrical components or control units are likely to be damaged.
4. When overhauling an ignition system, first perform fault diagnosis for an engine
with a fault diagnostic unit and record diagnosis results. Read fault codes again
and delete when finish the overhaul.
5. Wear insulated gloves to avoid electric shock when checking the ignition system
if the engine is started or running.
6. Before checking spark plug arcing, you must disconnect injector power supply
and make sure there are no fuel or other flammable materials in the surrounding.
19A
19A-2 Ignition System(LJ465) - The Ignition System
Component Diagrams
4
5
2
2
fpwx19a0013
1 One-cylinder high-voltage cable 5 Four-cylinder high-voltage cable

assembly assembly
2 Spark plug 6 Double ignition coil
3 Two-cylinder high-voltage cable 7 Hexagonal flange face bolt
assembly
4 Three-cylinder high-voltage
assembly
19A
Ignition System(LJ465) - The Ignition System 19A-3
Component Specification
Name Specification
Working temperature -40～125℃
Spark plug gap 1 - 1.1mm
Primary coil resistance 0.7±0.07Ω
Secondary coil resistance 9840±980Ω
General Specification
Application Specification
Ignition Type Simultaneous ignition of double-cylinder
Ignition Order 1–4 or 2-3
19A
19A-4 Ignition System(LJ465) - Ignition Module/High-voltage Coil/Spark Plug
Ignition Module/High-voltage Coil/Spark Plug

Overhaul
(b) Flip and turn over the driver seat.
fpwx19a0001
3. Dismount the high voltage cable.

(a) Gently turn from each cylinder and pull out
the high voltage cable.
fpwx19a0002
(b) Dismount the high-voltage cable in certain

order from ignition module side.
Note
Before disconnecting the high-voltage on an
ignition module, confirm the corresponding
position of high-voltage on the ignition module
of each cylinder and make appropriate markings.
19A fpwx19a0003
(c) Remove the high-voltage cable.
fpwx19a0010

Ignition System(LJ465) - Ignition Module/High-voltage Coil/Spark Plug 19A-5

(b) Remove 2 fixing bolts of the ignition module:
Tool: 10mm sleeve
fpwx19a0004
(c) Remove the ignition module.
fpwx19a0011
5. Dismount the spark plug.

(a) Dismount the spark plug with a dedicated
sleeve.
(b) Remove the spark plug.
fpwx19a0005
6. Check the high-voltage cable.

• Check the high-voltage cable for traces of breakdown.
• Check that the resistance value of the standard high-voltage cable meets the
following values:
19A
Working temperature: -40 - 150℃
Coil inductance: 290±30mH@1kHz
Air clearance: 0.5 - 1.5mm
7. Check the ignition module.

• Check the ignition module for cracks.
• Check the ignition module operation.
(a) Confirm that no fault code is stored with a fault diagnostic unit. If there is storage code,
record the code number. Even if it is not related to the ignition system, you should also
troubleshoot the stored code to solve the problem.
(b) Unplug the fuel pump fuse.
(c) Unplug sub-cylinder line and remove the spark plug.
(d) Connect a new spark plug to the high-voltage cable and contact the spark plug negative
pole with the cylinder block.
(e) Start the engine and check between spark plug electrodes for arcing.
(f) If the spark is weak or no spark, then perform the same check with a new ignition
module. If the spark strong when tested with a new ignition module, then the problem
lies obviously in the ignition module. Renew the ignition module. If there is no spark
as well when tested with a new ignition module, it indicates ignition circuit faults, then
you should check the ignition circuit. Dismount the spark plug with a right tool for and
check the spark plug.
(g) Detect for stored fault code with a fault diagnostic unit after this check. All codes should
be cleared except codes stored in step a.Then, perform troubleshooting on the recorded
code.
8. Check the spark plug.

• Check the spark plug insulator outer
surface for cracks.
• Check spark plug arcing position for
carbon deposit.
• Check positive and negative poles of
the spark plug for ablation.
fpwx19a0012 Check the spark plug arcing gap.
Standard value: 1 - 1.1mm
9. Install the spark plug.

Tighten the spark plug with a special tool.
Note
When installing a spark plug, tighten torque in
accordance with technical specifications set by
(20~28N·m) fpwx19a0006
Foton. Do not tighten it too loose or too tight to
avoid leakage or damage to the spark plug and
19A spark plug holes.
10 . Install the ignition module.

Tool: 10mm sleeve
Torque: 10±1N•m
(b) Connect the ignition module connector.
(10±1N·m)
fpwx19a0007
11 . Install the high-voltage cable.

Ignition System(LJ465) - Ignition Module/High-voltage Coil/Spark Plug 19A-7
(a) Install the high-voltage cable onto the ignition

module in accordance with the removal order.
fpwx19a0008
(b) Connect the high-voltage cable onto each

cylinder in accordance with the removal order.
fpwx19a0009
13 . Start the engine and check the engine for correct operating state.
19A
19A
Ignition System(4W10/4W12)
The Ignition System...........................19B-1
Precautions......................................19B-1
Component Specification.................19B-3
Ignition Module/High-voltage Coil/Spark
Plug......................................................19B-4
Overhaul...........................................19B-4
19B
19B
Ignition System(4W10/4W12) - The Ignition System 19B-1
The Ignition System

Precautions
3. Before dismounting electrical components, you must switch off all electrical
appliances and ignition switches, disconnect the negative battery cable,
otherwise electrical components or control units are likely to be damaged.
4. When overhauling an ignition system, first perform fault diagnosis for an engine
with a fault diagnostic unit and record diagnosis results. Read fault codes again
and delete when finish the overhaul.
5. Wear insulated gloves to avoid electric shock when checking the ignition system
if the engine is started or running.
6. Before checking spark plug arcing, you must disconnect injector power supply
and make sure there are no fuel or other flammable materials in the surrounding.
19B
19B-2 Ignition System(4W10/4W12) - The Ignition System
Component Diagrams
4
5
2
2
2
2
fpwx19b0013
1 One-cylinder high-voltage cable 5 Four-cylinder high-voltage cable

assembly assembly
2 Spark plug 6 Double ignition coil
3 Two-cylinder high-voltage cable 7 Hexagonal flange face bolt
assembly
4 Three-cylinder high-voltage
assembly
19B
Ignition System(4W10/4W12) - The Ignition System 19B-3
Component Specification
Name Specification
Working temperature -40℃～125℃
Spark plug gap 1 - 1.1mm
Primary coil resistance 0.7Ω±0.07Ω
Secondary coil resistance 9840Ω±980Ω
General Specification
Ignition Type Simultaneous ignition of double-cylinder
Ignition Order 1–4 or 2-3
19B
19B-4 Ignition System(4W10/4W12) - Ignition Module/High-voltage Coil/Spark Plug
Ignition Module/High-voltage Coil/Spark Plug

Overhaul
3. Dismount the high voltage cable.
(a) Disconnect ignition module connectors and
pull out high-voltage cables in certain order
from ignition module side.
Note
Before disconnecting the high-voltage on an
ignition module, confirm the corresponding
position of high-voltage on the ignition module
fpwx11B0080 of each cylinder and make appropriate markings.
(b) Remove the fixed upper cover of high voltage

cable.
Tool: hexagon wrench
fpwx19B0002
4. Check the high-voltage cable.

• Check the high-voltage cable for traces
of breakdown.
• Check whether the standard resistance
value of high-voltage cable is ≥2.5kΩ
.
fpwx05b0049
19B
(a) Remove 2 fixing bolts of the ignition module:
Tool: 10mm sleeve
fpwx11B0081
Ignition System(4W10/4W12) - Ignition Module/High-voltage Coil/Spark Plug 19B-5
(b) Remove the ignition module.
fpwx19B0005
6. Dismount the spark plug.

(a) Dismount the spark plug with a dedicated
sleeve.
(b) Remove the spark plug.
fpwx05b0047
7. Check the ignition module.

• Check the ignition module for cracks.
• Check the ignition module operation.
(a) Confirm that no fault code is stored with a fault diagnostic unit. If there is storage code,
record the code number. Even if it is not related to the ignition system, you should also
troubleshoot the stored code to solve the problem.
(b) Unplug the fuel pump fuse.
(c) Unplug sub-cylinder line and remove the spark plug.
(d) Connect a new spark plug to the high-voltage cable and contact the spark plug negative
pole with the cylinder block.
(e) Start the engine and check between spark plug electrodes for arcing.
(f) If the spark is weak or no spark, then perform the same check with a new ignition
module. If the spark strong when tested with a new ignition module, then the problem
lies obviously in the ignition module. Renew the ignition module. If there is no spark 19B
as well when tested with a new ignition module, it indicates ignition circuit faults, then
you should check the ignition circuit. Dismount the spark plug with a right tool for and
check the spark plug.
(g) Detect for stored fault code with a fault diagnostic unit after this check. All codes should
be cleared except codes stored in step a.Then, perform troubleshooting on the recorded
code.
8. Check the spark plug.
• Check the spark plug insulator outer

surface for cracks.
• Check spark plug arcing position for
carbon deposit.
• Check positive and negative poles of the
spark plug for ablation.
Check the spark plug arcing gap. Standard
fpwx19B0007
value: 1 - 1.1mm
9. Install the spark plug.

(a) Tighten the spark plug with a special tool.
Note
When installing a spark plug, tighten torque in
(27±2N·m)
accordance with technical specifications set by
Fukuda. Do not tighten it too loose or too tight
to avoid leakage or damage to the spark plug
fpwx19b0008
and spark plug holes.
10 . Install the ignition module.

Tool: 10mm sleeve
(10±2N·m)
fpwx19B0009
11 . Install the high-voltage cable.

(a) Install the high-voltage cable to the ignition
19B module according to markings on the ignition
module and connect the ignition module
connector.
fpwx19B0010
Ignition System(4W10/4W12) - Ignition Module/High-voltage Coil/Spark Plug 19B-7
(b) Install the high-voltage cable to the spark plug

of each cylinder.
Note
Make sure to hear the "click" sound to confirm
the high-voltage cable is mounted in place.
fpwx19b0011
13 . Start the engine and check the engine for correct operating state.
19B
19B
Starting and Charging(LJ465)
Starting and Charging System..........20A-1
Precautions......................................20A-1
Engine.................................................20A-4
Overhaul...........................................20A-5
Starter................................................20A-13
Overhaul.........................................20A-14
Battery...............................................20A-23
Use and Maintenance....................20A-24
Basic Check...................................20A-26
Common battery faults, cause analysis and
troubleshooting...............................20A-28
Replacement..................................20A-30
20A
20A
Starting and Charging(LJ465) - Starting and Charging System 20A-1
Starting and Charging System

Precautions
1. Explosive gas may escape from a battery. Engine compartment must be kept
well ventilated before battery maintenance in order to reduce personal injury.
First remove the negative (-) battery cable and finally connect the negative (-)
battery cable to avoid arcing.
2. Battery electrolyte is very dangerous and can damage the machine and cause
severe burns. When maintaining a battery, you should prepare a bucket of high
concentrations of soda as neutralizer. Wear safety eyepiece and protective
clothing to avoid personal injury.
masks to prevent flying debris and dirt from causing personal harm.
4. Do not over tighten electrical connections as this may damage the starter
5. Short-circuit of battery two terminals is not allowed, otherwise the battery would
be rapidly heated and is likely to burst. In addition, the escaping gas of a battery
can easily be ignited by a spark, so do not use naked flame near a battery.
6. When removing a battery, first remove the negative cable and then remove the
positive cable, then remove the battery retaining bracket and remove the battery
from the bracket. Install the battery in the reverse order.
7. Can not operate the engine when the battery is not connected, otherwise it will
damage the electrical system (electronic components).
8. As a generator is grounded with the negative pole, so the battery grounding
polarity must be the same, otherwise the battery will discharge through the
silicon diode resulting in diode burnout.
9. When the generator is running, do not check the generator for power generation
with the spark test method, rather you can check with a light bulb or a multimeter,
otherwise the diode may easily be damaged.
10 . When checking generator silicon rectifier elements, the use of a megger or 220V
AC for checking generator insulation should be strictly prohibited, or the diode
would be damaged through breakdown.
20A
20A-2 Starting and Charging(LJ465) - Starting and Charging System


1. Start switches and other control Check the circuit for reliable connec-
circuit (broken line) tion
Starter does not 2. Carbon brush and commutator 20A Starting and Charging(LJ465) -
work (poor contact) Starter, Overhaul
3. Starter internal line (open circuit, 20A Starting and Charging(LJ465) -
short circuit) Starter, Overhaul
20A Starting and Charging(LJ465) -
1. Battery (off-capacity)
Battery, Use and Maintenance
Check the cable for reliable connec-
2. Conducting line (poor contact)
tion
3. Commutator (surface burning or 20A Starting and Charging(LJ465) -
Starter unable greasy dirt) Starter, Overhaul
to start, the en- 4. Carbon brush (excessive wear)
gine can not be or brush spring (less elastic, result- 20A Starting and Charging(LJ465) -
started ing in poor contact with the commu- Starter, Overhaul
tator)
5. Electromagnetic switch (main 20A Starting and Charging(LJ465) -
contact ablation, poor contact) Starter, Overhaul
6. Bearings (wear), armature (rub 20A Starting and Charging(LJ465) -
shell) Starter, Overhaul
1. Starter relay (inner copper con-
The engine has tact plate and two contact adhe-
Starter, Overhaul
been started, sions)
the starter con-
2. Starter electromechanical pivot 20A Starting and Charging(LJ465) -
tinues to rotate
(broken or bent) Starter, Overhaul
and generates
sharp noise 3. starter contact tooth surface 20A Starting and Charging(LJ465) -
20A
(nap or stuck) Starter, Overhaul
1. Cable connection
tion
2. Rotor coil open-circuited
Engine, Overhaul
Generator fault
3. Rectifier diode damaged
Engine, Overhaul
4. Poor contact of the carbon brush
Engine, Overhaul
Starting and Charging(LJ465) - Starting and Charging System 20A-3

5. Adjuster damaged
Engine, Overhaul
1. Generator belt sagged
Engine, Overhaul
2. Poor contact of carbon brush,
slip ring contaminated by greasy
Engine, Overhaul
Generator un- dirt
dercharged 20A Starting and Charging(LJ465) -
3. Adjuster damaged
Engine, Overhaul
4. Too little battery electrolyte or
serious polar plates vulcanization
or polar plates too old
20A
20A-4 Starting and Charging(LJ465) - Engine
Engine
Component Diagrams
2
3
7
6
fpwx20a0078
1 Alternator assembly 5 Compressor bracket bolt

2 Components of hexagon headed components
bolt, flat washer and spring washer 6 Compressor bracket
3 Intake manifold bracket bolt 7 Compressor bracket bolt
components components
4 Generator bracket assembly 8 Distributor seat shoulder bolts
Generator Specification
Name Specification
20A Normian voltage formula 12
Polarity Negative grounding
Work mode Continuous rating type
Starting and Charging(LJ465) - Engine 20A-5
Overhaul
cap.
fpwx20a0001

Tool: 10mm wrench
CAMEL
谷城县石花镇武当路82号
-7611540
线：400-189-9507
骆驼
禁止烟火戴防护眼镜小心腐蚀参阅说明书担心爆炸

Pb RECYCLE FLAMMABLE SHIELD EYES FURIC ACID READ DIRECTION EXPLOSIVE
生产许可
CAREFULLY
CAMEL GH
生产许可证：000-00-00000
CO.,LTD.
fpwx20a0002
4. Lift the subsidiary engine cap.

passenger seat.
(b) Flip the driver seat, open the subsidiary
engine cap.
fpwx20a0003
5. Disconnect the generator connecting line.

(a) Remove generator power line terminal nuts,
and separate the line.
Tool: 10mm sleeve
(b) Disconnect generator connectors. 20A
fpwx20a0004
6. Loosen generator belt tensioner bolts.

Tool: 12mm sleeve
fpwx20a0005
7. Loosen 2 bolts of the generator lower

support.
Tool: 12mm sleeve
fpwx20a0006
8. Remove the generator belt.

Note
Check the generator belt for signs of crack and replace as needed.
9. Dismount the generator.
(a) Dismount generator belt tensioner bolts.
(b) Remove 2 pillar bolts on the lower part of the generator.
(c) Remove the generator.
10 . Dismount the generator pulley fixing bolt

with a pneumatic tool.
fpwx20a0007
20A
11 . Dismount 4 fixing bolts of the generator
front cover and the stator assembly.
Tool: 8mm sleeve
fpwx20a0008
12 . Insert a screwdriver into the gap between the front cover and the stator to
separate the front cover from the stator.
Note
• If it is difficult to separate them, then gently tap the front cover with a rubber
hammer and pry it with a screwdriver in the meantime.
• Do not insert the screwdriver too deep, so as not to damage the stator coil.
13 . Remove the stator with an electric

soldering iron (180 - 250W), be sure to
have this done within 4 seconds so as not
to conduct heat to the diode.
fpwx20a0009
14 . Dismount 4 screws of the rectifier.
fpwx20a0010
15 . When removing the rectifier from a

regulator, unsolder the part welded onto
the rectifier with an electric soldering iron.
Note
• Make sure not to allow heat generated by

the electric soldering iron being conducted
to the diode for a long period of time.
fpwx20a0011
• Do not exert excessive force on the diode
pin. 20A
16 . Remove and check the rotor.

• Check the rotor coil for conduction and

make sure it is conducting between slip
rings. Measure the rotor resistance, if too
small, it means that the rotor is
short-circuited. If not conducting or
short-circuited, you should replace the
rotor assembly.
fpwx20a0012
• Check rotor coil grounding. Confirm the

insulation between the slip ring and the
iron core, replace the rotor assembly if the
insulation fails.
fpwx20a0013
• Check the rotor shaft diameter.
fpwx20a0014
17 . Remove and check the stator.

• Check the stator for conduction and
confirm that the coil lead is conducting.
Replace the stator assembly if it not
conducting.
20A
fpwx20a0015
• Check coil grounding. Confirm conduction

between the coil and the stator core.
Replace the stator assembly if is
conducting.
fpwx20a0016
18 . Check the rectifier.

Diode group (three) check: connect both ends
of each diode with the ammeter and check
three diodes for breakover. If not conducting
in both directions, it indicates that the diode
is damaged, then you must replace the
radiator assembly.
fpwx20a0017
19 . Unsolder brush-lead solder joints to

remove the brush.
fpwx20a0018
20 . Replace the brush when it is worn to the

labeled line of wear limit.
fpwx20a0019 20A
21 . When installing a new brush, you should

weld on the brush-lead when the brush is
pressed in a brush bracket as shown.
fpwx20a0020
22 . Install 4 retaining screws of the rectifier.
fpwx20a0021
23 . Weld the connection of the rectifier with

the stator.
fpwx20a0022
24 . Before installing the rotor on the rear

cover, insert a steel wire from the small
jack located on the back cover, then pull
out the wire after lifting the brush and
installing the rotor.
fpwx20a0023
25 . Install the rotor.

26 . Install and tighten 4 fixing bolts between
(10±1N·m)
the front cover and the stator assembly.
Tool: 8mm sleeve
Torque: 10±1N•m
20A
fpwx20a0024
27 . Install the generator pulley and tighten the pulley nut with a pneumatic tool.
28 . Install the engine.

(a) Mount the generator in the correct position.
(b) Install 2 bolts on the generator lower support.
(25±3N·m)
Note
Install lower support bolts in place, do not lock
them and only tighten 2 bolts when the belt
tension is adjusted.
fpwx20a0025
29 . Install the conveyor belt.

30 . Install the belt tensioner bolt, tighten the
generator belt to the required value with
(25±3N·m)
a crowbar and tighten the belt tensioner
bolt at the same time.
Belt tightening:
Tools: crowbar, 13mm wrench
fpwx20a0026
31 . Tighten 2 bolts of the generator lower support.

Tool: 12mm sleeve
(a) Connect wiring harness and install generator

power line terminal nuts.
Tool: 10mm sleeve
Torque: 10±1N•m
(b) Connect the generator connector.
(10±1N·m)
fpwx20a0027
33 . Turn down the secondary engine cover

and lock the fixing buckle of front
passenger seat. 20A
fpwx20a0028

Tool: 10mm wrench
Torque: 10±1N•m
CAMEL
-7611540
线：400-189-9507
骆驼

生产许可
CAREFULLY
CAMEL GH
生产许可证：000-00-00000
CO.,LTD.
(10±1N·m)
fpwx20a0029
35 . Turn down the main engine cover and lock

the fixing buckle of driver seat.
fpwx20a0030
36 . Start the vehicle and check generator status.
20A
Starting and Charging(LJ465) - Starter 20A-13
Starter
Component Diagrams
1 2
fpwx20a0079
1 Starter bolt 3 Starter bolt

2 Starter assembly
Starter Performance
12V 20mΩ internal
Voltage
resistance of power source
Output power 1.0kW
Counterclockwise CCW as
Direction of rotation
viewed from the drive cap end 20A
Starter drive tooth itinerary Standard value 13±0.5mm
Starter armature out of Standard value 0.004mm
roundness Limit value 0.008mm
Standard value 45.5mm
Starter armature diameter
Limit value 45.46 - 45.54mm
Carbon brush wear value Limit value 2mm left until the brush lead
20A-14 Starting and Charging(LJ465) - Starter
Overhaul
cap.
fpwx20a0031

Tool: 10mm wrench
CAMEL
-7611540
线：400-189-9507
骆驼

生产许可
CAREFULLY
CAMEL GH
生产许可证：000-00-00000
CO.,LTD.
fpwx20a0032
4. Fix and lift the vehicle.

5. Dismount 6 bolts of the lower engine cover
sheet and remove the cover sheet.
Tool: 10mm sleeve
fpwx20a0033
20A
6. Disconnect starter connecting lines.

(a) Disconnect starter control line connectors.
(b) Dismount connecting wire nuts on the end of
starter power supply and separate the
harness.
Tool: 13mm wrench
fpwx20a0034
7. Dismount 2 bolts of the starter.

Tool: 12mm sleeve
fpwx20a0035
8. Remove and detect the starter.

• Pinion gap adjustment.
(a) Separate the field coil wire from the

electromagnetic switch M terminal.
S (b) Connect a 12V battery between S and M
M B terminals.
Note
Connect a 12V battery between S and M
terminals.
fpwx20a0036
(c) The pinion would pop up when 12V voltage

is connected between S and M terminals.
(d) When energized, measure the clearance

(pinion clearance) between the pinion and the
stopper with a vernier caliper.
20A
fpwx20a0037
(e) After de-energizing, check the gap between

the pinion and the stopper with a vernier
caliper.
Standard value: 13±0.5mm
fpwx20a0080
• Electromagnetic switch suction test.

(a) Disconnect the electromagnetic field coil wire
from the electromagnetic switch terminal.
S (b) Connect a 12V battery between S and M
M B terminals.
Note
This test must be executed quickly (within 10
seconds), so as not to burn the coil.
fpwx20a0039
(c) Switch the ignition switch to "ON", then the

pinion will pop up. You need to replace the
electromagnetic switch if the pinion does not
pop up.
• Electromagnetic switch maintaining test.

S (b) Connect a 12V battery between the S terminal
M B and the starter body.
Note
fpwx20a0040
20A (c) Manually pull out the pinion to pinion stopper

position.
(d) If the pinion is held at pop-up position, then
the system is operating correctly. If the pinion
bounces, then maintain the open circuit.
Replace the electromagnetic switch.
• Electromagnetic switch spring back test.


S (b) Connect a 12V battery between the M
M B terminal and the starter body.
Note
fpwx20a0041
(c) Pull out the pinion and then release it. If the
pinion quickly rebounds to its original position,
then it is operating correctly. If it does not
rebound, then replace the electromagnetic
switch.
Danger
When pulling out the pinion, be careful not to
get your fingers stuck.
9. Disconnect the electromagnetic field coil

wire from the electromagnetic switch
terminal.
Tool: 12mm sleeve
fpwx20a0042
10 . Dismount 2 retaining screws of the

electromagnetic switch.
11 . Dismount 2 fixing bolts of the starter
housing.
Tool: 8mm sleeve
fpwx20a0044
20A
12 . Clean the starter components.

• Do not place components in detergent, because the insulating property of yoke,
excitation coil assembly or armature may be damaged when they are soaked
in detergent.
• When these components are dirty, wipe out the dirt with cloth.
• Do not soak drive components in detergent, as the overrun clutch was applied
with oil at the factory. When cleaned in detergent the cleaning solvent will wash
off lubricating oil in the clutch.
• Drive components can be brushed clean with a brush dampened with cleaning
agent and then wiped dry with cloth.
13 . Check the armature.
(a) Support the armature with a set of V-block to
measure the surface out-of-roundness by
rotating the armature with a dial gauge when
there is no friction with the carbon brush.
Limit value: 0.008mm
fpwx20a0047
(b) Measure the armature diameter.

Limiting value: 45.46 - 45.54mm
fpwx20a0048
14 . Check the brush and the brush holder.

(a) Check for conduction between the brush holder plate and the brush holder, it is correct
if not conducting.
(b) Check whether the contact surface of each armature brush is particularly rough or not.
If the carbon brush wear value exceeds the limit value, then replace the carbon brush.
Limiting value: 2mm left until the brush lead
(c) When the carbon brush contact surface has been corrected or the carbon brush holder
has been replaced. Recondition the contact surface around the armature with a piece
of sandpaper.
15 . Check the overdrive clutch.

(a) Confirm that the pinion can not rotate
counterclockwise but can rotate freely in the
20A clockwise direction.
(b) Check the pinion for wear and damage.
Missing teeth, erosion and deformation are
not allowed.
fpwx20a0050
16 . Check the armature coil.

(a) Place the rotor on the coil short-circuit tester.

(b) Place a thin iron sheet above the rotor and
keep it parallel to the central axis of the rotor,
then rotate the rotor slowly and observe the
thin iron sheet. If the iron sheet is not attracted
and there is no vibration, then the rotor is
normal.
Note
fpwx20a0051
Clean the armature surface thoroughly before

performing this test.
(c) Check the insulation between the commutator

lug and the rotor core. It is correct if not
conducting.
fpwx20a0052
(d) Check for conduction between each

rectiblock. It is correct if conducting.
fpwx20a0053
17 . Check the electromagnetic switch.

(a) Coil open-circuit test.
A
• Check for conduction between terminal
M and body A.
• If not conducting, then replace the
electromagnetic switch. 20A
M
fpwx20a0054
(b) Contact point check.

B • Check for conduction between terminal
B and terminal M.
• If conducting, then replace the
M
fpwx20a0055
(c) Check the switch contacts.

B • Forcibly push down the
electromagnetic switch end shown to
close the inner contact. Check for
conduction between terminal B and
terminal M at the unreleased switch
end.
M
• If not conducting, replace the
fpwx20a0056
18 . Assemble the starter.

19 . Install the starter housing and tighten 2
fixing bolts.
Tool: 8mm sleeve
Torque: 10±1N•m
20 . Install the magnetic switch and tighten 2
retaining screws.
(10±1N·m)
fpwx20a0059
21 . Install the magnetic field coil lead at the

electromagnetic switch terminal and
tighten the nut.
Torque: 10±1N•m
20A
fpwx20a0061
22 . Install the starter and tighten 2 fixing bolts.

Tool: 12mm sleeve
(18~28N·m)
fpwx20a0062
(10±1N·m)
23 . Connect starter connecting wires.
(a) Connect the wiring harness and install starter
power supply terminal connecting wire nuts.
(b) Connect starter control cable connectors.
Tool: 13mm wrench
Torque: 10±1N•m
fpwx20a0063
24 . Install the lower engine cover sheet and

tighten 6 bolts.
Tool: 13mm sleeve
Torque: 10±1N•m
(10±1N·m)
fpwx20a0064 20A


Tool: 10mm wrench
Torque: 10±1N•m
CAMEL
-7611540
线：400-189-9507
骆驼

生产许可
CAREFULLY
CAMEL GH
生产许可证：000-00-00000
CO.,LTD.
(10±1N·m)
fpwx20a0065

fpwx20a0066
20A
Starting and Charging(LJ465) - Battery 20A-23
Battery
Component Diagrams
3
2
fpwx20a0077
1 Battery 4 Pallet
2 Pull rod 5 Hexagonal flange face nut
3 Pressing plate
Battery Specification
Standard voltage 12V
Rated Capacity 45Ah
20A
Idle Capacity 125CCA
20A-24 Starting and Charging(LJ465) - Battery
Use and Maintenance

1. Charging equipment:
Note
Since a battery must be with charged with DC power supply, but AC is what supplied
by a power plant, thus it must be converted to DC in order to charge a battery.
(a) Rectifier.
(b) Silicon controlled voltage regulating charger.
2. Charging Precaution:
(a) Charging should be done in a ventilated and dry room, preferably at room temperature
of 5℃ - 40℃.
(b) Neither overlap batteries nor lay them directly on the ground, rather you should place
them on a wooden frame and keep them away from alkaline batteries or other
chemicals.
(c) Charging site should ban ignition source and be away from heat source.
(d) Electrolytic solution temperature should not exceed 45℃, otherwise you should take
cooling measures (to reduce the charging current or stop charging or cool the solution
by filling it into a water tank).
3. Charging connection:
(a) Connect the charger positive pole with the battery positive pole, connect the negative
pole with the battery negative pole, do not reverse the order.
(b) For most batteries, charge can be determined according to the size of the motor power,
charging connection must be secure.
4. Charging method.
There are three charging methods in general, i.e. constant current charging, constant
voltage charging and fast charging.
5. Measure with an instrument after charging and determine whether battery
capacity returns to standard value through voltage method or volumetric method.
(a) Voltage method
Voltage Judging Processing
above 12.5V Normal Continue to use
11.5V - 12.5V Undercharge Recharge
20A
Over-discharge or internal
Below 11.5V Charge and then check
fault
(b) Indicator displays status

Capacity meter display Judging Processing
White region Adequate Continue to use
Green region Normal Continue to use
Yellow region Undercharge Recharge
Red region Over-discharge Charge and then check
6. Battery use and maintenance in winter:

(a) Keep the battery in a fully charged state to avoid freezing due to electrolyte specific
gravity decrease which may result in container rupture, plate bending, breaking and
dropping of active substances and other fault.
(b) Since battery capacity decreases in winter, so the engine should be preheated in case
of cold start, and each starter connection time should not exceed 15 seconds and start
interval should be 2 to 3 minutes, you should look for engine failure if start failed for
three times, troubleshoot and then start again.
20A
Basic Check
1. Appearance Check:
(a) First observe that the battery appearance is in good condition, fixing ties and wire
connections are secure.
(b) Observe the battery case and the central partition for cracks, beat the case and the
central partition with a crabstick respectively for crashing sound, since junctions of the
central partition with four sides of the case are especially prone to cracking, you should
check carefully.
(c) If any observation mirrors, then the green indicates fully charged, the red and white
indicates lack of electricity and no electricity respectively. Perform following capacity,
specific gravity and voltage detections.
2. Capacity detections:
(a) High rate discharge meter, also known as
discharge fork, consists of a DC voltmeter
and a load resistor.
(b) When performing a measurement, you should
press two prongs against the positive and
negative battery posts for five seconds and
observe the voltage that a battery can
maintain under heavy load discharge
fpwx20a0067
condition, then you can accurately determine
the discharge degree and the start capacity
of the battery.
(c) For high rate discharge meter of different
brands, you should specify the value in
accordance with the original manual. For
battery of good general technology condition,
single-cell voltage should be above 1.5V and
remain stable within 5 seconds. If voltage
decreases rapidly within 5 seconds or a
single-cell battery voltage is lower than other
single-cell battery for more than 0.1V, then it
indicates that the battery is faulty.
Here blow is a comparison table for results detected with a high rate discharge meter.
20A Display region Judging Processing
White region Adequate Continue to use
Green region Normal Continue to use
Recharge (see20A Starting and Charg-
Yellow region Undercharge
ing(LJ465) - Battery, Use and Maintenance.)
Recheck after charging (see20A Starting and
Red region No electricity Charging(LJ465) - Battery, Use and Mainte-
nance.)
3. Voltage detection:
Here blow is a comparison table for results detected with a digital multimeter.
Voltage Judging Processing

above 12.5V Normal Continue to use
Recharge (see20A Starting and Charg-
11.5 - 12.5V Undercharge ing(LJ465) - Battery, Use and Mainte-
nance.)
Recheck after charging (see20A Start-
Over-discharge or
Below 11.5V ing and Charging(LJ465) - Battery, Use
internal fault
and Maintenance.)
20A
Common battery faults, cause analysis and troubleshooting

1. A fully charged battery will lose power after long-term idle.
• Cause:
A fully charged battery gradually loses power after idle is a phenomenon known
as "self-discharge." Material impurity is an important reason responsible for
self-discharge. Impurities in electrode materials or the electrolyte will result in
potential difference between impurities and the pole plate, impurities and
impurities, thus forming a closed "local current", so that the battery is discharged.
• Solution:
For the severely self-discharged battery, you can fully discharge or
over-discharge it, so that impurities on the plate is resolved into the electrolyte,
then decant the electrolytic solution and clean the cell with distilled water, and
finally fill in the new electrolyte to recharge.
2. Battery explosion.
• Cause:
Battery explosion is mostly due to overcharge which results in electrolyte splitting
water into hydrogen and oxygen, thus generating a lot of bubbles; short-circuit
and curing fault within a battery; rapid rise in electrolyte temperature during
charging leads to substantial water evaporation; battery explosion will be the
result if the filler cap vent hole is clogged or too much gas is too late to escape
when the battery internal pressure reaches a certain limit (or slightly catch
kindling material).
• Solution:
(a) Battery vent should be kept open.
(b) Wiring on a post should be strong, so as to avoid generating sparks through looseness.
(c) Control the charge level, not to overcharge, so as to reduce the amount of gas evolved.
Charging room should be free of open flame and well ventilated.
3. Liquid level drops too quickly during battery use.
• Cause:
(a) Charge current is too strong, resulting in water evaporation.
(b) Battery case ruptured.
20A • Solution:
(a) Check the generator and generator control circuit.
(b) Replace battery.
4. Yellow or white paste is generated on the battery cover.
• Cause:
Yellow or white paste around the battery cover and post is the result of post,
clamp and mounting bracket corrosion due to sulfuric acid solution splashed on
the battery cover.
• Solution:
To avoid these pastes you can wipe out electrolyte spilled on the battery cover
and housing with a rag soaked in 10% soda solution. Then wipe with water, and
finally with clean cloth. Pastes on threads and posts should also be wiped clean
with soda solution soaked rag. If any oxide of poor conductivity, you should
scrape with knife to make it clean. After fastening the post and the clamp, it is
preferred to apply a layer of vaseline or grease on their surface.
Danger
Foton Gratouris furnished with a maintenance-free battery, if the battery is faulty, you
should replace the battery assembly. To avoid injury, it is prohibited to disassemble
a battery. Battery disassembly only intended to provide professionals with information
for detecting and finding fault causes.
20A
Replacement
cap.
fpwx20a0068
3. Disconnect the battery terminal cable.

(a) Disconnect battery negative terminal
connecting nuts.
(b) Disconnect the battery negative terminal.
CAMEL
-7611540
线：400-189-9507
骆驼 Note
生产许可
CAREFULLY
CAMEL GH
生产许可证：000-00-00000
CO.,LTD.
First disconnect the battery negative terminal
when replacing a battery.
fpwx20a0069
(c) Turn over the jacket and loosen battery

positive terminal connecting nuts.
(d) Disconnect the battery positive terminal.
CAMEL
Tool: 10mm wrench

-7611540
线：400-189-9507
骆驼

生产许可
CAREFULLY
CAMEL GH
生产许可证：000-00-00000
CO.,LTD.
fpwx20a0070
4. Dismount the battery fixing bracket.

(a) Loosen 2 nuts of the battery fixing bracket.
Tool: 10mm wrench
CAMEL
20A
-7611540
线：400-189-9507
Pb RECYCLE
禁止烟火
FLAMMABLE
戴防护眼镜
SHIELD EYES
小心腐蚀
FURIC ACID
参阅说明书
READ DIRECTION
CAREFULLY
担心爆炸
EXPLOSIVE
骆
生产许可
驼
(b) Remove the battery fixing bracket.

CAMEL GH
生产许可证：000-00-00000
CO.,LTD.
fpwx20a0071
5. Remove the battery.

Note
A battery should be placed upward, do not lay it sidelong or upside down.
6. Remove and clean the battery tray.
fpwx20a0072
7. Install the battery tray.

8. Install the battery.
9. Install the battery mounting bracket and
tighten 2 nuts.
Tool: 10mm wrench
CAMEL
-7611540
线：400-189-9507

骆驼
Torque: 10±1N•m
生产许可
CAREFULLY
CAMEL GH
生产许可证：000-00-00000
CO.,LTD.
(10±1N·m) fpwx20a0073
10 . Connect the battery terminal cable.

(a) Connect the battery positive terminal.
(b) Tighten battery positive terminal connecting
nuts and put on the protective jacket.
CAMEL
Tool: 10mm wrench

-7611540
线：400-189-9507
(10±1N·m)
骆驼

Torque: 10±1N•m
生产许可
CAREFULLY
CAMEL GH
生产许可证：000-00-00000
CO.,LTD.
fpwx20a0074
(c) Connect the battery negative terminal.

(d) Tighten battery negative terminal connecting
nuts.
CAMEL
Tool: 10mm wrench

-7611540
线：400-189-9507

骆驼
20A
Torque: 10±1N•m
生产许可
CAREFULLY
CAMEL GH
生产许可证：000-00-00000
CO.,LTD.
(10±1N·m)
Note
fpwx20a0075 If there are sediments on the terminal, it is
recommended to polish the terminal to remove
impurities, and then apply a thin layer of grease
before connecting terminals.

fpwx20a0076
20A
Starting and Charging(4W10/4W12)
Starting and Charging System..........20B-1
Precautions......................................20B-1
Engine.................................................20B-4
Overhaul...........................................20B-5
Starter..................................................20B-8
Overhaul...........................................20B-8
20B
20B
Starting and Charging(4W10/4W12) - Starting and Charging System 20B-1
Starting and Charging System

Precautions
1. Explosive gas may escape from a battery. Engine compartment must be kept
well ventilated before battery maintenance in order to reduce personal injury.
First remove the negative (-) battery cable and finally connect the negative (-)
battery cable to avoid arcing.
2. Battery electrolyte is very dangerous and can damage the machine and cause
severe burns. When maintaining a battery, you should prepare a bucket of high
concentrations of soda as neutralizer. Wear safety eyepiece and protective
clothing to avoid personal injury.
masks to prevent flying debris and dirt from causing personal harm.
4. Do not over tighten electrical connections as this may damage the starter
5. Short-circuit of battery two terminals is not allowed, otherwise the battery would
be rapidly heated and is likely to burst. In addition, the escaping gas of a battery
can easily be ignited by a spark, so do not use naked flame near a battery.
6. When removing a battery, first remove the negative cable and then remove the
positive cable, then remove the battery retaining bracket and remove the battery
from the bracket. Install the battery in the reverse order.
7. Can not operate the engine when the battery is not connected, otherwise it will
damage the electrical system (electronic components).
8. As a generator is grounded with the negative pole, so the battery grounding
polarity must be the same, otherwise the battery will discharge through the
silicon diode resulting in diode burnout.
9. When the generator is running, do not check the generator for power generation
with the spark test method, rather you can check with a light bulb or a multimeter,
otherwise the diode may easily be damaged.
10 . When checking generator silicon rectifier elements, the use of a megger or 220V
AC for checking generator insulation should be strictly prohibited, or the diode
would be damaged through breakdown.
20B
20B-2 Starting and Charging(4W10/4W12) - Starting and Charging System


1. Start switches and other control Check the circuit for reliable connec-
circuit (broken line) tion
Starter does not 2. Carbon brush and commutator 20A Starting and Charging(LJ465) -
work (poor contact) Starter, Overhaul
3. Starter internal line (open circuit, 20A Starting and Charging(LJ465) -
short circuit) Starter, Overhaul
1. Battery (off-capacity)
2. Conducting line (poor contact)
tion
3. Commutator (surface burning or 20A Starting and Charging(LJ465) -
Starter unable greasy dirt) Starter, Overhaul
to start, the en- 4. Carbon brush (excessive wear)
gine can not be or brush spring (less elastic, result- 20A Starting and Charging(LJ465) -
started ing in poor contact with the commu- Starter, Overhaul
tator)
5. Electromagnetic switch (main 20A Starting and Charging(LJ465) -
contact ablation, poor contact) Starter, Overhaul
6. Bearings (wear), armature (rub 20A Starting and Charging(LJ465) -
shell) Starter, Overhaul
1. Starter relay (inner copper con-
The engine has tact plate and two contact adhe-
Starter, Overhaul
been started, sions)
the starter con-
2. Starter electromechanical pivot 20A Starting and Charging(LJ465) -
tinues to rotate
(broken or bent) Starter, Overhaul
and generates
sharp noise 3. starter contact tooth surface 20A Starting and Charging(LJ465) -
(nap or stuck) Starter, Overhaul
20B Check the cable for reliable connec-
1. Cable connection
tion
2. Rotor coil open-circuited
Engine, Overhaul
Generator fault
3. Rectifier diode damaged
Engine, Overhaul
4. Poor contact of the carbon brush
Engine, Overhaul
Starting and Charging(4W10/4W12) - Starting and Charging System 20B-3

5. Adjuster damaged
Engine, Overhaul
1. Generator belt sagged
Engine, Overhaul
2. Poor contact of carbon brush,
slip ring contaminated by greasy
Engine, Overhaul
Generator un- dirt
dercharged 20A Starting and Charging(LJ465) -
3. Adjuster damaged
Engine, Overhaul
4. Too little battery electrolyte or
serious polar plates vulcanization
or polar plates too old
20B
20B-4 Starting and Charging(4W10/4W12) - Engine
Engine
Component Diagrams
2
9
12
10
1
11
13
14
3
4
5
8
6
7
fpwx20b0300
1 Generator tension adjustment block 8 Alternating current engine

2 Hexagonal flange face bolt 9 Hexagonal flange face bolt
3 Hexagonal flange face bolt 10 Big washer
4 Hexagonal flange face nut 11 Idler
5 Hexagonal flange face bolt 12 Drive belt (water pump/generator)
6 Compressor bracket 13 Hexagon socket head cap screw
7 Generator mounting bracket 14 Tensioner
Generator Specification
Name Specification
Normian voltage formula 12
20B
Polarity Negative grounding
Work mode Continuous rating type
Starting and Charging(4W10/4W12) - Engine 20B-5
Overhaul
2. Flip the front passenger side seat.
4. Dismount the A/C compressor belt. (Refer to Chapter 61 Heating and A/C - A/C
5. Dismount generator accessories.
(a) Disconnect generator connectors.
(b) Dismount generator output terminal retaining
nuts.
Tool: 13mm wrench
fpwx20b0001
6. Dismount the generator belt.

(a) Loosen the belt tensioner locking bolt and
remove the belt.
Tool: 10mm wrench
No. T45 hexagon wrench
fpwx20b0002
7. Dismount generator fixing bolts.

Tool: 10mm wrench
fpwx20b0003
8. Remove the generator assembly.
20B
fpwx20b0004
20B-6 Starting and Charging(4W10/4W12) - Engine
9. Remove generator back-end fixing bolts.
fpwx20b0005
10 . Check engine brushes and rectifier diode.
fpwx20b0006
11 . Install the generator

(a) Install the generator to the correct position
and tighten 3 bolts of the generator.
Tool: 10mm sleeve
Torque: 30±5N•m
(30±5N·m)
fpwx20b0007
(b) Connect the generator connector.

(c) Install generator output terminal fixing bolts.
Tool: 13mm sleeve
(10±1N·m)
Torque: 10±1N•m
fpwx20b0008
20B 12 . Install the generator to the correct position

and tighten the belt tensioner fixing bolt.
Tool: 10mm sleeve
(25±3N·m)
No. T45 hexagon spanner Torque: 25 ± 3N
·m
fpwx20b0009
Starting and Charging(4W10/4W12) - Engine 20B-7
13 . Install the A/C compressor belt. (Refer to Chapter 61 Heating and A/C - A/C
20B
20B-8 Starting and Charging(4W10/4W12) - Starter
Starter
Overhaul
4. Disassemble the starter.
(a) Disconnect the starter connector.
(b) Disconnect starter power supply terminal
connecting wire nuts.
Tool: 13mm wrench
fpwx20b0010
(c) Dismount 2 bolts of the starter.

Tool: 10mm sleeve
fpwx20b0011
(d) Remove the starter.
fpwx20b0012
5. Detect the starter.

(a) Pinion gap adjustment.
S Separate the field coil wire from the
•
20B M B electromagnetic switch M terminal.
• Connect a 12V battery between S and
M terminals.
Note
fpwx20b0013
• The pinion would pop up when 12V
voltage is connected between S and M
terminals.
Starting and Charging(4W10/4W12) - Starter 20B-9
(b) Check the clearance (pinion clearance)

between the pinion and the stopper with a
thickness gauge.
fpwx20b0014
(c) Electromagnetic switch suction test.

• Separate the field coil wire from the
S electromagnetic switch M terminal.
M Connect a 12V battery between S and
B •
M terminals.
Note
fpwx20b0015 seconds), so as not to burn the coil.
• Switch the ignition switch to "ON", then
the pinion will pop up. You need to
replace the electromagnetic switch if
the pinion does not pop up.
(d) Electromagnetic switch maintaining test.

M Connect a 12V battery between the S
B •
terminal and the starter body.
Note
• Manually pull out the pinion to pinion
stopper position.
• If the pinion is held at pop-up position,
then the system is operating correctly.
If the pinion bounces, then maintain the
open circuit. Replace the
electromagnetic switch. 20B
20B-10 Starting and Charging(4W10/4W12) - Starter
(e) Electromagnetic switch spring back test.

B • Connect a 12V battery between the M
M
terminal and the starter body.
Note
• Pull out the pinion and then release it.
If the pinion quickly rebounds to its
original position, then it is operating
correctly. If it does not rebound, then
replace the electromagnetic switch.
6. Install the starter.

(a) Install 2 starter fixing bolts.
Tool: 10mm sleeve
(30±2N·m)
fpwx20b0018
(b) Connect the connecting wire nut at the starter

power supply terminal and tighten it.
Tool: 13 mm sleeve
(10±1N·m)
Torque: 10±1N•m
(c) Connect starter control cable connectors.
fpwx20b0019
20B
Index
A Check on Vehicle (Cooling
System)...........................................17B - 5
Accelerator Pedal..........................12A - 30
Clean the fuel pipe (Fuel System)....12A - 4
Adjust the basic idling (throttle
Cleaning of throttle body (throttle
body).................................11A11B - 25, 25
body).................................11A11B - 23, 23
Adjustment of fixed idling adjusting screw
Common battery faults, cause analysis and
(SAS) (throttle body).........11A11B - 24, 24
troubleshooting (battery)...............20A - 28
Component Diagram (battery).......20A - 23
(4W10/4W12)..................................14B - 6
Component Diagram (Intake
Air Cleaner Assembly (LJ465).........14A - 5
System)...........................................14A - 7
Air Filter Assembly (4W10/4W12)....12B - 5
Component Diagram (starter)........20A - 13
Air Filter Assembly (LJ465)...........12A - 12
Component Diagrams
Air Inlet Pipe (4W10/4W12).............14B - 3
(Alternator)............................20A20B - 4, 4
Air Inlet Pipe (LJ465).......................14A - 4
Component Diagrams (Cooling
Air Intake Manifold Pressure/Temperature
System)...........................................17B - 2
Sensor...............................11A11B - 38, 36
Component Diagrams (Crankshaft, Cylinder
Air Intake System (4W10/4W12).....14B - 1
Block & Flywheel)..............15A15B - 51, 48
Air Intake System (LJ465)...............14A - 1
Component Diagrams (Cylinder Head and
Valve)................................15A15B - 34, 32
B
Component Diagrams (Exhaust Control
Basic Check (battery)....................20A - 26 System)...........................................13B - 1
Basic Principles (engine control Component Diagrams (Exhaust
system)..................................11A11B - 8, 8 Manifold)..........................................16B - 6
Battery...........................................20A - 23 Component Diagrams (Exhaust
Pipe)................................................16A - 2
C Component Diagrams (Fuel
System).................................12A12B - 7, 1
Camshaft overhaul (rocker, rocker shaft and
Component Diagrams (Ignition
camshaft).......................................15A - 31
System).................................19A19B - 2, 2
Camshaft overhaul (valve tappet and
Component Diagrams (Intake
camshaft).......................................15B - 30
System).............................14A14B - 2, 2, 9
Canister solenoid
Component Diagrams (lubrication
valve.......................11A11B11C - 56, 56, 8
system)............................................18B - 2
Canister Solenoid Valve
Component Diagrams (Piston and
(4W10/4W12)..................................13B - 2
Connecting Rod
Canister Solenoid Valve (LJ465).....13A - 5
Assembly).........................15A15B - 42, 41
Carbon Canister (LJ465).................13A - 2
Component Diagrams (Rocker, Rocker Shaft
Check (Fuel Tank Cap)....................13A - 1
and Camshaft)...............................15A - 25
Check (vehicle speed
Component Diagrams (Timing
sensor)..............................11A11B - 63, 62
Chain)............................................15B - 19
Check On the Vehicle (cooling
Component Diagrams (timing toothed
system)............................................17A - 4
belt)................................................15A - 18
A-1-
Component Diagrams（Cooling System） F
.........................................................17A - 2 Fault Symptom (starting and charging
Component Specification (ignition system)..................................20A20B - 2, 2
system)..................................19A19B - 3, 3 Front oxygen sensor..........11A11B - 50, 50
Coolant..................................17A17B - 6, 7 Fuel Filling Pipe and Breathing
Coolant Temperature Pipe...............................................12A - 26
Sensor...............................11A11B - 20, 20 Fuel Injector Assembly
Cooling System.....................17A17B - 1, 1 (4W12/4W10)..................................12B - 9
Crankcase Bleed Pipe Fuel Injector Assembly (LJ465).....12A - 16
(4W10/4W12)..................................13B - 5 Fuel System (4W10/4W12).............12B - 1
Crankcase Bleed Pipe (LJ465)........13A - 8 Fuel System (LJ465).......................12A - 1
Crankshaft position
sensor...............................11A11B - 47, 47 I
Flywheel............................15A15B - 51, 48 Idle stepper motor.............11A11B - 29, 28
Cylinder Head and Valve....15A15B - 34, 32 Ignition Module..................11A11B - 64, 63
Cylinder Head Overhaul (cylinder head and Ignition Module/High-voltage Coil/Spark
valve).................................15A15B - 35, 35 Plug.......................................19A19B - 4, 4
Intake Manifold (4W10/4W12).........14A - 9
D Intake Manifold (LJ465)...................14A - 7
Drain the Oil Tank (Oil System).......12A - 3 K
Driving Check (throttle position
sensor)..............................11A11B - 35, 34 Knock Sensor....................11A11B - 43, 43
E L
EGR System (4W10/4W12).............13B - 7 Lubrication System...............18A18B - 1, 1
EGR Valve (4W10/4W12)..............13B - 10
Electric Fuel Oil Pump Assembly M
(4W10/4W12)..................................12B - 7 Main Components (Engine Control
Electric Fuel Oil Pump Assembly System).............................11A11B - 15, 15
(LJ465)..........................................12A - 13 Maintenance Data (fuel system)......12A - 8
Electronic Fan Assembly.....17A17B - 9, 11
Engine...................................20A20B - 4, 4 O
Engine assembly...................15A15B - 5, 5
Engine Control Module Oil Filter.................................18A18B - 5, 5
(ECM).....................11A11B11C - 17, 17, 5 Oil pan...................................18A18B - 7, 7
Engine Control System.........11A11B - 1, 1 Oil Tank Assembly (4W10/4W12)....12B - 2
Engine Mechanism................15A15B - 1, 1 Oil Tank Assembly (LJ465)..............12A - 9
Engine Oil..............................18A18B - 2, 3 Oil Tank Cap........................12A13A - 24, 1
Engine Oil Pump...............18A18B - 10, 10 Oil Tank Door.................................12A - 21
Exhaust Control System Oil Tank Door Lock........................12A - 23
(4W10/4W12)..................................13B - 1 Onboard Check (canister solenoid
Exhaust Gas Recirculation Pipe valve)......................11A11B11C - 57, 57, 9
(4W10/4W12)..................................13B - 9 Onboard Check (front oxygen
Exhaust Manifold...................16A16B - 7, 6 sensor)..............................11A11B - 51, 51
Exhaust Pipe.........................16A16B - 1, 1 Onboard Check (idle stepper
Expansion tank......................17A17B - 8, 9 motor)............................................11A - 30
A-2-
Onboard Check (Idle Stepper Overhaul (Air Intake Manifold
Motor)............................................11B - 29 Pressure/Temperature Sensor).....11A - 41
Onboard Check (intake pressure Overhaul (canister solenoid
sensor)...........................................11B - 37 valve).11A11B11C13A13B - 58, 58, 10, 5, 2
Onboard Check (intake Overhaul (canister)..........................13A - 2
pressure/temperature sensor).......11A - 39 Overhaul (Coolant Temperature
Onboard Check (knock sensor).....11A - 44 Sensor)..............................11A11B - 21, 21
Onboard Check (Knock Sensor)....11B - 44 Overhaul (Crankcase Bleed Pipe)....13B - 5
Onboard Check (rear oxygen Overhaul (Crankshaft Position
sensor)..............................11A11B - 54, 54 Sensor)..............................11A11B - 48, 48
Onboard Check (vehicle speed Overhaul (crankshaft, cylinder block and
sensor)..............................11A11B - 62, 61 flywheel)........................................15A - 52
Operating Principle (Engine Control Module Overhaul (Crankshaft, Cylinder Block and
(ECM))...........................................11B - 17 Flywheel).......................................15B - 50
Operating Principle (Ignition Overhaul (EGR Valve)...................13B - 10
Module).............................11A11B - 65, 64 Overhaul (electronic fan
Operating Principles (Canister Solenoid assembly)............................17A17B - 9, 11
Valve)......................11A11B11C - 56, 56, 8 Overhaul (engine oil
Operating Principles (Coolant Temperature pump)................................18A18B - 10, 10
Sensor)..............................11A11B - 20, 20 Overhaul (Exhaust Gas Recirculation
Operating Principles (Crankshaft Position Pipe)................................................13B - 9
Sensor)..............................11A11B - 47, 47 Overhaul (front oxygen
Operating Principles (EGR sensor)..............................11A11B - 52, 52
System)...........................................13B - 8 Overhaul (Fuel Tank Cap)..............12A - 24
Operating Principles (Engine Control Module Overhaul (generator).............20A20B - 5, 5
(ECM))................................11A11C - 17, 5 Overhaul (idle stepper
Operating Principles (front oxygen motor)................................11A11B - 32, 31
sensor)..............................11A11B - 50, 50 Overhaul (ignition module/high-voltage
Operating Principles (idle stepper coil/spark plug)......................19A19B - 4, 4
motor)................................11A11B - 29, 28 Overhaul (intake air temperature
Operating Principles (Ignition sensor)...........................................11B - 42
Module).............................11A11B - 64, 63 Overhaul (Knock Sensor)...11A11B - 45, 45
Operating Principles (intake Overhaul (piston and connecting Rod
pressure/temperature sensor).......11A - 38 assembly)......................................15A - 43
Operating Principles (intake Overhaul (Piston and Connecting Rod
pressure/temperaturesensor)........11B - 36 Assembly)......................................15B - 42
Operating Principles (intake temperature Overhaul (Positive crankcase ventilation
sensor)...........................................11B - 41 valve)...............................................13A - 8
Operating Principles (Knock Overhaul (radiator)........................17A - 12
Sensor)..............................11A11B - 43, 43 Overhaul (Radiator).......................17B - 14
Operating Principles (Rear Oxygen Overhaul (rear oxygen
Sensor)..............................11A11B - 53, 53 sensor)..............................11A11B - 55, 55
Operating Principles (throttle position Overhaul (starter)................20A20B - 14, 8
sensor)..............................11A11B - 34, 33 Overhaul (thermostat)....................17B - 16
Operating Principles (Vehicle Speed Overhaul (Thermostat)..................17A - 14
Sensor)..............................11A11B - 61, 60 Overhaul (timing belt pulley)..........15A - 19
Overhaul (Air Intake Manifold Pressure Overhaul (timing chain).................15A - 20
Sensor)..........................................11B - 39 Overhaul (TPS).................11A11B - 36, 35
Overhaul (water pump).....17A17B - 17, 19
A-3-
Overhaul of rocker, rocker shaft (rocker, Replacement (Electric Fuel Pump
rocker shaft and camshaft)............15A - 26 Assembly)........................................12B - 7
Overview (EGR System).................13B - 7 Replacement (engine assembly).....15A - 5
Replacement (Engine Assembly)....15B - 5
P Replacement (Engine Control Module
(ECM))...............................11A11B - 18, 18
Replacement (exhaust manifold).....16B - 7
Assembly...........................15A15B - 42, 41
Replacement (Exhaust Manifold)....16A - 7
PRECAUTION.......................19A19B - 1, 1
Replacement (exhaust pipe)..16A16B - 3, 2
Precaution (Air Intake System)........14B - 1
Replacement (expansion tank)........17A - 8
Precaution (Fuel System)................12A - 1
Replacement (fuel filling pipe and breathing
Precaution (lubrication
pipe)...............................................12A - 26
system)..................................18A18B - 1, 1
Replacement (fuel filter
Precaution (starting and charging
assembly)..................................12A - 12, 5
system)..................................20A20B - 1, 1
Replacement (fuel injector
Precautions (Air Intake System)......14A - 1
assembly)..................................12A - 16, 9
Precautions (Cooling
Replacement (fuel tank
System).................................17A17B - 1, 1
assembly)..............................12A12B - 9, 2
Precautions (Engine Control
Replacement (fuel tank flap lock)...12A - 23
System).................................11A11B - 1, 1
Replacement (Fuel Tank Flap).......12A - 21
Precautions (engine mechanical
Replacement (intake
part).................................................15A - 1
manifold).............................14A14B - 9, 10
Precautions (Engine Mechanical
Replacement (intake pipe)...............14B - 3
Part).................................................15B - 1
Replacement (Intake Pipe)..............14A - 4
Precautions (exhaust pipe)....16A16B - 1, 1
Replacement (timing belt front
cover).............................................15A - 16
R
Rocker, rocker shaft and
Radiator.............................17A17B - 12, 14 camshaft........................................15A - 25
Rear oxygen sensor..........11A11B - 53, 53
Release the fuel system pressure (fuel S
system)............................................12A - 2
Starter.................................20A20B - 13, 8
Repair (throttle valve
Starting and Charging
body).................................11A11B - 26, 26
System..................................20A20B - 1, 1
Replace (air cleaner assembly).......14B - 6
System Component Description (Engine
Replace (battery)...........................20A - 30
Control System)................11A11B - 16, 16
Replace (engine oil)..............18A18B - 2, 3
System Function Introductions (engine
Replace (expansion tank)................17B - 9
control system)................................11B - 6
Replace (oil filter)..................18A18B - 5, 5
System Function Introductions (Engine
Replace (oil pan)...................18A18B - 7, 7
Control System)...............................11A - 6
Replace (timing front cover)..........15B - 16
System Overview (Engine Control
Replacement (4W10 Engine Control Module
System)......................11A11B11C - 2, 2, 1
(ECM)).............................................11C - 6
Replacement (Accelerator Pedal)...12A - 30
T
Replacement (air cleaner
assembly)........................................14A - 5 Table of fault symptom (Air intake
Replacement (coolant)..........17A17B - 6, 7 system)............................................14A - 3
Replacement (electric fuel pump Table of Fault Symptom (Cooling
assembly)......................................12A - 13 System).................................17A17B - 3, 4
A-4-
Table of Fault Symptom (engine mechanical V
parts)...........................................15A - 3, 3
Valve Overhaul (cylinder head and
Table of Fault Symptom (Fuel
valve).............................................15A - 38
System)...........................................12A - 5
Valve Overhaul (Cylinder Head and
The Ignition System..............19A19B - 1, 1
Valve).............................................15B - 37
Thermostat........................17A17B - 14, 16
Valve Tappet and Camshaft...........15B - 26
Throttle position sensor.....11A11B - 34, 33
Valve Tappets Overhaul (valve tappet and
Throttle valve body............11A11B - 23, 23
camshaft).......................................15B - 26
Timing Belt.....................................15A - 18
Vehicle speed sensor........11A11B - 61, 60
Timing Belt Front Cover.................15A - 16
Timing Chain.................................15B - 19
W
Timing Front Cover........................15A - 16
Water Pump......................17A17B - 17, 19
U
Use and Maintenance (battery).....20A - 24
A-5-
A-6-

Engine

Uploaded by

Copyright:

Available Formats

Engine

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Engine

Uploaded by

Copyright:

Available Formats

Edition：January 2015

Engine Control System(4W12) 11B

Engine Control System(4W10) 11C

Emission Control(LJ465) 13A

Emission Control(4W10/4W12) 13B

Engine Mechanism System(LJ465) 15A

Engine Mechanism System(4W10/4W12) 15B

Lubrication System(LJ465) 18A

Lubrication System(4W10/4W12) 18B

Ignition System(LJ465) 19A

Ignition System(4W10/4W12) 19B

Starting and Charging(LJ465) 20A

Starting and Charging(4W10/4W12) 20B

2015 Beiqi Foton Motor Co.,Ltd

All right reserved.No part of this service manual may

3. ECM Control Structural Diagram

Engine control module (ECM) Function

System 5V Sensor reference voltage

System power supply control

12V Power ground

Ignition system control

Ignition module driver ground Ignition coil (2/3 cylinder)

Fuel injector control

Coolant temperature (WTS) Sensor

Idle valve control

Fuel pump relay

Front oxygen sensor heating

Rear oxygen sensor heating

Vehicle speed sensor

Radiator low-speed fan relay

Radiator high-speed fan relay

Oil level signal

System fault indicator

Other system fault indicator

Diagnosis Diagnosis K line

11A 4. Engine Control System Diagram

1 Air inlet 9 Fuel pressure adjuster

5. Distribution Diagram of Engine Control System Main Components:

1 Air Intake Pressure/Temperature 7 Fuel injector 1

Signal Input ECM Control Output

Control Signal Description:

Correction Items Content

(e) Correction of engine mixture gas

(b) Ignition advance angle control. 11A

Correction signal ECM Output Control

11A (b) Calculate Target Idle.

1 Air Intake Pressure/Temperature 7 Fuel injector 1

Crankshaft position Magneto-electricity in- • Detect the position and speed

3. Remove the ECM.

(c) Disconnect the ECM connector, push down

(d) Remove the ECM connector.

(e) Remove 4 fixing bolts of the ECM.

(f) Remove the ECM module. 11A

• Make sure to remove the battery negative

4. Install the ECM module.

(b) Install the ECM connector.

(c) Put the seat in its original position.

3. Lift the vehicle, unscrew the drain bolt on

4. Dismount the engine coolant temperature

• Clean the mounting surface after the