2　 INSPECTION DATA AND MAINTENANCE PERIOD

2.1 TORQUE
The tightening performance of connecting bolt and nut is performed by screw thread. Each
fastener should be tightened to the torque specified in each section with moment wrench during
maintenance.
TABLE2-1
Specified torque(N·m)
System Tighten position
N·m kgf·m
Engine Cylinder head setscrew 55～60 5.5～6.0
Connection rod bearing cover retaining nut 3.5±0.2
35±2
*
Spark plug 20～30 2.0～3.0
18～22* 1.8～2.2*
Intake and exhaust manifold nut 18～23 1.8～2.3
Intake manifold nut M6 11～12 1.1～1.2
M8 21～25 2.1～2.5
Setscrew of air intake manifold bracket* 21～25 2.1～2.5
Exhaust manifold setscrew and retaining 2.1～2.5
21～25
nut *
Engine front hanger setscrew * 21～25 2.1～2.5
Tensioner setscrew 10～12 1.0～1.2
Synchronous gear setscrew on crankshaft 50～60 5.0～6.0
Crankshaft bearing cover* 10～12 1.0～1.2
Cylinder orifice * 5 0.5
Valve adjust nut 15～20 1.5～2.0
Synchronous chain cover setscrew 3～4 0.3～0.4
Synchronous chain M6 10～12 1.0～1.2
cover setscrew M8 21～25 2.1～2.5
Setscrew of oil pump 4～5 0.4～0.5
Oil collector setscrew * 10～12 1.0～1.2
Sump nut* 10～12 1.0～1.2
Setscrew of crankshaft wheel belt * 115±10 11.5±1.0
Synchronization gear setscrew of 50～60 5.0～6.0
crankshaft
Connecting rod bearing shell nut 28～32 2.8～3.2
Crankshaft bearing cap setscrew 43～48 4.3～4.8
Flywheel mounting setscrew 40～45 4.0～4.5
Oil pressure sensor 12～15 1. 2～1.5
12* 1.2*
Setscrew of oil filter nib 20～25 2.0～2.5
Engine rear mounting nut and 11～14 1.1～1.4
rear hanger bolt
 Oil pump safety valve spring 15～20 1.5～2.0
seat
Sump setscrew 4～5 0.4～0.5
Oil drain plug 20～25 2.0～2.5
Left and right engine hangers fastening 20～30 2.0～3.0
bolt a
Transmission and cylinder setscrew 4.5～5.5
45～55
and nut
Bracket mounting bolt 25～30 2.5～3.0
Valve chamber cover setscrew 4～5 0.4～0.5
10～12* 1.0～1.2
Tension pulley bracket bolt 15～23 1.5～2.3
and nut
Rear engine bracket-Body fastening 17～28 1.7～2.8
bolt
Engine beam-Body fastening bolt 45～50 4.5～5.0
Engine beam-LH and RH damper 18～23 1.8～2.3
retaining nut
O2 sensor 40～60 4.0～6.0
Coolant temperature sensor Max.20 Max.2.0
Throttle valve body mounting setscrew 8～10 0.8～1.1
Crank shaft position sensor setscrew 8～10 0.8～1.1
Crankcase Inside 53~59 5.3~5.9
setscrew* Outside 20~25 2.0~2.5
Intake pressure sensor setscrew 8～10 0.8～1.1
Coolant temperature sensor 15～20 1.5～2.0
Rocker chamber head setscrew 4.0～5.0 0.4～0.5
TIMING CHAIN GUIDE BOLT* 9 0.9
Flywheel disc setscrew* 65.5~72.5 6.55~7.25
Idler wheel setscrew* 45～55 4.5～5.5
Speed sensor setscrew * 10～12 1.0～1.2
Ignition shock sensor setscrew * 21~25 2.1~2.5
Clutch Clutch pressure plate setscrew 18～28 1.8～2.8
Transmission Transmission mounting setscrew 40～50 4.0～5.0
Transmission bolt（8mm） 18～28 1.8～2.8
Transmission bolt（6mm） 8～12 0.8～1.2
Oil drain and fill plug 25～30 2.5～3.0
Gear Cable nut 22～35 2.2～3.5
Shifting
Control

Rear axle Driven gear and differential housing 65～70 6.5～7.0

assembly bolt
Crave bevel pinion nut 170～220 17～22
Carrier and final drive 34～40 3.4～4.0
housing bolt
Drain plug 50～70 5.0～7.0
Fill plug 40～65 4.0～6.5
Final drive and rear axle housing bolt 25～30 2.5～3.0
Rear brake and rear axle housing 18～28 1.8～2.8
bolt
Propeller Propeller Shaft and final drive flange nut 18～28 1.8～2.8
Shaft
assembly

Suspension Strut support nut 65～85 6.5～8.5

Strut bracket bolt and nut 80～110 8～11
Tension rod and front control 80～110 8～11
arm nut
Front control arm (Steering 45～65 4.5～6.5
knuckle side)
Front control arm (Body side) 58～78 5.8～7.8
Front stabilizer bar and 23～30 2.3～3.0
tension rod bracket bolt
Tension rod bracket and body 45～65 4.5～6.5
bolt
Tension rod bracket and 18～28 1.8～2.8
stabilizer link nut
Stabilizer link and stabilizer 40～60 4.0～6.0
bar nut
Leaf spring U type bolt and 30～45 3.0～4.5
nut
Leaf spring front nut 45～70 4.5～7.0
Leaf spring rear nut 30～55 3.0～5.5
Rear absorber upper nut 22～35 2.2～3.5
Rear absorber lower nut 10～16 1.0～1.6
Steering Steering wheel nut 28～38 2.8～3.8
Steering column bolt 10～20 1.0～2.0
Steering lower shaft and 20～30 2.0～3.0
steering gear bolt
Steering gear bolt 20～30 2.0～3.0
Tie rod lock nut 40～50 4.0～5.0
Tie rod and knuckle nut 35～45 3.5～4.5
Front crossmember bolt 90～100 9.0～10
 Wheel nut 80～90 8.0～9.0
Spare bracket mounting bolt 8～12 0.8～1.2
Front brake bleeding screw 7～9 0.7～0.9
Caliper mounting bolt 70～100 7.0～10
Knuckle and front hub nut 175～190 17.5～19.0
Rear brake bleeding screw 7～10 0.7～1.0
Rear brake mounting bolt 18～26 1.8～2.6
Brake Booster mounting nut 11～17 1.1～1.7
Master cylinder and booster 8～12 0.8～1.2
nut
Mounting bolt of brake pedal bracket 20～26 2.0～2.6
Parking brake lever mounting bolt 10～14 1.0～1.4
Parking brake cable mounting bolt 10～14 1.0～1.4
Proportioning value mounting bolt 10～12 1.0～1.2
Connector mounting nut 10～12 1.0～1.2
Brake pipe nut 15～18 1.5～1.8
Front brake hose and brake 15～18 1.5～1.8
Six connector mounting bolt 10～12 1.0～1.2
Front, rear sensor bolt 8～10 0.8～1.0
Outer rearview mirror mounting 6.8～8.3 0.7～0.9
setscrew
Middle, rear seat mounting 18～28 1.8～2.8
bolt
Safety belt mounting bolt 34～54 3.4～5.4
Upper slide rail mounting bolt 4～6 0.4～0.6
Body
Front door lock body mounting 6.8～8.3 0.7～0.9
bolt
Front door lock ring mounting 26～32 2.6～3.2
bolt
Front door limiting stopper 6.8～8.3 0.68～0.83
mounting bolt
Front door hinge mounting bolt 20.6～32.3 2.1～3.3
(body side)
Front door hinge mounting bolt 16.7～25.5 1.7～2.6
(door side)
Sliding door lock body 6.8～8.3 0.7～0.9
mounting bolt
Sliding door lock ring 26～32 2.6～3.2
mounting bolt
Sliding door guide wheel bracket 20～28 2.0～2.8
mounting bolt
Sliding door hinge mounting 27.6～33.8 2.8～3.4
 bolt
Tail door gas spring mounting 11～15 1.1～1.5
bolt (side wall side)
Tail door gas spring mounting 6.66～9.94 0.67～1.0
bolt (tail door side)
Tail door bump stopper 8.4～11.1 0.84～1.1
mounting bolt
Tail door hinge mounting bolt 20～28 2.0～2.8
Tail door license plate 4.5～6.0 0.45～0.6
mounting bolt

Tail door lock ring mounting 26～32 2.6～3.2

bolt
Tail door lock body mounting 6.8～8.3 0.68～0.83
bolt
Front engine hood hinge 6.66～8.14 0.67～0.81
mounting bolt
Note ：The data with“*” is for DA471QLR series engine.

2.2 INSPECTION DATAS

● ENGINE（TABLE 2-2） TABLE 2-2
Item Standard Limit
1421kPa(300rpm/min) 1127kPa(300rpm/min)
Design value
1250kPa（12.5kg/cm ）*2
900kPa（9.0kg/cm2）*
Compressed
≤98kPa(300rpm/min)
pressure ≤98kPa(300rpm/min)
≤100kPa（1.0kg/
Deference between any two cylinder
≤100kPa（1.0kg/cm2）*
cm2）*
0.08mm
Cooling procedure ——
0.17～0.23mm*
Intake
0.1mm
Hot procedure ——
0.21～0.27mm*
Valve distance
0.1mm
Cooling procedure ——
0.17～0.23mm*
Exhaust
0.12mm
Hot procedure ——
0.17～0.23mm*
8° ～ 12° （ before
Spark angle advance TDC） ——
6°~7°（idling）*
Ca Camshaft Intake（mm） 38.06~38.22 37.93
Cam height
ms Exhaust（mm） 37.90~38.06 37.77
ha Camshaft vibration —— 0.1mm
ft, Radial clearance of camshaft 0.045-0.087 0.12
 cover（mm）
Diameter of camshaft bearing hole 23.00~23.021
Diameter of camshaft
22.934~22.955
journal（mm）
Out diameter of spindle (mm) 26.959~26.975 ——
Spindle Diameter of spindle hole (mm) 27.000~27.021 ——
Copulate clearance (mm) 0.025~0.062 0.15
Intake 5.465~5.480 ——
Valve stem O.D (mm)
Exhaust 5.440~5.455 ——
Valve guide seat O.D Intake
5.500~5.512 ——
spi Val (mm) Exhaust
nd ve Valve guide-to-stem Intake 0.020~0.047 0.07
le ste clearance (mm) Exhaust 0.045~0.072 0.09
Val
an m Valve stem end Intake 0.14 ——
ve
d gui movement limit (mm) Exhaust 0.18 ——
va de Thickness of valve Intake 1.0 0.7
lv seat head (mm) Exhaust 1.5 0.5
e Valve head contact Intake 2.228~3.428 ——
* and sealing width
Exhaust 1.987~3.387 ——
(mm)

Cylinder-to –contact surface declination

0.03mm 0.05mm
(mm)
Manifold install surface declination 0.05mm 0.1mm
Cylinder
Valve seat Intake
head 1.57-1.97mm ——
contact width
Exhaust 1.57-1.97mm ——
(mm)*
Valve spring perpendicular degree * —— 2.0mm
Valve guide I.D 5.5～5.12mm ——
Valve Valve guide-to-stem clearance Intake 0～0.047mm, ——
Exhaust 0～0.027mm
Cylinder-to –contact surface declination 0.06mm 0.05mm*
(mm)
I.D (mm) 65.5～65.502mm 71.070 mm*
Difference between I.D —— 0.05mm
Cylinder
Wear limit of cylinder —— 0.05mm
Cylinder-to –piston surface clearance 0.04～0.06mm ——
0.02~0.04 mm*
Conicity and ellipticity * —— 0.10mm
Piston O.D Standard 65.465～65.485 ——
70.970~70.990mm*
Enlarge 0.25mm 71.220~71.240mm ——
Piston dimension
0.5mm 71.470~71.490mm ——
*
Ring joint NO.1 ring 1.53～1.55mm
distance 0.03~0.07 mm*
 when NO.2 ring 1.52～1.54mm
assembly 0.02~0.06 mm*
Oil ring 2.81～2.83mm
0.06~0.15 mm*
Piston pin O.D * 16.995~17.000 mm ——
Piston pin I.D 15.99～16mm
17.006~17.014 mm*
Piston pin-to-connecting rod clearance 0.0125～0.0175mm
0.05mm
0.003~0.016mm*
NO.1 ring 1.47～1.49mm
Ring
thicknes NO.2 ring 1.47～1.49mm
s Oil ring 0.45mm
Clearanc NO.1 ring 0.040～0.075mm 0.12mm
e NO.2 ring 0.030～0.065mm
between
0.10mm
Piston ring and
groove
NO.1 ring 0.15～0.35mm 0.7mm
Piston 0.8mm*
ring end NO.2 ring 0.15～0.35mm 0.7mm
clearanc 0.30～0.50mm* 1.1mm*
e Oil ring 0.3～0.9mm 1.8mm
0.10～0.40mm* 1.6mm*

Item Standard Limit

Crank shaft Cam shaft spindle —— 0.06mm
and （3 ）vibration
#
0.04mm*
connecting Axial movement of camshaft * 0.11-0.31mm 0.35mm
rod Journal diameter 37.985～38mm ——
Crankshaft and 0.02～0.043mm 0.08mm
connecting rod brass 0.020-0.040mm* 0.065mm*
clearance
1 44.994-45.000mm ——
Journal
2 44.988-44.994mm ——
diameter*
3 44.982-44.988mm ——
Mai Mar 1 49.000-49.006mm ——
n ke 2 49.006-49.012mm ——
be d 3 49.012-49.018mm ——
ari di
ng git
ho al
le
di
 a
m
et
er
2.500mm ——
CRANKSHAFT Standard
THRUST
Large
BEARING
size:0.125m 2.563mm ——
THICKNESS*
m
Thick 5 1.999~2.003mm ——
ness 4 2.002~2.006mm ——
Identi
of 3 2.005~2.009mm ——
fy
beari 2 2.008~2.012mm ——
mark
ng 1 2.011~2.015mm ——
s
shell 0 2.014~2.018mm
* ——
Crankshaft jounel planeness
—— 0.01mm
and coning *
Connecting rod small 16.005～16.015mm ——
end hole diameter
Journal 49.985～50mm ——
Crankshaft spindle and 0.022～0.041mm 0.08mm
brass clearance 0.020-0.040mm* 0.065mm*
Connecting rod big end 0.36～0.59 0.7mm
strut interval 0.26-0.49mm* 0.53mm*
Diam Mar 41.994～42.000
——
eter k1
Mar 41.988～41.994
Pin * k2
Mar 41.982～41.988
k3
圆度和锥度 —— 0.01mm
Connect Bent 0.05mm 0.05mm
ing rod Distortion 0.1mm 0.1mm
Note ： the data with “*” is for DA471QLR series engine.

● Clutch and transmission（TABLE2-3） TABLE2-3

Item Standard Limit
Clutch Rivet head depth 1.2mm 0.5mm
Spline side clearance 0.8mm
Transmission Gear and Low gear, 1.0～1.4mm 0.5mm
ring high gear
 clearan 5th gear 1.2～1.6mm 0.5mm
ce
Synchronizer ring groove 10.1mm 10.4mm
width
Fork spring free 25.5mm 21.0mm
height
Gear clearance 0.06～0.15mm 0.3mm
● Lubricating system（TABLE2-4） TABLE2-4
Item Standard Limit
Lubricating Radial clearance of 0.12～0.20mm 0.30mm
system gear 外圈
Oil pump gear side clearance 0.045～0.120mm 0.17mm
Oil pressure switch 19.6～39.2kPa
pre-pressure
Engine oil pressure 0.294～0.44MPa

 Cooling system (TABLE2-5)

TABLE2-5
Item Standard Limit
Cooling Clam down 100N pressure on the belt between generator and water pump 7～10mm 10～15mm
system Temperature at which thermostat valve begins to open 82℃
Temperature at which thermostat valve become fully open 95℃
Thermostat valve lift 8mm

 Final drive assembly (TABLE (2-6)) TABLE 2-

6
Item Standard Limit
Final drive Mesh clearance of drive, driven gear 0.10～0.20mm
assembly Half-axle gear thrust clearance 0.37 mm(max)
Drive gear bearing start torque 0.588～
0.882N.m
 Suspension (TABLE2-7) TABLE 2-7
Item Standard Limit
Suspension Stroke of front shock absorber 104 mm
Stroke of rear shock absorber 160 mm
Height of rear spring 128 mm
Height of front spring 285.5 mm
Leaf spring length 995 mm
Camber 1°30′
Caster 3°00′
King-pin angle 9°30′
 Steering system (TABLE2-8) TABLE 2-8
 Item Standard Limit
Steering Steering angle (inner) 39°
system Steering angle (outer) 36°
Steering wheel play 0～30 mm
Steering gear rotation torque 1.1 N.m
Pinion and rack steering gear travel 147 mm
Toe in 2～5 mm
 BRAKE SYSTEM (TABLE2-9) TABLE 2-9
Item Standard Limit
Brake Thickness, Front brake disc 12.0 mm 10.0mm
system Run out, Front brake disc 0.15mm
Pad thickness, Front brake 15.5 mm 6.5mm
Lining thickness, Rear brake 7.0 mm 3.0mm
Inside diameter, Brake drum 220 mm 222mm
The distance between the brake pedal and the floorboard (depress 145mm
the pedal with 300N force)
 COMBINATION INSTRUMENT (TABLE2-10)

TABLE2-10
Real
20 40 60 80 100 120 140 160 180
（Km/h）
Speedometer Indication
— 40Com 60Com 80Com 100Com 120Com 140Com 160Com —
bin bin bin bin bin bin bin
（Km/h）
Vibration 35~150km/h；Less than 2km/h
Real
1000 2000 3000 4000 5000 6000 7000 8000
（rpm）
Tachometer Indication 1000 1000 1000 1000 1000 1000 1000 1000
（rpm） ±100 ±200 ±200 ±200 ±200 ±300 ±350 ±400
Vibration 1600~6400r/min；Less than 80 r/min
Scale
E（I） 1/2（Ⅴ） F（Ⅸ）

Resistance
Fuel meter （Ω）
90 32.5 6.4

Tolerance +20 +7 +4
（Ω） -10 -6 -2.5
Scale
Ⅲ Ⅶ Ⅸ

Temperature
Water 64 97 115
（℃）
temperature
Resistance
meter 89 30 18.3
（Ω）
Tolerance +8 +10 +4
（℃） -12 -4.5 -5
 2.3 MAINTENANCE SCHEDULE
Maintenance timetable for normal driving.
TABLE 2-11
Interval: km×100
2.5 10 20 30 40 50 60 70 80
This interval should be 0
judged by odometer reading
or months, whichever comes months 2 6 12 18 24 30 36 42 48
first.
ENGINE
Water pump(fan) drive belt(tension,
1 A — I — R — I — R
damage)
synchronizing toothed belt
2 I — I — I — I — I
（wear and damage）
3 IN and EH valve clearance A — A — A — A — A
4 Valve lash (clearance)* — — I — I — I － I
Engine bolts (All cylinder head
5 T — T — T — T — T
and manifold fixings)
6 Engine oil filter R R R R R R R R R
Replace every 5000km. More frequent replacement
7 Engine oil
if under dusty driving conditions
Fuel hoses and connections （ hoses
8 aging , connections crack, damage or I I I I I I I I I
loosening）
Cooling system hoses and connections
9 — — I — — I — — I
（leakage, damage）
High tension cords （ aging and
10 damage） — — I — — I — — I

11 High tension damping wire * — — I — I — I － R

12 Spark plugs — R R R R R R R R
13 Ignition wiring * — I — I — I － I
Clean every 1000km on asphalt road and clean
14 Air filter
every 2500km on dusty road
Pitch road — — — — R — — —
15 Air filter core*
Dust road Check referring to hard driving
Acceleration cable and throttle valve I.
16 spindle — I.L I.L I.L I.L I.L I.L I.L
L
17 Fuel filter — — — — R — — — R
18 Oil filter * Replace every 100,000 km
— — I — I — I — I
19 PCV valve — — — — — — — I*
Gear oil of transmission （ check
20 leakage at normal level） R I I I R I I I R

21 Damage and fastness of harness I I I I I I I I I

22 Coolant — — — — R — — — R
23 Drain system* — — I — I — I － I

24 Wiring harness and connector* — — — — I — — — I

25 Catalytic converter － － － － － － － － Ｉ
Rocker chamber head breather
26 － － Ｉ － － Ｉ － － Ｉ
tube and connector
27 Crankcase hose and nib － － Ｉ － － Ｉ － － Ｉ
※Ignition shock sensor tightening
28 torque A A A A A A A A A
※Distributor cap and rotor (wear and
29 － － Ｉ － － Ｉ － － Ｉ
damage)
Replace every 50000km. More frequent check if
30 Charcoal canister under dusty driving condition. Replace in time if
clogging or liquid fuel found.
31 Canister control valve * — — — — — — — — I

32 Clutch pedal play I I I I I I I I I

Brake discs and pads (wear,
damage)
33 - I I I I I I I I
Brake drums and shoes (wear,
damage)
Brake hoses and pipes (leakage,
34 - I I I I I I I I
damage, clamp)
35 Brake fluid(lever、leakage) I I I I R I I I I
Brake pedal (pedal-to-wall
36 I I I I I I I I I
clearance)
Brake lever and cable (stroke
37 I I I I I I I I I
and damage)
Tires (abnormal wear and
38 - I I I I I I I I
pressure)
39 Wheel, wheel nut(damage、torque) I I I I I I I I I
Shock absorber(oil
40 I I I I I I I I I
leakage、damage)
Propeller shaft (damage,
41 - - I - I - I - I
tightness)
Differential oil (leakage,
42 R I I I R I I I R
lever)
Suspension and steering
43 (tightness, damage, rattle, I I I I I I I I I
breakage)
44 Test drive Test drive on completion of each service
Notice one：“ *” is for DA471QLR and“※” is for DA465Q-1A ，United automotive electronic
system Co.,Ltd
Notice two:“R”－Replace or repair；“ I” －Inspection and correct or replace if
necessary；“ T” －Tighten to the specified torque；“ L” －Lubricate；“ A”－
Inspection and connect

3 TROUBLE SHOOTING
3.1 ENGINE
TABLE 3-1
Condition Possible cause Correction
Starter will not run
Poor starting 1． Main fuse blown off Replace
2． Contact not closing in main Repair or replace
switch, or this switch open-
circuited Recharge
3． Run-down battery Repair
4． Defective magnetic switch of
starter Clean and retighten
5． Loose battery terminal Replace
connection Retighten
6． Defective brushes in starter Repair or replace
7． Loose battery cord connection
8． Open in field or armature
circuit of starter
No sparking
1． Defective spark plug Adjust gap, or r replace
2． High tension cord short-circuit Repair or replace
(grounded)
3． Contact not closing positively Replace
in main switch, or this switch
open-circuited
4． Loose or blown fuse Set right or replace
5． Defective ignition coil Replace
Faulty intake and exhaust systems
1． Clogged air cleaner. Clean or replace
2． Clogged exhaust pipes Clean
3． Leaky intake system. Adjust
Abnormal engine internal condition
1． Ruptured cylinder head gasket Replace
2． Improper valve clearance Adjust
3． Weakened or broken valve spring Replace
4． Loose manifold, permitting air Tighten and ， as necessary,
to be drawn in replace gasket
5． Worn pistons, rings or cylinders Replace worn rings and pistons
as necessary
6． Broke valve timing belt Replace
7． Poor valve seating Replace or repair
8． Wrong kind of engine oil Replace
9． Burnt valves Replace
Malfunction of EMS system
 1． Crankshaft position sensor Check wire for damage
2． Intake temperature pressure Check wire for damage
sensor Check wire for open or short
3． Water temperature sensor Check connection or state
4． Repeating motor Check wire for normal work
5. Fuel pump assembly Check wire for damage
6. Electrical controller
Not enough Inadequate compression
power 1． Air cleaner dirty and clogged Clean or replace
2． Improper valve clearance Adjust
3． Valves not eating tight Repair
4． Valve stems tending to seize Replace
5． Broken or weakened valve spring Replace
6． Piston rings seized in grooves, Replace
or broken
7． Worn pistons, rings or cylinders Replace worn parts and rebore as
8． Leaky cylinder head gasket necessary
Replace
Improperly timed ignition
1． Improper ignition timing Adjust
2． Defective spark plug Replace
3． Leaks, loose connection or Connect or replace as necessary
disconnection of high tension
cord Replace
4． Ignition wire aging
Fuel system
1． Defective fuel pump or Repair or replace
insufficient pressure
2． Clogged fuel filter Replace
3． Float level out of adjustment Adjust
4． Clogged fuel pipe Clean or replace
5． Loose joint in fuel system Retighten
Exhaust systems
1． Clogged muffler Clean or replace
Malfunction of EMS system
1． Throttle position sensor Check or replace
2． Intake temperature pressure Check or replace
sensor Check fuel injector and
3． Oil tail pressure regulator valve
4． Water temperature sensor Check or replace
Others
1． Dragging brakes Adjust
2． Slipping clutch Adjust or replace
3． Too low battery voltage results Recharge or replace battery
in abnormal work of ECU.
Engine Electrical systems
hesitates 1． Spark plug gap out of adjustment Adjust gap
(Momentary 2． Deteriorated ignition coil, or Replace
lack of crack resulting in leakage
response as 3． Leaky high-tension cords Replace
the 4． Ignition timing out of Adjust as prescribed
accelerator adjustment
is depressed. Fuel system
Can occur at 1． Malfunctioning accelerator pump Replace
all car 2． Fuel tubes break Replace
speeds. Malfunction of EMS system
Usually most 1． Engine rotate speed exceeding Check for low gear
severe when interruption fuel rotate speed Replace
first trying 2． Check if electrical controller
to make the open for short Repair
car move, as 3． Check electrical controller
from a stop electrical source wire for open Repair or replace
sign. 4． Open or damaged crankshaft
position sensor
Others
1． Leady cylinder head gasket Replace
result in cylinder compress
pressure descending
2． Worn pistons, rings or cylinders Replace and rebore as necessary
or burnt valves result in low
compress pressure
Surges Ignition system
(Engine power 1． Improper ignition timing Adjust
variation 2． Defective spark plug or improper Adjust
under or gap
cruise. Feels 3． Leaky or loosely high tension Replace
like the car cord
speeds up and Malfunction of EMS system
down with no 1． Throttle position sensor damaged Check or replace
change in the 2． Intake temperature pressure Check or replace
accelerator sensor
pedal.) Others
1． Air cleaner dirty or clogged Clean
2． Deposit carbon on exhaust pipe Clean
3． Clogged muffler Clean
4． Too low compress pressure Replace worn parts and rebore as
necessary
5． Poor valve seating Repair
6． Improper valve clearance Adjust
7． Pistons tending to seize Replace piston and rebore as
necessary。
8． Bearing shell tending to seize Replace
Erratic Ignition system
idling 1.Improper ignition timing Adjust
 2.Defective spark plug or Replace or adjust
excessively large clearances
3.Leaky high tension cord. Replace
Malfunction of EMS system
1. Repeating motor Check or replace
2. Electrical controller Replace
3. Intake temperature pressure Check or replace
sensor
Others
1. Air cleaner dirty or clogged Clean
2.Leaky intake system.
3.clogged exhaust manifold Adjust
4. Improper valve clearance Clean or replace
5. Poor valve seating Adjust
6. Blown cylinder head gasket Repair
Replace
Abnormal Ignition system
detonation 1． Spark plug tending to overheat Change plug heat value
2． Improper ignition timing Adjust
Fuel system
1.Improper engine oil grade Replace with proper grade oil
Malfunction of EMS system
1． Knock sensor Replace
2． Intake temperature pressure Replace
sensor
Others
1. More carbon deposit on piston top or Clean
cylinder head Replace
2. Damaged cylinder gasket result Adjust
in too low compress press. Repair or replace
3. Improper valve clearance Replace
4. Pistons tending to seize
5. Weakened valve spring
Overheating Ignition system
1． Improper ignition timing Adjust
2． Wrong heat value of spark plugs Change heat value
Exhaust system
1． Clogged exhaust pipe hole Clean
Cooling system
1. Not enough coolant Refill
2.loose or broken water pump belt Adjust or replace
3.Erratically working thermostat Replace
4.Poor water pump performance Replace
5.leaky radiator cores Repair or replace
Lubrication system
1.Clogged oil filter Replace
2.Clogged oil strainer Clean
 3.Deteriorated oil pump performance Replace
4.Oil leakage from oil pan or pump Repair
5.Improper engine oil grade Replace with proper grade oil
6.Not enough oil in oil pan Replenish
Malfunction of EMS system
1.O2 sensor Replace
1． Not enough pressure of fuel pump Adjust or replace
2． Water temperature sensor Replace
Others
1.Dragging brakes Repair or replace
2.Slipping clutch Adjust or replace
3.Blown cylinder head gasket Replace
Engine noise Crankshaft noise
1． Worn-down bearings, resulting in Replace
excessively large running
clearances
2． Worn connecting-rod bearings Replace
3． Distorted connecting rods Repair or replace
4． Worn crankshaft journals Repair by grinding, or replace
crankshaft
5． Worn crankpins. Repair by grinding, or replace
crankshaft
Noise due to pistons, rings, pins
or cylinders
1． Abnormally worn cylinder bores Rebore to next oversize or

2． Worn pistons, rings or pins Replace

3． Pistons tending to seize Replace
4． Broken piston rings Replace
Others
1． Excessively large camshaft Replace
thrust play
2． Excessively large crankshaft Adjust
thrust clearance
3． Valve clearance too large Adjust
4． Not enough engine oil replenish
High fuel Ignition system
consumption 1． Improper ignition timing Adjust
2． Leak or loose connection of high
tension cord Repair or replace
3. Defective spark plug Replace
Fuel system
1． Fuel leakage from tank, pipe or Repair or replace
carburettor
2． Clogged air cleaner element Clean or replace
High fuel Abnormal condition in engine
consumption 1． Cylinder head burnt gas leakage. Tighten or replace gasket
 2． Poor valve seating Repair
3． Improper valve clearance Adjust
Others
1． Dragging brakes Adjust or replace
2.Slipping clutch Repair or replace
Excessive Oil leakage
engine oil 1． Loose oil drain plug Tighten
consumption 2． Loose oil pan securing bolts Tighten
3． Deteriorated or broken oil pan Replace
sealant
4． Leaky oil seals Replace
5． Blown cylinder head gasket Replace
6． Improper tightening of oil Tighten
filter
“Oil pumping” （ Oil finding its
way into combustion chambers.）
1． Sticky piston ring Remove carbon and replace rings
2． Worn piston ring groove and ring Replace
3． Improper location of piston ring Replace piston
gap Replace pistons and rebore as
4． Worn pistons or cylinders necessary
Oil leakage along valve stems
1． Defective valve stem oil seals Replace
2． Badly worn valves or valve guide Replace
bushes

3.2 CLUTCH
TABLE 3-2
Condition Possible cause Correction
Slipping 1． Loss of clearance at the tip of Adjust as prescribed
clutch release fork
2． Clutch facings dirty with oil Replace
3． Clutch facings excessively worn Replace
4． Weakened diaphragm spring Replace
5． Distorted pressure plate or Replace
flywheel surface
6． Improper clutch pedal free travel Adjust and, as necessary,
replace clutch facings
Dragging 1． Improper clutch pedal free travel Adjust free travel
clutch 2． Weakened diaphragm spring or worn Replace
spring tip
3． Worn or damaged transmission input Replace
shaft splines
4． Worn or damaged front input shaft Replace
bearing
 5． Excessively wobbly clutch disc Replace
6． Clutch facing broken or dirty with Replace
oil
Clutch 1． Glazed clutch facings Repair or replace
vibration 2． Clutch facing dirty with oil Replace
3． Wobbly clutch disc or poor facing Replace
contact
4． Weakened torsion spring Replace
5． Distorted pressure plate or Replace
flywheel surface
6． Loose clutch disc rivets Replace
7． Weakened engine mounting or
loosened mounting bolt or nut eplace
Noisy clutch 1． Worn or broken release bearing Replace
2． Input shaft front bearing worn down Replace
3． Excessive rattle of clutch disc hug Replace the disc
4． Cracked clutch disc Replace
5． Pressure plate and diaphragm spring Replace
rattling
Grabbing 1． Oily contamination on clutch disc Replace
clutch facing
2． Excessive worn clutch facing Replace
3． Rivet heads showing out of facing Replace
4． Weakened torsion spring Replace
3.3 TRANSMISSION
TABLE3-3
Condition Possible cause Correction
Gear slipping 1． Worn shift fork shaft Repair or replace
out of mesh 2． Worn locating steel balls Replace
3． Worn locating steel balls groove Replace
4． Weakened springs for locating steel Replace
balls
5． Worn shift fork Replace
6． Excessive rattling in thrust Replace
direction of gears or damaged C-
ring Replace
7． Damaged gear shift spline （ gear
outer ring and sleeve） Replace
8． Worn bearings of input shaft, main
shaft or countershaft
Gears 1． Weakened or broken synchronizer Replace
refusing to spring
disengage 2． Worn inner groove of synchronizer Replace
ring Replace the ring
3． Synchronizer ring seized on the Replace
cone
4． Distorted shift fork shaft or shift Replace
 fork
5． Worn shift fork
Excessive 1． Not enough oil in transmission Replenish
gear noise 2． Defective synchronizer Replace
3． Gear rattling in thrust direction Replace
4． Damaged or worn bearings Replace
Hard shifting 1． Clutch pedal play too large, Adjust
resulting in a “dragging clutch”
2． Worn clutch disc facings Replace
3． Clutch disc facings dirty with oil Replace
4． Distorted or unevenly worn shift Replace
fork shaft
5． Broken locating balls Replace
6． Worn synchronizer sleeve or ring Replace
7． Improper clearance between Replace
synchronizer ring and gear

3.4 EXHAUST MANIFOLD AND MUFFLER

TABLE 3-4
Condition Possible cause Correction

① Damage of TWC and O2 sensor, which Replace

caused by use of lead fuel.
Poor ② Damage of TWC and O2 sensor, which Replace
caused by misfire of ignition system.
emission
③ Leakage of exhaust system, ECU can’t
get the right signal of O2 sensor, causing Repair
air/fuel ratio rich
①loose exhaust pipe connection Retighten
②loose exhaust manifold Retighten
Poor
③broken manifold, pipe or muffler Repair or replace
muffling
④broken muffler gasket Replace
performance
⑤interference between body and Repair, eliminating any
muffler contact

3．5 Final drive assembly

Probable cause and maintain way of final drive can see TABLE3-5。
Condition Possible cause Correction
Noise of gear 1 Improper mesh clearance of drive and Adjust
driven gear Replace or adjust
2 wore gear or improper mesh clearance of Adjust
drive and driven gear Refill or replace
3 Improper mesh of drive and driven gear Replace or tighten
 Replace
④insufficient gear oil or improper sort
⑤driven gear swing when turning or loose
drive gear bolt
⑥damaged pinion and gear
Noise of ① （ period noise ） insufficient gear oil or Refill or replace
bearing improper sort Replace　
②（period noise）wore or damage of bearing Replace
③（sliding noise）noise of gear Replace
④（steering noise）half bearing damage

3．6 PROPELLER SHAFT

TABLE 3-6

Condition Possible cause Correction

Vibration and 1
Broken or worn bearings of universal Replace
noise joint spider
2 Distorted propeller shaft Replace
③ Unbalanced propeller shaft Replace
④loose propeller shaft Retighten
Noise ①wear or damage of joint Replace
occurring at ②wear of propeller shaft for bad Replace
standing lubrication Tighten
start or ③loose propeller shaft bolt Tighten
during ④loose joint flange bolt
coasting

3．7 BRAKE SYSTEM

TABLE 3-7
Condition Possible cause Correction
Not enough 1. Brake oil leakage from brake lines Locate leak point and repair
2. Brake discs or pads stained with oil Clean or replace
braking force
3. Overheated brakes Find cause and repair
4. Poor contact of shoes on brake drum Repair or proper contact
5. Brake shoes linings stained with oil or Replace
water
6. Badly worn brake shoe linings Replace
7. Defective wheel cylinders Repair or replace
8. Malfunctioning caliper assembly Repair or replace
Brake Pull (Brake 1. Shoe linings stained with oil or water Replace
not working in 2. Drum-to-shoe clearance out of Check for inoperative auto adjusting
union) adjustment
3. Drum out of round in some brakes Replace
4. Wheel tires inflated unequally Inflate equally
5. Malfunctioning wheel cylinder Repair or replace
6. Disturbed front end alignment Adjust as prescribed
7. Unmatched tires on same axle Use same tires on same axle
 8. Restricted brake tubes or hoses Check for soft hoses and damaged lines.
Replace with new hoses and tubes
9. Loose suspension parts Check all suspension mountings
10. Loose calipers Check and torque bolts to specifications

11. Malfunctioning caliper assembly Check for sluggish calipers, proper

lubrication of caliper slide bush and
caliper slide, and repair or replace
Excessive pedal 1. Partial brake system failure Check brake system and replace as
travel necessary
2. Air in brake system (pedal spongy Brake system bleeding
phenomenon)
3. Rear brake system not adjusted Adjust rear brakes(Repair auto adjusting
mechanism)
4. Bent brake shoes Replace brake shoes
5. Worn brake shoes Replace brake shoes
6. Insufficient brake fluid in master Fill reservoirs with approved brake
cylinder reservoirs fluid，check brake system for leaks
Dragging 1. Master cylinder pistons not returning Repair master cylinder
brakes （ A correctly
very light drag 2. Restricted master cylinder returning Clean
is present in all 3. Restricted brake tubes or hoses Check for soft hoses and damaged lines.
disc brakes Replace with new hoses and tubes
immediately 4. Incorrect parking brake Check and adjust to correct specification
after pedal is
released） 5. Weakened or broken return spring in Replace spring
the brake
6. Sluggish parking cables Repair or replace
7. Wheel cylinder or caliper piston Repair as necessary
sticking
Pedal pulsation 1.Damaged or loose wheel bearings Replace wheel bearings
(Pedal pulsates 2.Rear drums out of round Check run out
when depressed 3.Excessive disc lateral run out Check disc as specifications, repair or
for braking) replace
Braking noise 1. Glazed shoe linings or foreign Repair or replace shoe linings or pads
materials stuck to linings
2. Worn or damaged shoe linings Replace shoe linings or pads
3. Loose front wheel bearings Replace bearing
4. Distorted backing plates or loose Replace back plate, tighten or replace
mounting bolts bolts

3.8 SUSPENSION, STEERING SYSTEM AND TIRES

TABLE 3-8
Condition Possible cause Correction
Hard steering Wheel tires not adequately inflated Adjust tire pressure
Bind in tie rod end ball stud Repair or replace
Disturbed front wheel alignment Check front wheel alignment
Wobbly Wheel tires not adequately inflated Adjust tire pressure
steering wheelWobbly wheels Repair or replace
(Shimmy, Large difference in tire diameter Replace
shake orbetween right and left wheels
vibration) Loose hub nuts Retighten
Worn or loose tie rod ends Replace or retighten
Tire or wheel out of balance Balance wheel or replace tire
Blister or bump on tire Replace
Disturbed front wheel alignment Check front wheel alignment
Steering Unevenly worn wheel tires Replace
wheel pulling Brake dragging in one road wheel Repair
to one Wheel tires unequally inflated Adjust tire pressure
side （ car Worn or distorted tie rod Replace
pulls） Disturbed front wheel alignment Check front wheel alignment
Loose, bent or broken front or rear Tighten or replace suspension
suspension parts parts
Bad meshed steering gear Replace

Shocks Tire inflating pressure too high Reduce to the specification

coming to Poor shock absorber performance Replace
steering wheel Differences in tire diameter among four Adjust
(or wheel road wheels
tramp) Worn steering linkage connections Replace
Worn or broken front wheel bearings Replace
Loose front wheel Retighten
Blister or bump on tire Retighten
Small rotating torque of steering gear Replace
Rapid wear or Wheel tires improperly inflated Adjust tire pressure
uneven wear Differences in diameter among four tires Adjust or replace
of wheel tires Worn or loose road wheel bearings Replace
(Abnormal or Wobbly wheel tires Repair or replace
excessive tire Wheel tires improperly “rotated” to Adjust
wire) result in unbalance
Disturbed wheel alignment Adjust
Hard driving Replace tire
Steering noise Loose bolts and nuts Retighten
Loose leaf spring seat Retighten
Broken or otherwise damaged wheel Replace
bearing
Worn or sticky tie rod end Replace
Insufficient lubrication on tie rod end Lubricate or replace
Too much Worn wheel bearings Replace wheel bearing
play in Steering gear box attachments loose Tighten or repair
steering Steering gear box adjustments Check and adjust
Wear of tie rod ends or drag rod ball Replace tie rod end or tie rod
joint
Poor Bind in tie rod end ball studs Replace tie rod end
returnability Bind in steering column Repair and replace
Lack of lubricant steering gear box Check, lubricate or replace
Disturbed front end alignment Check and adjust front end
alignment
Steering gear box adjustment Check and adjust gear box torque
Improper tire pressure Adjust pressure

Abnormal Worn, sticky, loose tie rod ends or drag Replace tie rod end, drag rod
noise, front rod ball joint
end Damaged shock absorbers or mountings Replace or repair
Looseness of stabilizer bar Tighten bolt or replace
bushes
Loose wheel nuts Tighten
Loose suspension bolts or nuts Tighten bolts or nuts
Broken or otherwise damaged wheel Replace
bearings Replace
Broken suspension springs Replace
Wander or Mismatched or uneven tires Replace tire or inflate tires to
poor steering proper pressure
stability Loose tie rod ends or drag rod Replace tie rod end or drag rod
Faulty shock absorber or mounting Replace absorber or repair
mounting
Looseness of stabilizer bar Tighten or replace stabilizer bar or
bushes
Broken or sagging springs Replace spring
Steering gear box adjustment faulty Check or adjust steering gear box
torque
Front wheel alignment Check front wheel alignment
Wander or Broken or sagging springs Replace
poor steering Overloaded Check loading
stability Incorrect springs Replace
Ride too soft Faulty shock absorbers Replace
Overloaded Check loading
Suspension
Faulty shock absorber Replace
bottoms
Incorrect, broken or sagging springs Replace
Body leans or Looseness of stabilizer bar Tighten bolt or replace bushes
sways in Faulty shock absorber or mounting Replace shock absorber or tighten
corners mounting
Broken or sagging spring Replace
Overloaded Check loading

3.9 SPEEDOMETER
TABLE 3-9
Condition Possible cause Correction
Faulty ① Defective speed sensor Replace
indication ②defective transmission （ not enough Repair or replace
 oil in transmission or worn gears）
Replace
③defective speedometer
Repair
④ sticky speedometer pointer
Repair
⑤Connector trouble
Repair
①Power wire cut off
Replace
②Vehicle speed sensor trouble
Replace
③Odometer trouble
No indication Repair
④needle clogged
Replace
⑤Defective LCD
Repair
⑥Harness trouble

3.10 TACHOMETER
TABLE3-10
Condition Possible cause Correction
①Engine crank angle sensor trouble Replace
②Engine ECU trouble Replace
Fault
③Connector trouble Repair
indication
④Tachometer trouble Replace
⑤Tachometer needle clogged Repair
①Power wire cut off Repair
②Crank angle sensor trouble Replace
No ③ECU trouble Replace
indication ④signal wire open Repair
⑤Tachometer trouble Replace
⑥Tachometer handle trouble Repair

3.11 FUEL METER

TABLE 3-11
Condition Possible cause Correction
①Fuel sensor trouble (bobber clogged) Repair or replace
②Incomplete metal-to-metal contact in
Repair
terminal connection
Fault
③the wire connected to fuel sensor
indication Repair
ground
④Fuel gauge trouble Replace
⑤Defective LCD Replace
①Power wire of meter open Repair
②Fuel level sensor trouble Replace
No
③Harness to fuel sensor open Repair
indication
④Fuel gauge trouble Replace
⑤Defective LCD Replace

3.12 WATER TEMPERATURE METER

 TABLE 3-12
Condition Possible cause Correction
①Defective Water temperature sensor Replace
②Incomplete metal-to-metal contact in
Repair
terminal connection
Fault
③Harness connected to water
indication Repair
temperature sensor ground
④Defective water temperature meter Replace
⑤Defective LCD Replace
①The power wire of gauge open circuit Repair
②Defective Water temperature
Replace
sensor（open circuit）
No
③The harness to water temperature
indication Repair
sensor open circuit
④Defective water temperature meter Replace
⑤Defective LCD Replace