Service Manual of LIFAN720 (LF-20131225) PDF

Service Manual
LIFAN720
LIFAN INDUSTRY(GROUP) IMP&EXP CO.,LTD

Foreword
This manual covers the product structures, working principles and technical parameters of all LF720 models, providing
reference for the LIFAN AUTO service technicians and managers to perform inspection, fault diagnosis, removal,
installation, adjustment and maintenance and service.
This manual includes Volume Ⅰ , Volume Ⅱ and Volume Ⅲ LF720Wiring diagram available on request. This manual
has been edited with excellent pictures and their accompanying essays so that it is both popular and easy to understand.
Moreover, the manual also provides many maintenance skills to reduce working hours and improve ef ciency.
Observe the following instructions before referring to this manual:
1. Take time to read this manual carefully before performing inspection, fault diagnosis, removal, installation,
adjustment and maintenance when your vehicle in trouble. Be sure to perform operation and maintenance as
required, and pay attention to the captions WARNING, ATTENTION, HINT,etc..
2. This manual describes every option and model variant available to the LF720 series products. Because of the
variations in vehicle model layout, some of the items (e.g., devices, facilities or features) covered herein may not
apply to some particular models.
3. To avoid damage to vehicle devices or even safety accidents, it is strictly forbidden to modify the existing
devices or add other devices to the vehicles by users without authorization, especially for the electrical system,
brake system, steering system and other systems related to driving safety.
4. When your vehicle needs replacement parts, be sure to go to the LIFAN MOTOR authorized service stations for
purchasing the original spare parts supplied by the LIFAN Industry(Group) Imp.& Exp. Co.,Ltd.
5. It is your own responsibility for the safety accidents or any direct/indirect loss due to not following the
6. With the progress and development of technology, the LF720 series products will be improved and perfected
Imp.& Exp. Co.,Ltd. reserves the right, however, to change design at any time without prior notice. Revisions
without incurring any obligation whatsoever.

All rights reserved. No unit or individual is allowed to copy or print this manual without prior authorization from
LIFAN Industry(Group) Imp.& Exp. Co.,Ltd. Otherwise, LIFAN Industry(Group) Imp.& Exp. Co.,Ltd. reserves the
right to investigate for copyright liability in accordance with law.
CLIFAN INDUSTRY(GROUP) IMP&EXP CO.,LTD

Copyright reserved
Version No.: LF-20131225
Data expiration date: June 25, 2014
Volume I
0 Overview Overview 01
1 Engine Mechanical System 11
Control System 12
Fuel System 13
Intake and Exhaust System 14
Cooling System 15
Lubrication System 16
Exhaust Emission Control 17
Electrical System 18
2 Transmission Transmission 21
Clutch 22
3 Running System Front Suspension 31
LIFAN AUTO Rear suspension 32
Tires and Wheels 33
4 Drive System Drive Shaft 41
Rear Axle 42
Volume Ⅱ
5 Brake System Service Brake 51
Parking Brake 52
6 Steering System Steering System 61
7 Electrical System A/C Systen 71
Safety Protection Device 72
Audio System 73
Driver Information System 74
Lighting System 75
Horn and Cigarette Lighter 76
8 Body and Accessories Accessories 81
Door and Lock 82
Windows and Rearview Mirrors 83
Seats 84
Dashboard and Console 85
Wiper and Washer System 86
Index
Overview
How to use this manual............................................. 01-1
General information............................................... 01-1 01
Index....................................................................... 01-1
Preparation............................................................. 01-1
Maintenance specifications:................................... 01-1
Maintenance procedures......................................... 01-1
"Warning", "Hint", and "Attention"...................... 01-3
System of international units (SI)........................... 01-3
Vehicle identification.................................................. 01-4
Vehicle identification.............................................. 01-4
Vehicle specifications.................................................. 01-5
Vehicle specifications............................................. 01-5
Maintenance guide................................................... 01-11
Preparation........................................................... 01-11
Maintenance hints................................................ 01-13
Vehicle lifting....................................................... 01-18
How to perform vehicle troubleshooting............... 01-20
General information............................................. 01-20
Troubleshooting analysis...................................... 01-20
Analysis of customer complaints......................... 01-21
Fault simulation.................................................... 01-21
Circuit troubleshooting method............................ 01-23
Standard bolt torques.............................................. 01-24
Tightening torques of common thread specifications
. ............................................................................ 01-24
LIFAN AUTO
Overview-How to Use This Manual 01-1
How to use this manual

General information
01
1. This manual provides a general description for performing maintenance for you. Following the description in this
manual to operate can improve your maintenance quality and efficiency.
2. Common maintenance operation can be divided into three main working procedures as follows:
• Diagnosis
• Replacement, Inspection and Repair, Debugging
• Final inspection
3. This manual mainly specifies the first process "diagnosis" (See fault diagnosis in each chapter), the second
process "replacement, overhaul and commissioning", and the third process "final inspection".
4. This manual analyzes and explains the maintenance problems as viewed from system description ( in theory),
fault diagnosis( to find problems) and maintenance guide ( to solve problems)
• System description:
Including preparation, maintenance data, precautions, system description, principle explanation, component
diagram, on-board inspection and other. Makes description and explanation based on the principle of the
system, describing the problems as viewed from the whole system to provide theoretic guide for maintenance,
and analyzes and solves the problems from the perspective of the whole system.
• Troubleshooting
Including Table of Fault Symptom, Table of Fault Diagnosis and other. Description mainly focuses on some
common and potential vehicle fault symptoms, pointing out the possible fault positions and solutions, in order
to assist you to determine the fault causes and locate the fault positions in a better and quicker manner.
• Maintenance guide:
It classifies systems according to the components, provide specific repair guidance for inspection, detection,
dismantling and installation, so as to provide your repair quality and efficiency.
5. Although the following basic operations are not especially detailed in this manual, they are absolutely necessary in
practical operations.
• Use of jack
• If necessary, clean the removed parts.
• Visual inspection
6. Each chapter of this manual contains the precautions for maintenance. Before maintenance, be sure to read the contents
of precautions carefully to avoid incorrect operation which can cause damage to parts or personal injuries.
Index
There is an Index of Glossary attached to the end of this manual so that you can use it in the process of maintenance.
Preparation
At the beginning of each chapter of this manual, the special tools, recommended tools, equipment and accessories
required in the process of maintenance service are listed and their individual purposes are described.
Maintenance specifications:
The maintenance specifications are indicated by boldface in this manual to avoid stopping your ongoing work to refer
to the maintenance specifications. For the sake of quick lookup, the maintenance specifications are also introduced in
the second part of each chapter in this manual.
Maintenance procedures
1. To meet the needs in the chapters, the component diagrams are added to detail the system to be maintained.
LIFAN AUTO
01-2 Overview-How to Use This Manual
2. The component diagrams clearly describes the assembly relationship of the parts in the form of explosive view.
Parts assembly relationship
Differential front bearing cover Differential gear

Differential front bearing Differential gear shaft
Speedometer gear ring Differential gear shaft elastic cylindrical pin
Case fastener Differential casing
Gear shaft retainer Differential ring gear
Axle shaft gear washer Differential ring gear
Axle shaft gear Differential rear bearing cover
Differential gear washer
Part namelist
3. If the installation procedure is the reversal of the removal procedure, only the important part is described.
4. This manual uses illustrations for the important part and the operation part in the working procedures, giving
their detailed descriptions, and lists the operation methods, reference data and precautions.
5. The working procedures are described in the following forms:
• The illustrations show "What to Do" and "Where to Do".
• The operation procedure titles show "What to Do".
• The operation procedures show "How to Finish Tasks" and provide assistant operation information, such as
"Warning", "Hint", "Attention" .
LIFAN AUTO
Overview-How to Use This Manual 01-3
Example:
Illustration What to do
01
What to do and where to do
1. Check the gear backlash between pinion and axle shaft gear
(a). Check the gear backlash between pinion and axle shaft
gear, if the backlash exceeded standard value, the appro-
priated space ring shall be selected, and the backlash
measured.
Standard value: 0.025~0.150mm
Task finished
Attention:
Gear backlash on both side shall be equability by
adjustment.
Help info
"Warning", "Hint", and "Attention"

Symbols in the text
Warning
△ Hint
Attention
The overstriking indicates that you are required to take the necessary measures or not to take the forbidden measures.
If you ignore "Warning", the following consequences can be caused:
Warning • Cause serious injury to the technicians.

• Cause serious injury to other technicians around the working area.
• If improperly repaired, it will cause serious injury to the driver and passengers.
Hint: Provide additional Attentions, which is helpful to increase work efficiency of maintenance
The overstriking is used to state and strengthen the necessity of a certain diagnosis or maintenance procedure. The
purpose indicated by "Attention" is as follows:
• Define a procedure
Attention • Provide complementary information to complete a procedure.
• Specify the reason why it is operated according to the recommended procedure.
• Provide information which is useful for complete procedure in an effective way.
System of international units (SI)

The Unit in this manual adopt the system of international units (SI).
For example:
Torque: 30N•m
LIFAN AUTO
01-4 Overview-Vehicle Identification
Vehicle identification
Vehicle identification
1. Vehicle identification Number (VIN)
(a). Vehicle identification number (VIN) is used to register
vehicle and identify vehicle according to the number. It
located at the position between left upper ① of dashboard
panel and front passenger seat lower frame ② . Nameplate
of the vehicle is located at position ③ on side of left B-pillar.
The nameplate is also marked with vehicle identification
number (VIN).
① Vehicle VIN plate
② Vehicle VIN plate
③ Vehicle nameplate
2. Engine model and factory number

(a). The engine model and serial number are printed on the
engine cylinder body as shown in the figure above.
① Engine model
② Series number
LIFAN AUTO
Overview-Vehicle specifications 01-5
Vehicle specifications
Vehicle specifications
1. Vehicle basic parameters 01
Basic type three-compartment four-door five-seat one-cover and one rear door.
Driving type Front-engine, front wheel drive
Overall dimensions Length × Width × Height (no load): 4700×1765×1490mm
Wheelbase 2700mm
Front wheel track 1520mm
Rear wheel track 1520mm
Front overhang 960mm
Rear overhang 1040mm
Trunk volume 620L (estimated)
Passenger number 5 people
Possibility parameters
Approach angle 19° (full load) 22° (no load)
Departure angle 15° (full load) 24° (no load)
Minimum ground clearance 130mm (full load) 170mm (no load)
Minimum turning radius 5.5m
Mass parameters
Curb mass 1265kg
Axle load mass (front/ rear) 765/500kg
Full load mass 1690kg
Axle load mass (front/ rear) 900/790kg
Full-load axle load percentage (front/

49/51% (estimated)
rear)
2. Vehicle basic performance parameters
Performance parameters
Maximum speed 180km/h
Acceleration performance (0~100km) 17s
Total fuel consumption per 100 km. 7.9L/100km
Max. grade ability % 30%
LIFAN AUTO
01-6 Overview-Vehicle specifications
3. Engine characteristic parameters
Model LFB479Q
Type In-line four-cylinder 16-valve, water cooling, double overhead camshaft
Total displacement 1794ml
Bore × stroke 79×91.5mm
Compression ratio 10
Maximum power 98kW(6000r/min)
Maximum torque 168N•m(4400r/min)
Fuel supply mode Multipoint electronic-control fuel injection
Ignition type Double coil no-distributor ignition
4. Types and parameters of engine accessories and chassis main assemblies
Exhaust system Two three-way catalytic converters and 2 mufflers
Air Intake System Air intake pipeline, air filter
Fuel supply system Including fuel pump, fuel filter, pressure adjustor, accelerator pedal, etc. oil tank 55L
Cooling System Tube type radiator, electric fan
Clutch Single piece, dry, film spring
Transmission
Type Five-speed manual transmission, mechanical flexible shaft operation
Gear ratio (1st) 3.182
Gear ratio (2nd gear) 1.895
Gear ratio (3rd gear) 1.250
Gear ratio (4th gear) 0.969
Gear ratio (5th gear) 0.784
Gear ratio (reversing gear) 3.133
Drive shaft
Type Sliding bush is three-fork type, fixed end is ball type.
Final drive
Speed ratio 4.308
Suspension
Front suspension McPherson independent suspension
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Rear suspension Torque beam non-independent suspension
Tires and wheels 01

Tire type Radial tire
Tire specification 205/ 55 R16 (standard configuration)
Steering
Steering gear type Gear rack, hydraulic boosting steering
Steering gear Steering wheel with external diameter of 370mm, pipe column angle can be adjusted.
Fixed wheel
Camber 0°05′±45′ (no load) -0°50′±45′ (full load)
Toe-in 2±2mm (no load) 0.1±2mm (full load)
Kingpin inclination 11°45′±30′ (no load) 12º15′±30′ (full load)
Caster 5°30′±30′ (no load) 6°5′±30′ (full load)
Rear wheel camber -1°20′±30′ (no load)-1°30′±30′ (full load)
Toe-in of rear wheel 1±3mm (no load) 0.2±3mm (full load)
Braking system
Structure type Hydraulic double-pipeline, vacuum booster, equipped with anti-lock brake system (ABS)
Service brake Front wheel has vent disc brake, and rear wheel has disc brake.
Parking brake Mechanical cable, brake rear wheel
A/C System
Structure type Evaporation compression refrigeration, water heat type
It uses electric adjustment, which can control air flow direction and select and adjust air speed,
Manipulation
temperature and air circulation.
Refrigerant R134a
Compressor model Ortega -106
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5. Types and parameters of body structure
Body
Body type Load-bearing vehicle body, 2-compartment four-door one-cover five-seat one rear door.
White body Fully-metal-closed structure
Door assembly Rolling window frame, four doors open, with anti-impact rod
Engine hood Open to rear part, bending arm hinge
Rear trunk assembly Volume is about 620L, torque rod mechanism
Front and rear bumpers Injection moulding
Interior and Exterior Trims
Internal trim Injection moulding structure with surface texture
The upper section is slush moulding structure, while lower section is injection moulding
Dashboard
structure with surface texture.
A, B, C column is injection moulding structure with surface texture; upper section of the door
A, B, and C-pillar and door inner panel is vacuum absorption moulding, and lower section is injection moulding structure with surface
texture.
Front windshield: laminated glass

Windshield
Rear windshield: toughened glass
Exterior rearview mirrors: convex mirrors on left and right sides , electrically adjustable
Rearview mirrors
Interior rearview mirrors: anti-glare type
Front seat: independent seat, front and rear positions, backrest angle and seat headrest can be
adjusted. It is also equipped with seat belt. Driver seat has overall lifting function; standard
Seats driver seat and front passenger seat are equipped with waist adjusting function.
Rear seat: nonadjustable, non-independent seat, equipped with seat belt; backrest is 4/6 division.
6. Structure and parameters of electrical system
Power supply, starter and recharging system
Circuits Single-wire, negative grounding; DC voltage is 12V.
Generator Complete type, AC, built-in voltage regulator, specification of 12V / 90A.
Starter Electromagnetic control type (engine self-provided); power is 1.3kW.
Electric fan Double-step speed adjusting double fan.
Battery Maintenance free lead-acid battery with capacity of 70Ah.
Lighting & signal system
Headlamp (high-beam) 60W white
Headlamp (low-beam) 55W white
Headlamp (position lamp) 5W white
Front headlamp (turn signal lamp) 21W amber
Side turn signal lamp LED amber
LIFAN AUTO
Front fog lamp 55W white
Rear fog lamp 21W red
Tail lamp (brake lamp) 21W red 01

Tail lamp (turn signal lamp) LED red
Tail lamp (rear width lamp) LED red
Tail lamp (reversing lamp) 21W white
Rear license plate lamp LED white
High-mounted brake lamp LED red
Interior combination ceiling lamp 10W white
Instrument system
Instrument cluster with electronic odometer, including water temperature gauge, fuel gauge,
Instrument cluster
speedometer, engine tachometer, etc.
Including battery recharging indicator, engine oil pressure indicator, fuel warning, brake fluid
level indicator, engine fault detection indicator, manual brake indicator, anti-theft indicator,
Indicator lamps seat belt indicator, electronic airbag indicator, instrument panel lamp, high-beam/ low-beam
lamp indicator, fog indicator, turn signal lamp (emergency lamp) indicator, ABS indicator, door
opening indicator, etc.
Including cigarette lighter, rear defroster, wiper and washer, remote control door lock, anti-theft
Auxiliary electrical system
device, airbag, glass lifter, etc.
7. Lubricating oil, fuel, steering fluid, brake fluid, coolant, air conditioner refrigerant and capacity
Lubricant
Engine oil model Above 15W/30 SL
Engine oil volume 4L
Transmission double-curve gear oil

80W/90GL4
model
Transmission double-curve gear oil

2L
volume
Lithium grease model of bearing and

7022
ball joint
Lithium grease quality of bearing and

0.34kg
ball joint
Fuel
Fuel type 93# or higher lead free gasoline
Fuel tank volume 55L
Steering fluid, brake fluid, coolant, air conditioner refrigerant
Power steering oil type ATF220
LIFAN AUTO
Power steering oil volume 0.7~0.8L
Brake fluid model DOT4
Brake fluid volume 0.65L
Coolant type Glycol type, freezing point is selected according to the temperature.
Coolant volume 6.5L
A/C refrigerant type R134a
A/C refrigerant volume 0.75kg
Windshield washing fluid type SFFC-CI-35C1
Windshield washing fluid volume About 3.0L
LIFAN AUTO
Overview-Maintenance guide 01-11
Maintenance guide
Preparation
1. Maintenance hints 01
(a). Operation and maintenance hints:
1 Clothes Be sure to wear work uniforms and safety shoes, and a helmet.
2 Vehicle protection Before maintenance operation, be sure to get ready for guard plates, seat covers and others.
To avoid confusion or dirt to parts, put the removed parts in place in the specified order.
3 Store the removed parts. For non-reusable parts, such as washers, O-rings and lockout nuts, replace them in
accordance with the instructions in the manual.
Before operation, prepare the tool holders, special maintenance tools, instruments, oils,
4 Toolbox
clothes as well as the parts to be replaced.
After analysis and diagnosis of faults, take effective measures to remove them.
5 Maintenance Before removing or assembling electrical devices, disconnect the battery negative cable
according to the actual conditions.
LIFAN AUTO
01-12 Overview-Maintenance guide
When two people, or more people work together, it is important to ensure the safety of the
other persons involved.
When performing the maintenance work of the engine which is running, be sure to check
the ventilation of the workshop.
6 Safe operation
In the operation of the high temperature, rotating, moving or vibrating parts, be careful not
to burn or injure yourself.
When jacking up the vehicle, be sure to set safety bases near the support points.
When lifting the vehicle, be sure to use the safety equipment.
LIFAN AUTO
Maintenance hints
1. Pre-coated parts
01
(a). Pre-coated parts refer to the studs, nuts and other parts
which have been coated with sealant in the factory.
(b). For any re-tightened, loosened or moved pre-coated part in
any form, be sure to re-coat it with the specified sealant.
(c). When reusing any pre-coated part, be sure to clean its
original sealant, and use compressed air to dry it. And then,
coat the specified sealant onto the thread of the bolt or nut.
(d). When it is necessary to use sealant, wait for some time until
the sealant is solidified.
2. Washers
(a). If necessary, add a seal ring to a washer to avoid leakage.
3. Bolt, nut, screw

(a). Before using them, be sure to check whether its number of
damaged threads are more than three. If it is, replace it.
(b). Be sure to follow all specifications related to the tightening
torques of bolts. Be sure to use a torque wrench.
4. Fuse
(a). When replacing a fuse, make sure that the rated current
intensity of a new one is correct. Do not use any fuse with a
current intensity more than or less than the rated value.
LIFAN AUTO
5. Battery
(a). When checking or repairing, if it is necessary to disconnect
the battery, be sure to disconnect the negative (-) terminal
which the cable grounding the body.
(b). To avoid damage to the battery terminal, loosen the terminal
nut, and remove the cable by lifting it upwards. Do not
twist or pry it.
(c). Wipe the battery terminal with a cloth. Don't ream or grind
it with a rasp or other grinding tools.
(d). Unscrew the nut and re-install the cable terminal back to the
battery terminal. And then screw the nut. Don't strike the
cable terminal to the battery terminal with a hammer.
6. Electrical components
(a). When undrawing any electrical connector, be sure to pull
the connector body. Don't pull its wires.
(b). Be careful not to drop electrical components, such as

sensors or relays. If there is electrical component drop to
hard ground, replace it.
(c). It is forbidden to use impact-type wrench to dismantle or
install temperature control switch or temperature sensor.
(d). When checking the conduction of the wire connectors, be
sure to carefully insert the tester probe to avoid bend to the
terminal.
(e). After replacement of electrical components, make sure to
test the function of electrical components to make sure it is
functioning properly.
LIFAN AUTO
7. Use of torque wrenches with extension tools

(a). When using a special maintenance tool or a torque wrench
with extension tool, if the value displayed by the wrench
reaches the maximum torque value, it is an indication that
01
the actual torque is overloaded.
(b). This manual only indicates the special torque values. When
using a special maintenance tool or extension tool, be sure
to calculate the torque with the following formula.
(c). Formula T`=TxL2/(L1+L2).
T` Torque wrench reading (N•m)
T Torque (N•m)
L1 Special maintenance tool or tool length (cm)
L2 Torque wrench length (cm)
8. Snap-fits
(a). Special clamp tongs are required to remove snap-fits. The removal and installation methods for the snap-fits used
in the common body parts are shown in the following table.
△ Hint:
If the clamp tongs are damaged in the process of maintenance, be sure to replace them.
Attention
• If a snap-fit is damaged in the process of maintenance, be sure to replace it with a new one.
• Be sure to replace non-reusable snap-fits. Don't recover them.
LIFAN AUTO
Shape (example) Removal / installation
Slip joint pliers
Snap-fit remover
Protective belt
Screwdriver
Protective belt
Scraper
Dismounting Mounting
LIFAN AUTO
Shape (example) Removal / installation
01
LIFAN AUTO
Vehicle lifting
Warning
• To avoid personal injury, when performing any work in or below the vehicle just supported by a jack, be
sure to use the jack stands.
• To avoid damage to the vehicle, serious personal injury or even death accident, when removing the major
parts from the vehicle and supporting the vehicle with the lift, be sure to use the jack stands to support
the vehicle at the points designated for proper lifting opposite to the parts to be removed.
Attention
• When you raise or lift the vehicle at the frame side rails or at other points designated for proper lifting,
make sure the jack pads not to crash the Three-Way Catalytic Converter, brake pipes or fuel pipes.
Crashing the above parts can cause damage to the vehicle or reduction to the vehicle performance.
• Before the start of any lifting procedures, make sure to park the vehicle on clean, hard, level ground.
• Make sure all lifting devices meet the weight standards and in good working conditions.
• Make sure all vehicle load is distributed evenly and immobile. If you support the vehicle only at the frame
side rail, make sure the lifting device not to apply an excessive force to the frame side rail or not to cause
damage to the frame side rail.
• When you lift the vehicle at the front-end position, make sure the jack or jack pad do not touch the front
outer panel, front outer panel choke plate or front fender. Crashing the above parts can cause damage to
the vehicle.
△ Hint:
When lifting the vehicle, be sure to select the support points properly to make the vehicle lifting safe. Important points
for lifting of LIFAN 2-compartment and three-compartment car are shown as follows:
1. Side lifting, the lifting points for the lift stand in the workshop are shown in the figure below.
LIFAN AUTO
2. Axle lifting, be sure to apply a piece of special crossbar below the triangular arm. Make sure that the
lifting point on the rear axle is at the crossbeam at the axle center.
01
LIFAN AUTO
01-20 Overview-How to perform vehicle troubleshooting
How to perform vehicle troubleshooting

General information
To meet customer's requirement on high comfort, the electric wiring of LIFAN 720 model uses CAN communication
system to make the wire of complete vehicle compact and have strong systematic, which makes the troubleshooting of
the vehicle is more complex.
In general, to troubleshoot the complicated circuit faults and difficulty failures, the service technicians should be
provided with rich knowledge and skills. However, diagnosis of most faults should be made one by one in an attempt to
determine the exact location of a fault. So long as the service technician understands each system sufficiently and has
basic machine and circuit knowledge, he or she will be able to perform accurate diagnosis and necessary maintenance to
troubleshoot the faults.
According to the characteristics of the LIFAN 720 models and the operability of modern vehicle repair, this manual
provides accurate and effective fault solutions for the service technicians.
△ Hint:
Because LIFAN 720 model is designed with many electric controllers, sensors and actuators, part is uneasy to be
damaged. Improper repair may cause damage of these parts. Therefore, when detecting vehicle fault, do not inspect
actuators, sensors and circuits of control system at random, otherwise, your action is not only in vain, but also can
damage some parts related to controller.
Therefore, when troubleshooting the vehicle faults, first of all, be sure to understand the location and symptom of a fault
properly in order to determine and eliminate it accurately and quickly.
Troubleshooting analysis
△ Hint:
• Here is just a simple list of the basic operating procedures.
• Troubleshoot the faults in accordance with the operating procedures described later.
• For every common fault, this manual provides a description of the most effective methods of troubleshooting.
(Refer to fault diagnosis specified in each Chapter)
• Before starting maintenance operation, it is important to determine the relevant circuit troubleshooting procedures at first.
1. The vehicle is brought in the factory for service.
2. Analysis of customer complaints

(a). Ask about customer complaints about the vehicle conditions and the fault symptoms.
3. Verification and inspection of faults

(a). Check the battery positive voltage.
Voltage: 11~14V (engine stops)
(b). Check the fuses, connectors and wiring harness for open-circuit and short-circuit.
(c). . Make the engine warm-up to its normal operating temperature.
(d). Determine the fault symptom in accordance with the Table of Fault Symptom
LIFAN AUTO
Overview-How to perform vehicle troubleshooting 01-21
4. Table of fault symptom

(a). According to the determined the fault of the symptom, determine the system or part to be checked from the Table
of Fault Symptom.
5. Inspection of circuits and parts 01
(a). Determine the system or part to be checked from the Table of Fault Symptom.
6. Service
(a). According to the indication of fault troubleshooting, repair the damaged system or part .
7. Verification of testing
(a). After the repair is completed, confirm whether the fault has been troubleshot.
(If fault still exists, re-confirm detection procedures according to the same condition and environment.)
Analysis of customer complaints

△ Hint:
• In the process of fault analysis, be sure to confirm the faults of the symptoms, and eliminate all prejudices in
order to make an accurate judgment. To determine the fault of the symptom, it is very important to ask about
customer complaints about the relevant faults and symptoms.
• The following 5 points are important for fault analysis. Both the faults deemed to be irrelevant in the past and the
past repair instances are helpful to maintenance. Therefore, be sure to gather information as much as possible.
The symptom fault-related information can provide a reference for fault analysis. Be sure to confirm and list the
Table of Customer Fault Analysis properly.
Main contents of customer fault analysis

• What is the name--Vehicle model, name of system
• What is the time--Date, time , frequency
• Where--Road conditions
• Under what conditions - Operating conditions, driving conditions, weather conditions
• How did it happen?- Faults
Fault simulation
△ Hint:
The most difficult fault diagnosis means any fault cannot be found. In this case, first listen the detail analysis of fault
from the customer, and then inspect customer vehicle with the same or similar faults. For a technician, no mater how
rich his experience and how skillful his technology, if he doesn't analyze fault, he is easy to neglect important points
during repair and make wrong judgment, which will make the case worse. For example: for faults that caused when
engine is in cooling condition or by road bumping during the traveling of vehicle, etc. If the fault cannot be determined
when the engine is cold or the vehicle is stationary. Vibration, being heated or water leakage may often lead to faults and
it is difficult to make such faults recur, so, here introduces the fault simulation check method.
When parking the vehicle, simulate external conditions for effective detection.
Main contents of symptom simulation:
For the use of fault simulation method, first, verify the failure symptoms, but be sure to check the fault area and failed
parts. To achieve that end, before starting the detection, install the detector in place. According to the fault symptoms,
narrow the range of the possible fault circuits for searching as much as possible. And then, using the fault simulation
method, determine whether the circuit is damaged or normal, while verifying the fault. To narrow the range of the
possible faults, refer to the Table of Fault Symptom of each system.
LIFAN AUTO
01-22 Overview-How to perform vehicle troubleshooting
1. Vibration method
Jiggle Vibration appears to be the main cause of the fault.
(a). Components and sensors
Vibrate the possible faulty sensor gently with your fingers,
and check if there is trouble.
Warning
An excessive force can cause the relay open-circuited.
(b). Connectors
Gently shake the connector in the horizontal and vertical
directions.
(c). Harnesses
Slightly shake wire harness and connector in horizontal and
vertical directions, vibrate shaft, and completely inspect
main fault areas.
LIFAN AUTO
Overview-How to perform vehicle troubleshooting 01-23
2. Heating method
Heat the area to be detected and the fault seems to happen.
(a). Heat the location where the fault may occur with a hair
dryer or equivalent, and check whether the fault will occur. 01
Attention
• Heating temperature should not exceed 60 ° C (Limiting
the temperature and do not cause damage to the parts).
• Don't heat any ECU part directly.
3. Sprinkling method
The fault seems to happen under rainy or wet conditions.
(a). Sprinkle water onto the vehicle, and check and observe
whether the fault will occur.
Attention
• Do not spray directly on the engine but onto the front
end of the radiator, indirectly changing the temperature
and humidity.
• It is forbidden to spray water onto the electrical
components directly.
△ Hint:
Water-leak of the vehicle can cause damage to some electrical
components. Be sure to be especially careful to perform the water
sprinkling test on the vehicle.
4. Other
When the electricity load is excessive, the fault seems to happen.
(a). Switch on all electrical loads, and check whether the fault will occur.
Circuit troubleshooting method

1. Basic inspection
△ Hint:
Without special statement, all resistances are measured at 20 ° C temperature. Because after the vehicle starting, the
measured value of the resistance at high temperature will be immediately increased. Therefore, be sure to measure the
resistance after the engine cooling down.
2. Circuit open and short check method
See Chapter 91 Wiring--Description of diagnosis and maintenance method
LIFAN AUTO
01-24 Overview-Standard bolt torques
Standard bolt torques

Tightening torque (N•m)

Thread type Thread specification
Grade 8.8 Grade 10.9 Grade 12.9
M4 3.0 4.4 5.1
M5 5.9 8.7 10
M6 10 16 18
M8 25 36 43
M10 49 72 84
Coarse thread
M12 86 126 145
M14 135 200 236
M16 210 310 365
M18 300 430 600
M20 425 610 710
M8X1 27 39 46
M10X1.25 52 76 90
M12X1.25 93 135 160
M12X1.5 89 130 155

Fine thread
M14X1.5 145 215 255
M16X1.5 226 330 390
M18X1.5 340 485 570
M20X1.5 475 680 790
LIFAN AUTO
Mechanical system of engine
Mechanical system of engine..................................... 11-1 Cylinder block........................................................ 11-135
Preparation............................................................. 11-1 Components diagram.......................................... 11-135
Repair specifications.............................................. 11-6 Check.................................................................. 11-136 11
Precautions........................................................... 11-10 Crankshaft oil seal................................................. 11-137
On-Vehicle check................................................. 11-11 Replace............................................................... 11-137
Dismantle engine assembly.................................. 11-14
Engine assembly installation................................ 11-22
Troubleshooting........................................................ 11-28
Problem symptoms table...................................... 11-28
Drive belt................................................................... 11-32
Components diagram............................................ 11-32
Check.................................................................... 11-33
Replace................................................................. 11-33
Intake manifold........................................................ 11-34
Check.................................................................... 11-35
Replace................................................................. 11-36
Exhaust manifold..................................................... 11-40
Check.................................................................... 11-41
Replace................................................................. 11-42
Timing sprocket mechanism................................... 11-44
Check.................................................................... 11-45
Replace................................................................. 11-47
Camshaft................................................................... 11-59
Check.................................................................... 11-60
Replace................................................................. 11-62
Cylinder head........................................................... 11-67
Check.................................................................... 11-68
Replace................................................................. 11-69
Valve.......................................................................... 11-77
Check.................................................................... 11-78
Replace................................................................. 11-84
Piston connecting rod.............................................. 11-93
Check.................................................................... 11-94
Replace................................................................. 11-99
Crankshaft and flywheel.......................................11-115
Components diagram.......................................... 11-115
Check.................................................................. 11-116
Replace............................................................... 11-120
LIFAN AUTO
Mechanical System of Engine-Mechanical system of engine 11-1
Mechanical system of engine

Preparation
1. Special tool
11
S/N Tools Contour drawing No. Description
Used for removing the oil

1 Oil pan remover
pan
Used for removing and

2 Valve collet remover
installing the valve collets
Tool for installing and Used for removing and

3
removing valve guide installing the valves
Used for reaming the valve

4 Reamer
guides
Used for dismantling and

5 Oil filter disassembler
installing the engine oil filter
LIFAN AUTO
11-2 Mechanical System of Engine-Mechanical system of engine
Tool for installing front Used for installing the

6
oil seal of crankshaft crankshaft front oil seal
Crankshaft rear oil seal Used for installing the

7
installation tool crankshaft rear oil seal
Used for installing the

8 Piston installer
pistons.
LIFAN AUTO
2. Recommended tools
11
1 Radiator cap detector Detect radiator pressure
Engine oil pressure

2 Detect engine oil pressure
gauge
Used for measuring the

3 Cylinder pressure gauge
cylinder pressure
4 Hoist Used for hoisting the engine
Spring loaded thrust

5 Check valve spring force
meter
LIFAN AUTO
Check radial runout and

6 Dial indicator
clearance of parts
Check inner diameter of

7 Inside micrometer
parts
8 Dial caliper Measure the length of parts

Connecting-rod
9 degree of distortion of
collimator
connecting-rod
Used for removing the

10 Circlip pliers
retaining rings
Dismantle and install piston

11 Piston ring expander
ring
LIFAN AUTO
12 Feeler gauge Check clearance of parts 11
13 Cylinder bore gauge Measure cylinder bore
14 Micrometer screw gauge Measure diameter of parts
LIFAN AUTO
Repair specifications
1. Technical specifications
Standard cylinder pressure 1.2MPa
Minimum cylinder pressure 1.0MPa

Cylinder pressure
Maximum cylinder pressure 1.3MPa
Maximum cylinder pressure

0.1MPa
difference
Idle speed 80~300kPa

Engine oil pressure
Rated speed 330~430kPa
Minimum diameter of exhaust camshaft timing sprocket 97.3mm
Minimum diameter of crankshaft timing sprocket 51.6mm
Maximum thickness of timing chain rail 1.0mm
Cylinder block joint surface 0.05mm
Cylinder head flatness Intake side: 0.10mm
Exhaust side: 0.10mm
Camshaft radial runout 0.03mm
Intake camshaft 44.168~44.268mm

Maximum lift of intake/exhaust
camshaft
Exhaust camshaft 43.705~43.805mm
No.1 exhaust: 24.949~24.965mm

Camshaft journals
Others 22.949~22.965mm
Standard axial
0.040~0.095mm
clearance
Camshaft axial clearance
Maximum axial
0.1mm
clearance
Free length 43.40mm
Mounting elasticity 153~169N(33.88mm)

Valve spring
Maximum working
335.3~370.7N(24.1mm)
elasticity
Maximum deviation 1.6mm

Valve spring verticality
Maximum deviation
2°
angle
Standard Thickness 1.0mm

Valve edge thickness
Minimum thickness 0.7mm
Standard length 88.65mm

Intake:
Minimum length 88.35mm
Valve length
Standard length 88.69mm
Exhaust valve
Minimum length 88.39mm
Intake: 5.470~5.485mm
Valve stem diameter
Exhaust Valve 5.465~5.480mm
LIFAN AUTO
Width of intake valve-seat 1.0~1.4mm

Width of valve-seat contact
Width of exhaust valve-seat 1.0~1.4mm
Valve guide inner diameter 5.510~5.530mm
Thickness of mechanical tappet head 5.055~6.005

11
Standard oil-film
0.025~0.060mm
clearance
Intake:
Maximum oil-film
0.08mm
clearance
Valve oil-film clearance
Standard oil-film
0.030~0.065mm
clearance
Exhaust
Valve
Maximum oil-film
0.10mm
clearance
Valve-guide mounting-hole inner diameter 10.285~10.306mm
Valve-guide specified pressing-in capacity 8.7~9.1mm
Intake: 0.20~0.25mm
Valve clearance (cold)
Exhaust valve 0.30~0.35mm
Standard piston diameter 78.925~78.935mm
Standard oil-film clearance 0.065~0.085mm

Piston oil film clearance
Maximum oil-film clearance 0.085mm
Piston pin mounting hole diameter 20.006~20.015mm
Piston pin outer diameter 20.004~20.013mm
Standard axial clearance 0.16~0.34mm

Piston-connecting-rod
axial clearance
Maximum axial clearance 0.34mm
Standard oil-film clearance 0.030mm~0.054mm

Piston-connecting-rod
oil-film clearance
Piston pin oil film Standard oil-film clearance 0.002~0.011mm

clearance (piston
pin mounting
holes)
Connecting-rod small end hole inner diameter 20.012~20.021mm
Oil film clearance Standard oil-film clearance 0.001~0.017mm

of piston pin
(small end hole of
connecting rod)
First compression ring groove 0.03~0.08mm

Piston ring groove
clearance
Second compression ring 0.03~0.07mm
First compression ring 0.20~0.35mm
Standard piston Second

0.40~0.55mm
ring gap compression ring
Film loop 0.20~0.70mm

Piston ring opening
clearance First compression
1.05mm
ring
Maximum piston
Second
ring gap 1.20mm
compression ring
Film loop 1.10mm
Maximum connecting-rod distortion 0.05mm/100mm
LIFAN AUTO
Maximum connecting-rod bending 0.05mm/100mm
Standard diameter 7.30~7.40mm

Connecting-rod bolt diameter
Minimum diameter 7.20mm
Maximum crankshaft radial runout 0.03mm
Crankshaft main journal diameter 47.982~48.000mm
Maximum taper and bore out of round of main journal of crankshaft 0.02mm
Crankshaft-connecting-rod journal diameter 43.992~44.000mm
Taper an bore out of round of connecting rod journal of crankshaft 0.02mm
Standard oil-film clearance 0.014~0.032mm

Crankshaft oil film clearance

Cylinder block main bearing
cap fixing bolt diameter
Top surface warping on upper of cylinder block (maximum warping) 0.05mm
Cylinder block bore diameter 79.00~79.13mm
2. Torque specifications
Item N•m
Oil drainage bolt of oil pan 42~46
Engine left mounting fixed bolts 85~90
Engine right mounting fixed bolts 85~90
Fixed bolt of engine front mounting 85~90
Engine rear mounting fixed bolt 85~90
Fixed bolt of power steering pump 45
A/C compressor fixed bolts 25
Fixed bolts and nuts of electric throttle body 10~12
Intake manifold fixed bolts 30
Exhaust manifold fixed bolts 37
Fixed bolts of upper heat insulator of exhaust manifold 18
Fixed bolts of exhaust camshaft timing sprocket 54
Fixed bolts of intake camshaft timing sprocket 60
Fixed bolts of chain slipper 19
Fixed bolts of timing chain fixing rail 13
Front cover fixed bolts 23
Fixed nut of the tensioner 11
Crankshaft pulley fixed bolts 138
LIFAN AUTO
Item N•m
Water pump fixed bolts 11
Fixed bolts of engine front mounting support 52
Fixed bolts and nuts of belt tensioner Bolts: 69 Nuts: 29

11
Generator fixed bolts Short bolts: 25 Long bolts: 54
Cylinder head cover fixed bolts 11
Fixed bolts of ignition coil 11
Spark Plug 40
Camshaft bearing cap fixed Fixed bolts of No.1 camshaft

23
bolts bearing cap
Other bolts 13
Cylinder head fixed bolts (fastening them twice) First time 49, second time 90
Fuel rail fixed bolts 11
Fixed bolt of connecting rod cap 50
Cylinder block water-drain bolt 23
Engine oil filter 25~30
Oil strainer fixed bolts 25
Oil pan fixed bolts 10
Crankshaft main bearing cap fixed bolts( fastening them twice) First time 40, second time 60
Fixed bolts of upper and lower bodies of cylinder 18
Flywheel fixed bolts 88
Engine oil pressure sender torque 14~16
LIFAN AUTO
Precautions
1. Before discharging engine coolant, first cool the engine.
2. When disconnecting fuel pipe, working environment shall keep away from fire source and children as far as
possible.
3. After oil pipe is removed, each fuel pipe joint shall be sealed to prevent fuel pipe from blocking or fuel leakage.
4. When dismantling the engine, you do not damage matching surface and sliding face.
5. When dismantling the engine, use tapes or equivalents to seal opening of the engine to prevent foreign matters
from going into the engine.
6. During the course of dismantling, it is necessary to identify and arrange disassembled parts in order so as to
make troubleshooting and reinstall them.
7. Before repairing or replacing, clean and check parts thoroughly.
8. When assembling the engine, the principle of tightening bolts and nuts is to tighten bolts or nuts in the middle
by the same torque, and then tighten bolts or nuts on internal and external diagonal lines. If there is a specified
sequence, please operate according to the specified sequence.
9. When assembling the engine, please replace with new gaskets, oil seals and seal rings.
10. When applying sealant, it shall be applied uniformly. After applying, install the component within specified
period.
11. When assembling the engine, check if engine pipe and vacuum pipe are blocked carefully.
12. When each sensor connector, a clear "click" is heard, which means the connector is in the right position.
13. After repairing and assembling the engine, start the engine and increase the engine speed, check if engine
coolant, fuel and engine oil and exhaust gas leak.
Attention:
If there is other specified in this manual, follow the specification.
LIFAN AUTO
On-Vehicle check
1. Inspect engine coolant.
(a). Check if engine coolant leaks.
• Fill coolant into radiator assembly. 11
• Connect radiator cover to tester and adjust the pressure of
radiator to the standard value, and then observe whether
pressure value reduces.
Standard pressure of radiator: 94.2~115.8kPa (exhaust)
4.9kPa (intake)
180kPa (sealing)
△ Hint:
• If the pressure decreases, check hose, radiator assembly and
water pump leak.
• If the engine has no coolant leakage mark, check heater
core, cylinder block & head.
(b). Insect the quality of coolant (See Chapter 15 Cooling
System - Cooling System, Onboard Inspection).
2. Check engine oil
(a). Check engine oil level.
• Warm up the engine, stop it and then wait for 5 min.
• Check whether the oil level is between the upper and
lower marks of the dipstick.
△ Hint:
If the oil level is at or below the lower mark, check the oil for
leakage, and add oil to bring it to the upper mark.
(b). Inspect whether engine oil goes bad, discolor or mixed

water (A: engine oil, B: water), If any, replace it.
△ Hint:
The normal oil is transparent and relatively thick. If the oil
becomes dark and thin, replace the oil.
LIFAN AUTO
3. Check the oil pressure

(a). Disconnect engine oil pressure sensor connector.
(b). Dismantle engine oil pressure sensor and install engine oil
pressure gauge.
(c). Warm up the engine and observe engine oil pressure gauge.
Engine oil pressure at idle speed: 80~300kPa
Engine oil pressure at rated speed: 330~430kPa
△ Hint:
If the pressure is not within specified range, check engine oil
pump.
(d). Take down pressure gauge, install engine oil pressure sensor
and connect sensor connector.
Engine oil pressure sensor torque: 14~16N• m
△ Hint:
Coat bond onto the sensor thread when installing the engine oil
pressure sender .
Attention:
Don't start the engine just after installing the engine oil
pressure sender . Be sure to wait for a period of time before
starting the engine.
4. Inspection of air filter upper cover
(a). Remove the air filter upper cover.
(b). Remove the air filter element.
(c). Check visually the air filter element for dirt or damage. If
there is , clean or replace it.
5. Inspection of drive belt

(a). Check the drive belt for oil stains. If there is any, clean it.
(b). Check the drive belt for ageing, crack or wear. If it is ,
replace it.
LIFAN AUTO
6. Inspection of cylinder pressure

(a). Preheat the engine and then stop it.
Attention:
After warming up the engine, shift the shift lever to the neutral
position and apply the parking brake. 11
(b). Disconnect the connector of each ignition coil.
(c). Disconnect the connector of each injector.
(d). Remove the fixed bolt of each ignition coil, and remove the
4 ignition coils in turn.
(e). Remove each spark plug with the socket and the extension
bar.
Attention:
• Do not damage the insulation section of ignition coil.
• While dismantling, mark the cylinder of ignition coil
to facilitate subsequent installation.
(f). Install the pressure gauge into the mounting hole of the
spark plug.
(g). Start the engine and read the value shown in pressure gauge.
Standard cylinder pressure: 1.2MPa
Minimum cylinder pressure: 1.0MPa
Maximum cylinder pressure: 1.3MPa
△ Hint:
Before starting, it is necessary to inspect whether battery is in fully
charged condition, if no, recharge battery or replace battery.
(h). Use the same method to test pressure of other cylinders,
and calculate the maximum pressure difference between
cylinders.
Maximum cylinder pressure difference: 0.1MPa
Attention:
All tests should be finished in very short time (about 15s), to
avoid damaging starter.
LIFAN AUTO
Dismantle engine assembly

1. Release fuel system pressure
(a). Open upper cover of fuse box, and unplug fuel pump relay.
(b). Start the engine, and maintain idle speed until engine flames
out automatically.
(c). If starting the engine for 2~3 times, the pressure in fuel
system can be exhausted completely.
(d). Turn off ignition switch and install fuel pump relay.
(e). Install upper cover of fuse box.
2. Dismantle battery
(a). Dismantle positive and negative wire harnesses of battery.
(b). Dismantle fixed bolts of connecting rod of battery, and
remove connecting rod and tie rod of battery.
(c). Remove battery and battery bottom cover.

(d). Dismantle fixed bolts of battery bracket and remove battery
bracket.
LIFAN AUTO
3. Disconnect connectors of oil injector, ignition coil and

various sensors.
(a). Open upper cover of fuse box, and unplug engine wire
harness connector.
11
(b). Disconnect connectors of each ignition coil and oil injector.
(c). As shown in figure 1, disconnect canister solenoid

connector.
(d). As shown in figure 2, disconnect electronic throttle position
sensor connector.
(e). As shown in figure 3, disconnect camshaft position sensor
connector.
(f). As shown in figure 4, disconnect coolant temperature sensor
connector.
LIFAN AUTO
(g). As shown in figure 1, disconnect VVT control valve

connector.
(h). As shown in figure 2, disconnect air intake pressure and
temperature sensor connector.
△ Hint:
Air intake pressure and temperature sensor connector is located at
the back of intake manifold.
(i). As shown in figure 2, disconnect knock sensor connector.

△ Hint:
Knock sensor is located at the cylinder block under the intake
manifold.
(j). As shown in figure 3, disconnect crankshaft position sensor
connector.
△ Hint:
Crankshaft position sensor is located at transmission housing.
(k). As shown in figure 1, disconnect speedometer sensor
connector.
△ Hint:
Speedometer sensor is located at transmission housing.
(i). As shown in figure 1, disconnect oxygen sensor connector.

△ Hint:
Oxygen sensor connector is located at exhaust manifold.
(m) As shown in figure 2, disconnect reversing switch connector.
△ Hint:
Reversing switch is located at transmission housing.
LIFAN AUTO
(n). Disconnect air conditioner compressor clutch connector.
11
(o). As shown in figure 1, disconnect generator output power

cable and disconnect generator connector.
(p). As shown in figure 2, disconnect engine oil pressure sender
connector.
△ Hint:
Engine oil pressure sender is located at engine oil filter.
(q). As shown in figure 3, disconnect starter power supply cable
and disconnect starter connector.
(r). As shown in figure 4, dismantle grounding cable on
transmission housing.
4. Dismantle air filter assembly

Attention:
After air filter assembly is dismantled, it is necessary to use
clean plastic bag or equivalent to cover the throttle port, to
prevent foreign matters from entering into it.
5. Exhaust engine coolant and oil
(a). Slight lift the vehicle to the specified height through lifting
table.
(b). Dismantle water drain plug at the bottom of radiator, drain
engine
coolant into a collector.
△ Hint:
For the sake of convenience, you can open the radiator cap.
Attention:
• To avoid a burn, conduct this after the engine is cool.
• When opening the radiator cap, wrap the radiator cap with
a thicker cloth to unscrew it slowly. Release the pressure in
the radiator before opening the radiator cap fully.
• Do not spill the coolant on the drive belt.
LIFAN AUTO
(c). Dismantle drain bolt of oil pan, and drain engine oil.
Torque: 42~46N•m
6. Disconnect all connections of oil pipe, vacuum pipe and

water pipe.
(a). As shown in figure 1, disconnect oil intake pipe of fuel rail.
△ Hint:
After fuel pressure release, there is still some fuel deposited inside
oil pipe, so it is necessary to wrap the oil pipe joint by using clean
cloth when disconnecting oil pipe, to avoid fuel spraying out.
Attention:
• Do not bend or twist resin pipe.
• If fuel sprays out, clean the sprayed fuel, to prevent
rubber or leather
tools and parts from contacting with gasoline.
(b). As shown in figure 2, disconnect air intake pipe of canister
solenoid.
(c). Dismantle tightening clamps of intake and outlet hose of
radiator, and disconnect water pipe connection.
LIFAN AUTO
(d). Disconnect heat water pipe and vacuum boosting hose.
11
7. Dismantle clutch slave cylinder and oil pipe assembly from transmission (See Chapter 22Clutch - Clutch Slave
Cylinder, Replacement)
8. Dismantle transmission gear shifting selector, gearshift cable (See Chapter 21 Transmission - Transmission
Control Mechanism, Replacement)
9. Dismantle front wheel assembly
10. Dismantle left and right propeller shaft (See Chapter 41 Propeller Shaft - Propeller Shaft Assembly, Replacement)
11. Dismantle the drive belt.

(a). As shown in figure, use ring spanner to exert force to
tensioner in clockwise direction, and install drive belt.
12. Remove the fixed bolts from the A/C compressor, and
disengage the A/C compressor from the engine.
△ Hint:
To avoid refilling refrigerant, separate air conditioner compressor
from engine without dismantling air conditioner pipeline.
Attention:
Do not bend air conditioner pipeline, and fix the air conditioner
compressor to one side of engine compartment, to facilitate
taking out engine smoothly.
LIFAN AUTO
13. Dismantle fixed nuts on the front of three-way catalytic

converter.
△ Hint:
To facilitate taking out engine smoothly, it is better to dismantle
three-way catalytic converter (first disconnect rear sensor
connector).
14. Dismantle fixed bolts of power steering pump to separate

power steering pump from engine.
15. Use engine lifting tool to lift engine.
△ Hint:
Make the cable of lifting tool freely in vertical direction.
16. As shown in figure 1, dismantle fixed bolts of engine left

suspension, and take it out.
17. As shown in figure 2, dismantle fixed bolts of engine left
suspension, and take it out.
LIFAN AUTO
18. As shown in figure 1, dismantle fixed bolts of engine rear

overhang, and take it out.
△ Hint:
To facilitate taking out engine smoothly, it is better to dismantle
engine rear overhang mounting bracket.
11
19. As shown in figure 2, dismantle fixed bolts of engine
front suspension.
20. Slowly lift engine lifting bracket and lift engine with transmission assy out.
Attention:
• Before lifting engine, re-inspect whether all connectors, grounding cables, oil pipes, vacuum pipes and
water pipes are completely disconnected.
• During lifting, pay attention to observe parts around engine, to prevent damage caused by extruding.
21. Dismantle fixed bolts of transmission assy, and remove transmission assembly
LIFAN AUTO
Engine assembly installation
1. Use engine lifting bracket to lift engine with transmission assembly, and place it to the engine
compartment.
Attention:
To avoid bumping engine hood.
2. Slowly lower the engine, after complete engine assembly locates at support position, stop lowing.
Attention:
Prevent oil pipe, vacuum pipe, air conditioner pipe and water pipe in engine compartment from being damaged by
extruding
3. As shown in figure 1, install fixed bolts of engine left
suspension.
Torque: 85 ~ 90N•m
Attention:
Temporarily do not tighten the fixed bolts. Tighten them after
front, rear, left, right suspensions of engine are completely
installed on proper place.
4. As shown in figure 2, install fixed bolts of engine right
suspension.
5. As shown in figure 1, install fixed bolts of engine left

suspension.
6. As shown in figure 2, install fixed bolts of engine front
suspension.
LIFAN AUTO
7. Install power steering pump and tighten fixed bolts

Torque: 45 N•m
8. Install air conditioner compressor assembly and tighten
fixed bolts
Torque: 25 N•m 11
Attention:
Do not bend air condition pipeline.
9. Install left and right propeller shaft (See Chapter 41 Propeller Shaft - Propeller Shaft Assembly,
Replacement)
10. Install front wheel assembly
11. Install transmission gear selector, gear shifting cable (See Chapter 21 Transmission - Transmission Control
mechanism, Replacement)
12. Install clutch slave cylinder and oil pipe assembly (See Chapter 22Clutch - Clutch Slave Cylinder,
Replacement)
13. Install all water pipes, vacuum pipes and oil pipes.
(a). Install heat water pipe and vacuum boosting hose.
(b). As shown in figure 1, install fuel intake pipe of fuel rail.

Attention:
Do not bend or twist resin pipe.
(c). As shown in figure 2, install air intake pipe of canister
solenoid.
LIFAN AUTO
(d). Install intake and outlet hose of radiator and tighten the
clamp.
14. Install air filter assembly
15. Install fuel injector, ignition coil and various sensor

connectors.
(a). Install ignition coil connector.
△ Hint:
When a silvery "clicking" sound is heart, it indicates that the
connector is installed in proper position.
(b). Install fuel injector connectors.
(c). As shown in figure 1, install canister solenoid connector.

(d). As shown in figure 2, install electronic throttle position
sensor connector.
(e). As shown in figure 3, install camshaft position sensor
connector.
(f). As shown in figure 4, install coolant temperature sensor
connector.
LIFAN AUTO
(g). As shown in figure 1, install VVT control valve connector.

(h). As shown in figure 2, install air intake pressure and
11
(i). As shown in figure 2, install knock sensor connector.

(j). As shown in figure 3, install crankshaft position sensor
connector.
(k). As shown in figure 1, install odometer sensor connector.
(i). As shown in figure 1, install front oxygen sensor connector.

(m). As shown in figure 2, install reversing switch connector
LIFAN AUTO
(n). Install air conditioner compressor clutch connector.
(o). As shown in figure 1, install generator output power cable

and install generator connector.
(p). As shown in figure 2, install engine oil pressure sender
connector.
(q). As shown in figure 3, install starter power supply cable and
install starter connector.
(r). As shown in figure 4, install grounding cable on
transmission housing.
16. Install fixed nuts of three-way catalytic converter
LIFAN AUTO
17. Install battery.

(a). Install battery bracket and tighten fixed bolts of bracket.
(b). Install battery bottom plate and battery to battery bracket.
Upper
11
(c). Install battery connecting rod and tie rod, and tighten fixed
bolts of connecting rod.
(d). Install positive and negative wire harnesses of battery.
Attention:
When connecting battery wire harness, first connect positive
wire harness of battery, and then connect negative wire harness
of battery.
LIFAN AUTO
Troubleshooting
Problem symptoms table
Use the table below to help you find the cause of the problem. Check each part in order. If necessary, repair or replace
these parts.
Symptom Suspected area Recommended action
1. Battery (voltage < 8V) The battery is charging or replaced
2. Battery (connection corruption or Clean and tighten the battery wiring. Apply a thin layer of
looseness) petroleum jelly on wiring end
3. Starter motor (failure) Check the starter. If necessary, replace it
4. Fuel supply system (no fuel) Fill fuel
5. Fuel supply system (with air) Discharge fuel supply system
6. Fuel supply system (polluted) Clean fuel supply system and replace fuel filter
7. Fuel supply system (wrong connection

Connect fuel pipe according to correct method
of intake and outlet oil pipe)
8. Fuel supply system (fuel pump Repair the complete vehicle harness and re-connect the fuel
open-circuit) pump connector.
Slightly flooded cylinder: Open the throttle fully and start the starter.
9. Fuel supply system (fuel floods the
The engine cannot be started Severely flooded cylinder: Remove the spark plug and start the
cylinder)
starter, let the residual oil of the cylinder and the spark plug dry
before restoring.
10. Fuel supply system (fuel injector is

Replace the nozzle
blocked)
11. Ignition system (ignition coil

connector is in bad connection or Connect ignition coil connector correctly
wrong connection)
12. Spark plug (wrong clearance) Readjust gaps of all spark plugs
13. Ignition system (spark plug is

Replace spark plug
damaged)
14. Ignition system (ignition coil is

Replace ignition coil
damaged)
15. Engine timing (wrong timing) Adjust timing
16. Engine oil (too high viscosity) Replace engine oil
1. Fuel supply system (fuel intake pipe

Fuel supply system supplements pressure
pressure<350kPa)
2. Fuel supply system (fuel tank

Fill fuel
volume is insufficient)
3. Fuel supply system (fuel filter is

Replace fuel filter
blocked)
4. Fuel supply system (engine fuel

Replace engine inlet oil pipe
inlet pipe leak)
The engine is combusted but
can not be started
5. Fuel supply system (fuel pressure
Replace fuel pressure regulator
adjustor is damaged)
6. Fuel supply system (fuel pump

Replace fuel pump
pressure is insufficient)
7. Fuel supply system (air filter is

Clean intake port and replace air filter element
blocked)
8. Exhaust system (three-way catalytic

Replace three-way catalytic converter
converter is blocked or damaged)
LIFAN AUTO
1. Ignition system (spark plug wire

Reconnect connector
harness is in bad connection)
2. I g n i t i o n s y s t e m ( s p a r k p l u g
Readjust gaps of all spark plugs
clearance is inconsistency)
Engine idle speed unstable 11
4. Ignition system (individual fuel

Clean or replace fuel injector
injector is blocked)
1. Fuel supply system (fuel tank

Fill fuel
volume is insufficient)
2. Fuel supply system (engine fuel

Replace fuel inlet pipe
inlet pipe leak)
The engine is stalled during
3. Fuel supply system (with air) Discharge fuel supply system
normal working
4. Fuel supply system (fuel filter or
Replace fuel filter or clean fuel pipe
fuel pipeline is blocked)
5. Fuel supply system (fuel is mixed

Replace fuel
with water)
1. Intake system (unsmooth air intake) Clean intake port and replace air filter element
2. Intake air pressure/ temperature Clean intake air pressure and temperature sensor detection hole.
sensor hole clogged If necessary, replace the sensor
3. Intake system (throttle not fully Adjusting accelerator limit screw to ensure the accelerator is
opened) fully open
4. Ignition system (fuel injector is blocked) Clean or replace fuel injector
5. Ignition system (spark plug is

Clean spark plug and adjust the gap
Engine acceleration is poor stained or has improper clearance)
or slow
6. Fuel supply system (polluted) Clean fuel supply system and replace fuel filter
7. Fuel supply system (fuel pump

Replace fuel pump
doesn't work)
8. Cylinder pad (untight sealing) Replace cylinder gasket
9. Valve (has burning, deformation and pit) Replace the valve
10. Exhaust system (intake system is

Check exhaust system and three-way catalyst
not smooth)
1. Intake system (intake system is not

Clean intake port and replace air filter element
smooth)
2. Intake system (throttle not fully Adjusting accelerator limit screw to ensure the accelerator is
opened) fully open
3. Exhaust system (poor exhaust) Check exhaust system and three-way catalyst
Engine power is not enough
4. Parts of power transmission system
Check related parts of transmission system
(high resistance)
5. Engine (overheating) Check engine cooling system
6. Ignition system (fuel injector is

blocked)
1. Ignition system (high-voltage

Reconnect all connectors and replace the damaged parts.
circuit leaks electricity)
Unstable rotating speed
during running
2. Ignition system (fuel injector is
blocked)
It is shook during 1. Ignition system (high-voltage

Reconnect all connectors and replace the damaged parts.
acceleration circuit leaks electricity)
LIFAN AUTO
1. Fuel system (fuel is not standard

Replace fuel
type)
Knocking
2. Engine (overheat) Check engine cooling system
Immediately restore the ignition of the misfiring cylinder.

1. Ignition system (misfire) Otherwise, disconnect the connector of the injector of the
Delayed combustion (high
cylinder to protect the three-way catalytic converter.
exhaust temperature)
2. Engine exhaust valve failure Repair the engine.
1. Engine (abnormal condition) Overhaul the engine.
2. E F I s y s t e m ( E F I s y s t e m h a s
Overhaul the EFI system.
abnormal control)
3. Exhaust system (exhaust manifold

or three-way catalytic converter Fasten the bolts, if necessary, replace the gasket.
joints leak)
4. Exhaust system (oxygen sensor

Tighten the oxygen sensor.
thread leaks air)

Excessive emissions
measured by the Replace the catalytic converters and oxygen sensors (under the
converter and oxygen sensor
performance test method standard conditions, service life is not more than 80,000 km).
expires use period)

converter and oxygen sensor have
Replace the catalytic converters and oxygen sensors.
heavy metal poisoning or damaged
due to overheat)

converter and oxygen sensor has Shifting to 3rd gear, driving at 70km/h for 10 minutes.
sulfur poisoning)
9. ECM or EFI system (bad grounding

Improve the positions of the system grounding wires.
connection)
10. ECM housing grounded Insulate the ECM housing.
Excessive emissions tested

by the Bayesian Active 1. Engine (not fully preheated) Warm up the engine.
Shape Model (BASM)
High CO and HC
1. Engine (not fully preheated) Preheating the engine, perform the high idling-speed test firstly.
concentration when idling
LIFAN AUTO
1. Incorrect measurement methods Use the reliable computation method.
2. Vehicle status Overhaul the vehicle.
3. Engine status Overhaul the engine.

11
4. Cooling system (thermostat is
Replace thermostat.
damaged)
5. Cooling system (coolant temperature

Replace the coolant temperature sensor,
sensor is damaged)
Abnormal fuel consumption
6. Ignition system (fuel injector leaks
Replace fuel injector
fuel)

8. Exhaust system (oxygen sensor is

Replace the oxygen sensor.
damaged)
9. ECM (ECM is damaged) Replace ECM
Irregular malfunction lamp

1. Ignition system (connector is in bad Check all terminals of the ignition system and reconnect the
on or off during vehicle
connection) connectors.
running
LIFAN AUTO
Drive belt
Components diagram
1 Drive belt
LIFAN AUTO
Check
1. Inspection of drive belt
(a). Check the drive belt for ageing, crack, wear or oil dirt. If
any, repair the drive belt. If necessary, replace it.
11
Replace
1. Dismantle the drive belt.
2. Installation of drive belt

Attention:
• Make sure that the installation road of drive belt is
correct.
• Make sure that drive belt is installed into the wedge
groove properly.
LIFAN AUTO
Intake manifold
Components diagram
1 Rubber seal ring 4 Electronic throttle assembly
2 Bolt 5 Bolt
3 Intake manifold assembly 6 Nut
LIFAN AUTO
Check
1. Inspection of intake manifold
(a). Inspect whether intake manifold has crack or other damage,
If any, replace it.
11
(b). Check intake manifold matching surface for deformation. If

any, replace it.
(c). Inspect whether rubber seal ring of intake manifold is
damaged, If any, replace it.
2. Inspect electric throttle.

(a). Check the throttle body for dirt. If any, clean it.
LIFAN AUTO
Replace
1. Removal of intake manifold
(a). As shown in figure 1, disconnect intake pressure and
(b). As shown in figure 2, disconnect electric throttle position
sensor connector.
(c). Dismantle vacuum boosting hose.
(d). As shown in figure 3, dismantle fixed clamp of air filter

hose, and disconnect hose connection.
Attention:
Use clean plastic bag or equivalent to plug the inlet of throttle,
to prevent foreign matters from entering it.
(e). As shown in figure 1, dismantle fixed clamp of PCV valve
(f). As shown in figure 2, dismantle canister solenoid hose.
(g). As shown in figure 4, dismantle engine vent hose.
LIFAN AUTO
(h). Remove intake manifold fixed bolts, and then remove intake
manifold assembly.
11
(i). Dismantle fixed bolts and nuts of electric throttle, and

remove electric throttle assembly.
2. Installation of intake manifold

(a). Install electric throttle assembly onto the intake manifold,
and tighten fixed bolts and nuts of electric throttle.
LIFAN AUTO
(b). Install intake manifold with electric throttle assembly onto

the cylinder head, and tighten fixed bolts.
Torque: 30 N•m
(c). As shown in figure 3, install air filter hose onto the electric
throttle, and tighten hose clamp.
(d). As shown in figure 1, install hose of PCV valve and tighten
fixed clamp.
(e). As shown in figure 2, install canister solenoid hose.
(f). As shown in figure 4, install engine vent hose.
Attention:
Make sure all pipelines are connect firmly and reliably.
(g). Install vacuum boosting hose.
LIFAN AUTO
(h). As shown in figure 1, install air intake pressure and

(j). As shown in figure 2, install electric throttle position sensor
connector.
11
LIFAN AUTO
Exhaust manifold
Components diagram
1 Bolt 4 Nut
2 Upper heat insulator of exhaust manifold 5 Lower heat insulator of exhaust manifold
3 Exhaust manifold assembly 6 Exhaust manifold gasket
LIFAN AUTO
Check
1. Inspection of exhaust manifold
(a). Inspect whether intake manifold has crack or other damage,
If any, replace it.
11
(b). Check the exhaust manifold gasket for damage. If there is ,

replace it.
LIFAN AUTO
Replace
1. Removal of exhaust manifold
(a). Disconnect front oxygen sensor connector.
(b). Dismantle front fixed nuts of three-way catalytic converter.
(c). Dismantle fixed bolts of upper heat insulator of exhaust

manifold, and remove upper heat insulator.
(d). Dismantle fixed nuts of exhaust manifold, and remove
exhaust manifold.
(e). Remove lower exhaust manifold pad.
LIFAN AUTO
2. Install the exhaust manifold.

(a). Install the exhaust manifold gasket.
(b). Install exhaust manifold assembly onto engine, and tighten
fixed nuts.
Torque: 37 N•m 11
(c). Install upper heat insulator of exhaust manifold onto
exhaust manifold, and tighten fixed bolts.
Torque : 18 N•m
(d). Install front fixed nuts of three-way catalytic converter.
(e). Install front oxygen sensor connector.
LIFAN AUTO
Timing sprocket mechanism

Components diagram
1 Nut 10 Timing chain fixed rail
2 Timing belt tensioned rubber piece 11 Crankshaft timing sprocket
3 Front cover 12 Intake timing sprocket (VVT)
4 Nut 13 Exhaust camshaft timing sprocket
5 Tensioner assembly 14 Bolt
6 Bolt 15 VVT bolt
7 Timing belt tensioner assembly 16 Timing chain movable rail
8 Bolt 17 Bolt
9 Timing chain
LIFAN AUTO
Check
1. Inspect tensioner
(a). As shown in figure, lift tensioning shaft lock plate 1, and
inspect whether tensioning shaft 2can freely move, if no,
replace tensioner. 11
(b). As shown in figure, make the lock plate 1 lock tensioning

shaft, and inspect whether tensioning shaft can freely move,
if no, replace tensioner.
Attention:
This tensioning shaft only can be shrunk inside, while it can't
be extend outside.
2. Inspect timing chain

(a). Inspect whether timing chain is damaged, If any, replace it.
LIFAN AUTO
(b). As shown in figure, use spring pressure gauge to exert 140N

force to timing chain, and then use dial caliper to check the
length of chain. If the length exceeds maximum extension
length, replace the chain.
Maximum extension length of chain: 122.6mm
△ Hint:
As method shown in left figure, select 3 or more points as samples
to inspect chain length.
3. Inspect exhaust camshaft timing sprocket

(a). As shown in figure, put the chain wind the exhaust camshaft
timing sprocket.
(b). Use dial caliper to check diameter of camshaft timing
sprocket when a timing chain is equipped. If this value is
lower than the specified value, replace camshaft timing
sprocket.
Minimum diameter: 97.3mm
Attention:
When measuring, 2 measuring legs of dial caliper must tightly
contact with chain roller.
4. Inspect crankshaft timing sprocket.

(a). As shown in figure, put the chain wind the crankshaft
timing sprocket.
(b). Use dial caliper to check diameter of crankshaft timing
sprocket when a timing chain is equipped. If this value is
lower than the specified value, replace crankshaft timing
sprocket.
Attention:
When measuring, 2 measuring legs of dial caliper must tightly
contact with chain roller.
LIFAN AUTO
5. Inspect timing chain movable rail assembly

(a). Use dial caliper to check the thickness of timing chain
movable rail. If the thickness of rail is more than maximum
thickness, replace timing chain movable rail assembly.
Maximum thickness: 1.0mm
11
Replace
1. Dismantle timing sprocket mechanism components
(a). Dismantle fixed bolts of ignition coil, and remove all
ignition coils in order.
Attention:
• While dismantling, mark the cylinder of ignition coil to
facilitate subsequent installation.
(b). Use socket and extending rod to dismantle each spark plug.
LIFAN AUTO
(c). As shown in Fig. 1, dismantle PCV valve hose clamps,

disconnect hose connection.
(d). As shown in Fig.2, disconnect vent hose.
(e). Dismantle fixed bolts of cylinder head cover, and remove

cylinder head cover.
(f). Dismantle drive belt.

(g). Remove the fixed bolts of the generator assembly, and then
remove the generator assembly.
LIFAN AUTO
(h). Dismantle fixed bolts and nuts of timing belt tensioner

assembly, and remove the tensioner.
11
(i). Dismantle engine front mounting with bracket assembly.
(j). Dismantle fixed bolts of water pump, and remove water

pump assembly.
LIFAN AUTO
(k). Dismantle fixed bolts of crankshaft pulley.

△ Hint:
While dismantling fixed bolts of crankshaft pulley, to avoid
rotation of crankshaft, it is necessary to first fix flywheel.
(i). Use a puller to remove crankshaft pulley.
Attention:
When using a puller, do not damage crankshaft pulley.
(m). Dismantle fixed nuts of tensioner, and remove tensioner.
(n). Dismantle fixed bolts of front housing, and remove front

housing.
△ Hint:
When removing front cover, it may be not easy to remove the
cover due to sealants. Use a rubber hammer to knock front cover.
Attention:
Don't tap it with an iron hammer or a hard tool.
LIFAN AUTO
(o). Dismantle fixed bolts of timing chain movable rail and fixed
rail assembly, and remove timing chain movable rail and
fixed rail assembly.
Attention:
To avoid damage of valve rod caused by rotation of camshaft
or crankshaft after dismantling of timing chain, it is necessary 11
to rotate crankshaft before dismantling, to make all pistons
locate at upper limit point or lower limit point.
(p). Remove timing chain.
(q). Remove retainer of crankshaft timing sprocket.

(r). Remove crankshaft timing sprocket and positioning pin.
Attention:
Store location pins together to prevent them from losing.
(s). As shown in figure 1, dismantle fixed bolts of exhaust

camshaft timing sprocket, and remove exhaust camshaft
timing sprocket.
(t). As shown in figure 2, dismantle VVT bolts, and remove
intake camshaft timing sprocket.
LIFAN AUTO
Attention:
To avoid rotation of camshaft, it is necessary to use wrench to
exert reversing force to camshaft (please exert force on position
shown in figure).
2. Install timing sprocket mechanism components

(a). As shown in figure 1, install exhaust camshaft timing
sprocket and tighten the bolts.
Torque: 54 N•m
(b). As shown in figure 2, install intake camshaft timing
sprocket and tighten VVT bolts.
Torque: 60 N•m
Attention:
To avoid rotation of camshaft, it is necessary to use wrench to
exert reversing force to camshaft (please exert force on position
shown in figure).
LIFAN AUTO
(c). Install crankshaft timing sprocket and positioning pin.

(d). Install crankshaft timing sprocket retainer ring.
11
(e). Install timing chain.

Attention:
As shown in the figure, align the timing marks when installing
the timing chain.
(f). Install timing chain movable rail (as shown in figure 1),
fixed rail assembly (as shown in figure 2), and tighten fixed
bolts.
Fixed bolts of moving rail
Torque: 19N•m
Fixed bolts of fixing rail
Torque: 13N•m
LIFAN AUTO
(g). As shown in figure, uniformly apply sealant on the surface

of front housing.
Attention:
Before applying new sealant, make sure that old sealant is
clean out totally.
(h). Install front housing onto engine, and tighten all fixed bolts.
Torque: 23N•m
(i). Install tensioner onto the mounting position, and tighten

2fixed nuts.
Torque: 11N•m
△ Hint:
When install tensioner, first lock the tensioner plunger piston by
using lock piece. After fixed bolts of the tensioner is installed,
rotate crankshaft counter clockwise to release locking piece.
LIFAN AUTO
(j). Rotate crankshaft in clockwise, and inspect whether

tensioner is installed properly.
11
(k). Install crankshaft pulley and tighten bolts.

Torque: 138N•m
△ Hint:
While installing fixed bolts of crankshaft pulley, to avoid rotation
of crankshaft, it is necessary to firstly fix flywheel.
(l). Install water pump assembly and tighten bolts.

Torque: 11N•m
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(m). Install engine front mounting with bracket assembly, and

tighten bolts.
Torque: 52N•m
(n). Install belt tensioner assembly and tighten bolts and nuts.
Bolt torque: 69N•m
Nut torque: 29N•m
(o). Install generator assembly and tighten bolts.

Short bolt torque: 25N•m
Long bolt torque: 54N•m
(p). Install drive belt.
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(q). Install cylinder head cover assembly and tighten all fixed
bolts.
Torque: 11N•m
11
(r). As shown in figure 1, install hose of PCV valve and tighten

fixed clamp.
(s). As shown in figure 2, install vent hose.
(t). Use socket and extending rod to install each spark plug.
Torque: 40N•m
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(u). Install each ignition coil in order, and tighten bolts.

Torque: 11N•m
Attention:
Install according to marks made at the time of dismantling.
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Camshaft
Components diagram
11
1 Bolt 5 Exhaust camshaft

2 No.1 camshaft bearing cap 6 Bolt
3 Bolt 7 Intake camshaft bearing cap
4 Exhaust camshaft bearing cap 8 Intake camshaft
LIFAN AUTO
Check
1. Inspection of camshaft radial run-out
(a). Place the camshaft on V block, measure circumference
radial runout at intermediate journal with a dial gauge. If
radial runout is larger than the maximum value, replace the
camshaft.
Maximum value: 0.03mm
2. Inspection of maximum lift of intake/exhaust camshaft

(a). As shown in the Fig. , measure maximum lift of intake/
exhaust camshaft with a screw micrometer. If it does not
conform to the specification, replace it.
Intake: 44.168±44.268mm
Exhaust: 43.705±43.805mm
3. Inspection of camshaft journal

(a). Inspect whether camshaft journal and bearing cap has
rusting, abrasion and other damage. If any, replace it. If
necessary, replace the cylinder head.
LIFAN AUTO
(b). Measure the camshaft journal with the screw micrometer,

and if it is inconsistent with the specified value, then check
the clearance of oil film.
No. 1 exhaust:24.949~24.965mm
Others: 22.949~22.965mm
11
4. Inspection of camshaft axial clearance

(a). Install intake/exhaust camshaft on cylinder head.
(b). Make the camshaft in alternate motion, and measure the
axial clearance of camshaft. If it is inconsistent with the
specified value, replace the camshaft, and replace the
cylinder head when necessary.
Standard axial clearance: 0.040~0.095mm
Maximum axial clearance: 0.10mm
LIFAN AUTO
Replace
1. Removal of camshaft assembly
Attention:
Do not damage the insulation section of ignition coil.
While dismantling, mark the cylinder of ignition coil to
(c). As shown in Fig. 1. Dismantle fixed clamp of PCV valve

LIFAN AUTO

11
(f). Dismantle timing sprocket mechanism.

(g). As shown in figure 1, dismantle fixed bolts of exhaust
camshaft timing sprocket, and remove exhaust camshaft
timing sprocket.
(h). As shown in figure 2, dismantle VVT bolts, and remove
intake camshaft timing sprocket.
(i). Dismantle fixed bolts of camshaft bearing cap, and remove

all camshaft bearing caps.
Attention:
• Remove the fixed bolts of the camshaft bearing cap
pairwise.
• Put the removed camshaft bearing caps in order. Be
careful to distinguish the intake/exhaust camshaft
bearing caps.
(j). Remove intake, exhaust camshafts.
LIFAN AUTO
Attention:
Pay attention to identify intake and exhaust camshafts.
1: Intake camshaft; 2: exhaust camshaft.
2. Installation of camshaft assembly

(a). Install the intake and exhaust camshafts to the cylinder
head.
Attention:
• Uniformly apply a layer of oil on the contact surface of
each camshaft.
• Pay attention to identify intake and exhaust camshafts.
(b). Install camshaft bearing cap onto mounting position, and
tighten fixed bolts of bearing cap.
Torque of fixed bolts of No.1 camshaft bearing cap: 23N•m
Other toque: 13 N•m
Attention:
• As shown in figure, pay attention to identify the
sequence of intake, exhaust camshaft bearing cap , and
do not mixedly install them. 1 is intake side (mark letter
is I); 2 is exhaust side (mark letter is E).
• Tighten fixed bolts of camshaft bearing cap in pair.
• After tightening the bolts of the camshaft bearing caps,
make sure that the camshafts cam rotate smoothly. No
seizure is permitted.
LIFAN AUTO
(c). As shown in figure 1, install exhaust camshaft timing

sprocket, and tighten fixed bolts of chain wheel.
Torque: 54 N•m
(d). As shown in figure 2, install intake camshaft timing
sprocket, and tighten VVT bolts.
11
Torque: 60 N•m
(e). Install timing sprocket mechanism.
(f). Install cylinder head cover assembly and tighten fixed bolts.
Torque: 11N•m
(g). As shown in figure 1, install PCV valve hose, and tighten

hose clamp.
(h). As shown in figure 2, install vent hose.
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(i). Use socket or extending rod to install each spark plug.

Torque: 40N•m
(j). Install each ignition coil in order and tighten bolts.

Torque: 11N•m
Attention:
LIFAN AUTO
Cylinder head
Components diagram
11
1 Cylinder head fixed bolts 2 Cylinder head assembly
LIFAN AUTO
Check
1. Cleaning of cylinder head
(a). Clean the sealant and oil on the cylinder head.
(b). Clean the carbon deposits inside the cylinder head
combustion chamber.
Attention:
Don't use any sharp tool to scrape the carbon deposited. When
removing the carbon, be careful not to scrape or damage the
metal surface.
(c). Use the high-pressure water jets to clean the cylinder head.
△ Hint:
It is mainly related to water pipe and oil pipe.
(d). Dy the cylinder head with high-pressure air.
Attention:
With the high-pressure air, be sure to wear goggles and
protective masks to prevent the flying debris or dirt from
causing personal injuries.
2. Inspection of cylinder head cluster

(a). Check the cylinder head fixed bolts for damage. If so,
replace them.
(b). Check the cylinder block matching surface and the intake
and exhaust sides for flatness with the ruler and feeler
gauge. If the flatness exceeds the maximum value, replace
the cylinder head.
Cylinder block joint surface
Intake side:0.10mm
Exhaust side:0.10mm
LIFAN AUTO
Replace
1. Remove the cylinder head
11
Attention:
Do not damage the insulation section of ignition coil.
While dismantling, mark the cylinder of ignition coil to
(c). As shown in figure 1. Dismantle fixed clamp of PCV valve

(e). As shown in figure 3, disconnect canister solenoid hose.
LIFAN AUTO
(f). Remove canister electromagnetic valve.
(c). Remove the fuel rail fixed bolts, and then remove the fuel
rail.
(h). Dismantle intake manifold assembly.
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(i). Dismantle exhaust manifold assembly.
11
(j). Dismantle cylinder head cover assembly.
(k). Dismantle timing sprocket mechanism.

(l). Dismantle intake camshaft with chain wheel assembly
(m). Dismantle exhaust camshaft with chain wheel assembly
LIFAN AUTO
(n). Dismantle fixed bolts of cylinder head to remove cylinder

head and its pad.
△ Hint:
The dismantled bolts should be placed together, to avoid missing.
(o). Remove the valve cluster.
Attention:
While dismantling cylinder head bolts, unscrew and dismantle
cylinder head bolts in order shown in figure.
2. Install the cylinder hood assembly.

(a). Install the valve cluster.
(b). Install cylinder head pad onto the cylinder block.
Attention:
Pay attention to replace with new cylinder head pad;
meanwhile pay attention to the face and back sides, to ensure
correct installation.
(c). Install cylinder head onto engine cylinder block, and install
and tighten fixed bolts of cylinder head.
Torque: first time 49N•m
Second time 90N•m
LIFAN AUTO
Attention:
• Coat a proper amount of clean oil onto the threads of
the cylinder-head fixed bolts.
• When tightening cylinder head bolts, tighten twice
according to the order shown in figure.
11
(d). Install intake and exhaust camshaft with timing sprocket

assembly.
(e). Install timing sprocket mechanism.
(f). Install cylinder head cover assembly and tighten fixed bolts.
Torque: 11N•m
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(g). Install exhaust manifold assembly.

fixed bolts of upper heat insulator
Torque : 18 N•m
Exhaust manifold fixed bolts
Torque: 37 N•m
(h). Install intake manifold with throttle assembly onto the

cylinder head.
Torque: 30 N•m
(i). Install fuel raid onto the cylinder head.

Torque: 11N•m
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(j). Install canister control valve.
11
(k). As shown in figure 1, install PCV valve hose and tighten

fixed clamp of hose.
(i). As shown in figure 2, install vent hose.
(m). As shown in figure 3, install canister solenoid hose.
(n) Use socket and extending rod to install each spark plug.
Torque: 40N•m
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(o). Install each ignition coil in order and tighten bolts.

Torque: 11N•m
Attention:
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Valve
Components diagram
11
1 Valve lock clamp 5 Valve spring
2 Valve upper seat 6 Exhaust valve
3 Exhaust valve oil seal 7 Intake valve oil seal
4 Valve guide 8 Intake valve
LIFAN AUTO
Check
1. Inspection and adjustment of valve clearance
(a). Check valve clearance.
• Adjust the No.1 cylinder piston to the top dead center
position of the compression stroke.
△ Hint:
Rotate the crankshaft pulley, and align its timing mark to the "5"
mark on the pulley cover.
• Measure valve clearance of 1, 3, 5, 6 valves (8) with a

feeler gauge and record them.
• Rotate crankshaft to 360°, and use feeler gauge to check
the clearance of the rest valves; record the results.
Standard clearance of intake valve (cooling): 0.20~0.25mm
Standard clearance of exhaust valve (cooling): 0.30~0.35mm
△ Hint:
If the valve clearance is inconsistent with the standard value, you
can replace the tappet of the valve head to make its valve clearance
reach the standard value. For adjusting method, see Step (b).
(b). Adjust valve clearance.

• Remove the camshaft.
• Take out the tappet to be replaced.
• Measure tappet top end thickness with a screw
micrometer.
• Calculate new tappet top end thickness.
Calculation method:
New mechanical tappet top end thickness = measured clearance
value – standard clearance value + replaced tappet top end
thickness
△ Hint:
Rotate the crankshaft pulley, and align its timing mark to the "5"
mark on the pulley cover.
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2. Inspection of valve cluster

(a). Inspect whether valve keeper has cracks or damage, If any,
replace it.
11
(b). Measure free length of valve spring with a dial caliper.

If it does not conform to the specification, replace it. the
specification, replace it.
Free length: 43.40mm
(c). Measure spring force at standard compression length with

a spring–loaded thrust meter. If it does not conform to the
specification, replace it.
Installation elasticity: 153~169N(33.88mm)
Maximum working elasticity: 335.3~370.7N(24.1mm)
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(d). Use an angle square to inspect the verticality of each spring

according to the clearance between the end of valve spring
and angle square. If the value exceeds specified value,
replace it.
Maximum deviation:1.6mm
Maximum deviation angle: 2°
(e). Clean all carbon deposit on the value. Check if working

surface and valve stem of each valve are worn, burnt or
deformed. If they are, repair them. If necessary, replace the
valve.
(f). Measure valve edge thickness with a try square. If measured

value is less than the minimum value, replace the valve.
Standard thickness: 1.0mm
Minimal thickness: 0.7mm
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(g). Measure valve length with a dial caliper. If it does not

conform to the specification, replace it.
Standard length
Intake valve: 88.65mm Exhaust valve: 88.69mm
Minimum length 11
Intake valve: 88.35mm Exhaust valve: 88.39mm
(h). Measure valve stem diameter with a micrometer. If it does

not conform to the specification, replace it.
Intake: 5.470 ~ 5.485mm
Exhaust Valve: 5.465 ~ 5.480mm
(i). Check the width of valve-seat contact.

△ Hint:
• Apply a layer of blotting membrane on valve seat and then
install the valve on cylinder head.
• Rotate the valve 1/4 turns several times with the valve
grinding tool, and then remove the valve.
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Attention:
• The imprint on valve fitting surface of the valve shall be
continuously annular, and the annular imprint width
shall be within specified range.If the imprint between
valve seat and valve is not uniform or imprint width is
not within specified range, it is necessary to regrind or
cut again, grind or polish the valve seat.Intake valve seat
width: 1.0~1.4mm
• Intake valve seat: use valve seat reamer to repair it

twice. Two reamers shall be used for repairing: the
first reamer forms 15° and the second forms 45°. At the
second time, it is necessary to repair valve seat width
required.
Intake valve seat width: 1.0~1.4mm
• Exhaust valve seat: repairing procedure is the same as

that of intake valve.
Exhaust valve seat width: 1.0~1.4mm
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(j). Grind the valve.

△ Hint:
First apply coarse grinding paste on the surface of valve seat, and
use grinding tool to grind the valve. And apply fine grinding paste
to grind, until the contact surface between valve and valve seat is
more than 75%. 11
(k). After grinding, completely clean valve and valve seat.
(l). Measure the valve guide inner diameter with the internal
micrometer.
Valve guide inner diameter: 5.510 ~ 5.530mm
(m). Inner diameter of valve guide pipe minus diameter of
valve rod gets the clearance of valve guide pipe. If the oil
clearance is more than the maximum value, replace the
valve and the guide.
Standard oil film clearance:
Intake: 0.025 ~ 0.060mm
Exhaust valve: 0.030 ~ 0.065mm
Maximum oil film clearance:
Intake: 0.08mm
Exhaust Valve: 0.10mm
(n). Measure the inner diameter of the valve guide mounting

hole with the internal micrometer.
Inner diameter: 10.285~10.306mm
△ Hint:
If inner diameter of mounting hole of guide pipe is more than
maximum value, the guide pipe of cylinder head should be
processed to be 10.335~10.350mm, to facilitate installation of
larger valve guide pipe (as shown below).
Inner diameter of valve guide

Diameter of valve guide pipe hole (mm)
STD 10.285~10.306
O/S0.05 10.335-10.356
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(o). Check the thickness of top section of mechanical tappet. If

it is not a standard value, replace it.
Standard value: 5.055 ~ 6.005mm
Replace
1. Removal of valve cluster
Attention:
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(e). As shown in Fig. 3, disconnect canister solenoid hose.
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(f). Take down canister control valve.
(g). Remove the fuel rail fixed bolts, and then remove the fuel
rail.
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(h). Dismantle intake manifold assembly.
(i). Dismantle exhaust manifold assembly.
(j). Dismantle fixed bolts of cylinder head cover, and remove

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(k). Dismantle timing sprocket mechanism.

(l). Dismantle intake camshaft with chain wheel assembly
(m). Dismantle exhaust camshaft with chain wheel assembly
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(n). Dismantle mechanical column and cylinder head assembly.
(o). Remove the valve keeper.

(p). Remove the valve, valve spring retainer, valve spring and
valve oil seal in turn.
Attention:
• The intake valve oil seal is gray and the exhaust valve oil
seal is black.
• Once the oil seal has been removed, don't reuse it any
longer. Be sure to use a new oil seal when installing.
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(q). Heat the cylinder head to 80~100°C.
(r). Put the cylinder head onto the wooden plate, and use special
tool to take out valve guide pipe of cylinder head.
Attention:
• Once the valve guide has been removed, don't reuse it
any longer.
• The interference fit between the valve guide and the
cylinder head is applied, so a valve guide with a enlarged
size will be required when installing the new valve guide.
2. Install valve cluster

(a). Heat the cylinder head to 80~100°C.
(b). Remove the cylinder head and put it on the wood block.
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(c). Ream the valve guide hole with the special tool (11mm
reamer) to remove the burrs before installing the valve
guide in the cylinder head.
(d). Using the special tool, press the new valve guide in the
valve guide hole with the specified pressing-in capacity
until the special tool contacts the cylinder head. 11
Specified pressing-in capacity: 8.7 ± 9.1mm
(e). Use special tool (5.5mm reamer) to cut valve guide pipe
hole to the specified clearance.
Standard oil film clearance:
Intake: 0.025 ~ 0.060mm
Exhaust valve: 0.030 ~ 0.065mm
(f). Install the valve, the valve spring, the valve oil seal and the
valve upper seat in turn.
(g). Install the valve collet with the special tool.
Attention:
• The intake valve oil seal is gray and the exhaust valve oil
seal is black.
• Once the oil seal has been removed, don't reuse it any
longer. Be sure to use a new oil seal when installing.
• It is forbidden to tap or strike the special tool with the
hammer or other object when installing the valve collet.
Install the oil seal to the valve guide just by pressing
the special tool by hand gently. Tapping or striking the
special tool can cause damage to the oil seal.
(h). Install mechanical column and cylinder head assembly.
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(i). Install intake camshaft with timing sprocket assembly.

(j). Install exhaust camshaft with timing sprocket assembly.
(k). Install timing sprocket mechanism.
(i). Install cylinder head cover assembly and tighten all fixed
bolts.
Torque: 11N•m
(m). Install exhaust manifold assembly.

Torque : 18 N•m
Torque: 37 N•m
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(n). Install intake manifold with throttle assembly onto the

cylinder head, and tighten fixed bolts.
Torque: 30 N•m
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(o). Install fuel guide rail onto the cylinder head, and tighten
fixed bolts of fuel guide rail.
Torque: 11N•m
(p). Install canister solenoid.
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(q). As shown in figure 1, install PCV valve hose and tighten

(r) As shown in figure 2, install vent hose.
(s). As shown in figure 3, install hose of canister solenoid.
(t). Use socket and extending rod to install each spark plug.
Torque: 40N•m
(u). Install each ignition coil in order, and tighten bolts.

Torque: 11N•m
Attention:
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Piston connecting rod

Components diagram
11
1 Piston ring I 7 Connecting rod
2 Piston ring II 8 Connecting-rod bearing bush(upper)
3 Combined oil ring 9 Connecting-rod bearing bush(lower)
4 Piston 10 Connecting-rod cover
5 Retainer of piston pin 11 Connecting rod bolts
6 Piston pin
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Check
1. Visual check for connecting rod assembly
(a). Check if connecting rod and connecting rod cap are scored,
cracked, burred, scratched or worn.
Attention:
If there is any obvious abrasion on any position of connecting
rod or connecting rod cover, they must be replaced as a
complete assembly.
(b). Check if connecting rod bearing bush and piston pin are
cracked, scored or damaged. If necessary, replace it.
(c). Check if piston skirt, pin hole, top and piston ring slot is
damaged and worn. If necessary, replace them.
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2. Check axial clearance of piston rod

(a). As shown in the Fig., use a feeler gauge to measure axial
clearance of piston rod. If the axial clearance is more than
the maximum value, replace the connecting-rod group.
Standard axial clearance: 0.16~0.34mm
11
Maximum axial clearance: 0.34mm
3. Check connecting rod oil clearance

(a). Remove the fixed bolts of the connecting-rod cover, and
then remove the connecting-rod cover with bearing bush
assembly.
(b). A section of plastic oil clearance gauge goes through
crankshaft connecting rod journal.
(c). Install connecting rod cap and tighten fixed bolts.
Torque: 50 N•m
(d). Remove the fixed bolts of the connecting-rod cover, and

then remove the connecting-rod cover with bearing bush
assembly.
(e). Measure the plastic oil film clearance at the widest position.
If the oil film clearance is more than the maximum value,
replace the bearing bush. If necessary, grind or replace
crankshaft.
Standard oil film clearance: 0.030 ~ 0.054mm
Maximum oil clearance: 0.08mm
(f). Remove all plastic oil film gauges.
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4. Check piston diameter

(a). At the 25.6mm position from the top of piston, use a screw
micrometer to check piston diameter which is vertical to
center line of piston pin.
Standard value of piston diameter: 78.925~78.935mm
5. Check piston oil clearance

(a). Measure the diameter of the cylinder bore at the A, B and C
positions with the cylinder bore gauge.
Standard diameter: 79.00 ~ 79.13mm
△ Hint:
Measure once along the axial direction and the thrust direction at
each position, respectively.
(b). Calculate the difference between the maximum and the
minimum of the six measured values.
Maximum difference: 0.10mm
Attention:
If it exceeds maximum value, replace upper block of the
cylinder.
(c). Subtract the measured value of the piston from the
measured value of the inner diameter of the cylinder bore
to get the piston oil film clearance. If the piston oil film
clearance is more than the maximum value, be sure to
replace all the four pistons, and re-bore the four cylinder-
bores. If necessary, replace the cylinder block.
6. Check piston pin oil clearance
(a). Measure piston pin mounting hole diameter with an inside
micrometer.
Piston pin hole diameter: 20.006~20.015mm
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(b). Measure piston pin excircle diameter with a screw

micrometer.
Piston pin excircle diameter: 20.004~20.013mm
(c). Piston pin mounting hole minus piston pin excircle diameter
is equal to piston pin oil film clearance. If oil film clearance
is larger than the maximum value, replace the piston pin. If 11
necessary, replace the piston.
(d). Measure inner diameter of connecting rod small end hole

with an inside micrometer.
Inner diameter of connecting rod small end hole:
20.012~20.021mm
(e). Subtract the outer diameter of the piston pin from the inner
diameter of the connecting-rod small end to the piston pin
oil film clearance. If the oil film clearance is more than the
maximum value, replace the connecting-rod. If necessary,
replace the piston and connecting-rod.
7. Check piston ring slot gap

(a). Measure the gap between piston ring and wall with a feeler
gauge. If the gap exceeds the maximum value, replace the
piston.
Groove clearance:
The first compression ring groove: 0.03~0.08mm
The second compression ring groove: 0.03~0.07mm
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8. Check piston ring gap

(a). Insert piston ring into cylinder hole.
(b). As shown in figure, use piston to push piston ring into
cylinder hole, to make it slightly exceeds the bottom of
stroke.
(c). Measure piston ring gap with a feeler gauge. If the gap is
larger than the maximum value, replace piston ring.
Standard piston ring gap
The first compression ring: 0.20~0.35mm
The second compression ring: 0.40~0.55mm
Film loop: 0.20~0.70mm
Maximum piston ring gap
The first compression ring: 1.05mm
The second compression ring: 1.20mm
Piece ring: 1.10mm
Attention:
Attention: If a new piston ring is used and then piston ring gap
is still larger than the maximum value, it is necessary to bore 4
cylinders again or replace cylinder block.
9. Check connecting rod
(a). As shown in figure, use connecting rod collimator and
feeler gauge to inspect the curvature of connecting rod. If
the curvature exceeds maximum value, replace connecting
rod components.
Maximum bending: 0.05mm (per 100mm)
(b). As shown in figure, use connecting rod collimator and

feeler gauge to inspect the curvature of connecting rod.If
the curvature exceeds maximum value, replace connecting
rod components.
Maximum torsion resistance: 0.05mm (per 100mm)
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10. Inspection of connecting-rod bolt diameter

(a). Measure the outer diameter of the connecting-rod bolt
with the dial caliper. If the outer diameter is less than
the minimum value, be sure to replace the whole set of
connecting-rod bolt and nut.
Standard outer diameter:7.30~7.40mm 11
Minimum outer diameter: 7.20mm
Replace
1. Dismantle ignition coil and spark plug.
Attention:
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2. Dismantle vent hose and solenoid valve

(a). As shown in figure 1. Dismantle fixed clamp of PCV valve
(b). As shown in figure 2, disconnect vent hose.
(c). As shown in figure 3, disconnect canister solenoid hose.
(d). Remove canister solenoid.
3. Dismantle fuel guide rail.

(a). Remove the fuel rail fixed bolts, and then remove the fuel
rail.
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4. Dismantle intake and exhaust manifold.

(a). Dismantle intake manifold assembly.
11
(b). Dismantle exhaust manifold assembly.
5. Removal of cylinder head assembly

(a). Dismantle fixed bolts of cylinder head cover, and remove
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(b). Dismantle timing sprocket mechanism.

(c). Dismantle intake camshaft with chain wheel assembly
(d). Dismantle exhaust camshaft with chain wheel assembly
(e). Dismantle cylinder head assembly.
6. Dismantle oil pan and oil strainer.

(a). Dismantle fixed bolts of oil pan, and use oil pan detacher to
remove oil pan.
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(b). Remove the fixed bolts of the oil stainer, and then remove
the oil stainer.
11
7. Dismantle piston and connecting rod assembly.

(a). Dismantle drain bolt, and tilt cylinder head to completely
drain coolant.
(b). Rotate crankshaft, to make No.1 and No.4 cylinder in

lowest point (it means No.1 and No.4 connecting rod cover
exposes vertically).
(c). Dismantle fixed bolts of connecting rod cover, and remove
connecting rod cover and bearing bush.
(d). Use the same method to dismantle other connecting rod
covers and bearing bushes.
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(e). Clean all carbon deposited on the top of cylinder.
(f). Push out the piston assembly.

Attention:
To avoid damage to the connecting-rod end face, be sure to use
wooden or rubber object instead of metallic object to push out
the piston assembly.
(g). Remove the piston assembly from the other side.
Attention:
Place the piston and connecting-rod cluster in the correct
sequence. Keep in mind not to mix them.
8. Dismantling of piston and connecting-rod assembly

(a). Using the piston ring expande, remove the top ring, second
ring and the combined oil ring.
Attention:
Put the piston rings and the combined oil ring in the correct
order, and make marks on the them.
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(b). Remove the two piston pin circlips with the snap-ring
caliper.
11
(c). Drive out the piston pin with the punch bar.
9. Reassembly of piston and connecting-rod assembly

(a). Use circlip pliers to install snap ring of piston pin onto one
end of piston pin hole.
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Attention:
As shown in figure, make sure that the end 1 of snap ring of
piston pin is located at opening 2 of piston pin hole.
(b). Apply a layer of clean oil uniformly on piston pin.

(c). Align the small end of connecting rod to piston pin hole,
and insert piston pin into pin hole.
Attention:
• After installation, rotate the piston pin. Make sure that
the piston pin is free to rotate.
• When installing, be careful to align the forward marks

of the piston and the connecting-rod.
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(d). Use circlip pliers to install the other end of snap ring of
piston pin hole.
Attention:
Make sure that the end of snap ring of piston pin is located at
the opening of piston pin hole.
11
(d). Using the clean oil, lubricate the piston ring and the piston
skirt.
(f). Use piston ring expander to install the first and second
compression ring and combined oil ring.
Attention:
Install the piston rings and the combined ring properly
according to the marks made at the time of removal.
10. Installation of piston and connecting-rod assembly

(a). Install the upper bush of the connecting-rod bearing.
Attention:
• Make sure that the connecting-rod and the connecting-
rod bearing bush back are clean without any debris.
• It is forbidden to lubricate the bearing bush back.
• When installing, make sure that the positioning tongue
of the bearing bush is in alignment with the positioning
groove on the connecting-rod.
△ Hint:
Drop clean oil onto the inside of the connecting-rod bearing
bushes.
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(b). As shown in the left figure, rotate and adjust the position of
the piston ring joint.
Attention:
Each piston ring joint is not permitted to align to the piston pin
or other piston ring joint. Otherwise, the sealing efficiency of
the piston ring cannot be achieved.
(c). Compress the piston ring to its working position with the
piston ring compressor.
△ Hint:
If there is no special tools, you can make a ring barrel with sheet
iron by yourself.
(d). Rotate crankshaft, to make the installed connecting rod

journal locate at the lower limit point.
(e). Use piston installation tool and wooden bar to push piston
assembly into each cylinder.
△ Hint:
Before installation, coat a thin layer of clean oil onto the cylinder
wall.
Attention:
Be sure to push the piston assembly with wooden or rubber
material instead of metallic material.
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Attention:
• As shown in figure, make the forward mark of piston
towards forward.
• While installing and dismantling, follow the mark to
install piston, and do not install them wrongly.
11
(f). Install the lower bush of the connecting-rod bearing in the

connecting-rod end cap.
Attention:
• Make sure that the connecting-rod end cap and the
connecting-rod bearing bush back are clean without any
debris.
• It is forbidden to lubricate the bearing bush back.
• When installing, make sure that the positioning tongue
of the bearing bush is in alignment with the positioning
groove on the connecting-rod end cap.
(g). Use clean lubricating oil to lubricate the inside of lower
bush of connecting rod bearing bush.
(h). Install the connecting-rod end cap and tighten its fixed
bolts.
Torque: 50 N•m
Attention:
Make sure to install the connecting-rod cap in place to make its
positioning groove align the connecting-rod positioning pin.
(i). Install other connecting-rod end caps in the same manner.
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(j). Install drain bolts and tighten them.

Torque: 23N•m
11. Install oil strainer and oil pan.

(a). Install oil strainer onto the cylinder block, and tighten fixed
bolts of oil strainer.
Torque: 25 N•m
(b). Apply a layer of sealant uniformly on the mounting surface

of oil pan.
Attention:
Before applying new sealant, make sure that old sealant
deposited on cylinder block and oil pan is cleaned out totally.
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(c). Install oil pan onto the cylinder block, and tighten fixed bolts
of oil pan.
Torque: 10 N•m
△ Hint:
When installing the fixed bolts, be sure to coat clean oil onto the bolt 11
threads.
Attention:
When tightening the bolts, be sure to start tightening the bolts in
the middle and then work to both sides.

(a). Install cylinder head cover assembly onto the cylinder block.
(b). Install intake, exhaust camshaft with timing sprocket

assembly.
(c). Install timing sprocket mechanism.
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(d). Install cylinder head cover assembly and tighten all fixed
bolts.
Torque: 11N•m
13. Install intake and exhaust manifold.

(a). Install exhaust manifold assembly.
Torque : 18 N•m
Torque: 37 N•m
(b). Install intake manifold with throttle assembly onto the

Torque: 30 N•m
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14. Install fuel guide rail.

(a). Install fuel guide rail onto the cylinder head, and tighten
Torque: 11N•m
11
15. Install canister solenoid and vent hole.

(a). Install canister solenoid.
(b). As shown in figure 1, install hose of PCV valve, and tighten

hoseclamp.
(c). As shown in figure 2, install vent hole.
(d). As shown in figure 3, install canister solenoid hose.
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16. Install spark plug and ignition coil.

(a). Use socket or extending rod to install each spark plug.
Torque: 40N•m
(b). Install each ignition coil in order and tighten bolts.

Torque: 11N•m
Attention:
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Crankshaft and flywheel

Components diagram
11
1 Flywheel 4 Thrust plate
2 Crankshaft bearing bush (lower) 5 Crankshaft
3 Crankshaft bearing bush (upper)
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Check
1. Check crankshaft radial runout
(a). Place crankshaft on V block.
(b). Measure radial runout of intermediate journal with a dial
gauge. If radial runout is larger than the maximum value,
replace the crankshaft.
Maximum radial runout: 0.03mm
2. Check the main journal diameter of crankshaft

(a). Using the spiral micrometer, measure each main journal
diameter. If the diameter is inconsistent with the specified
value, check the oil-film clearance. If necessary, grind or
△ Hint:
If the main journal or the connecting-rod journal is inconsistent
with the specified standards, be sure to grind the crankshaft and
connecting-rod journal. According to the grinding situations, select
the thickened bearing bushes with different levels.
3. Inspect ovality of main journal of crankshaft.

(a). As shown in figure, inspect ovality of each main journal, if
it exceeds maximum value, replace crankshaft.
Maximum ovality:0.02mm
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4. Check connecting-rod journal diameter

(a). Using the spiral micrometer, measure each connecting-rod
journal diameter. If the diameter is inconsistent with the
specified value, check the oil-film clearance. If necessary,
grind or replace the crankshaft.
Connecting-rod journal diameter: 43.992~44.000mm 11
5. Inspect ovality of connecting rod journal of crankshaft.

(a). As shown in figure, inspect ovality of connecting rod
journal of crankshaft, if it exceeds maximum value, replace
crankshaft.
Maximum ovality:0.02mm
6. Check crankshaft oil-film clearance

(a). Clean all crankshaft journals and crankshaft bearing bush.
(b). Install the upper bearing of crankshaft onto the upper block
of cylinder, and install crankshaft onto the upper block of
cylinder.
(c). A section of plastic oil clearance gauge goes through main
journal of the crankshaft.
Attention:
Don't rotate the crankshaft.
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(d). Install the lower bearing of crankshaft onto the lower block
of cylinder.
(e). Install the lower block of cylinder onto the upper block of
cylinder, and tighten 10 fixed bolts of main bearing cap
Torque: First 40 N•m
Second 60 N•m
△ Hint:
Tighten the fixed bolts of the main bearing cap twice.
(f). Remove the ten fixed bolts of the main bearing cap based
on the sequence shown in the figure, and then remove the
main bearing cap.
△ Hint:
Unscrew the fixed bolts in multiple times.
(g). Measure the plastic oil-film clearance gauge at the widest

position. If the oil-film clearance is more than the maximum
value, replace the bearing bush. If necessary, grind or
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7. Inspection of fixed bolts of cylinder block main bearing

cap
(a). Using the dial caliper, measure the outer diameter of the
fixing bolt of the cylinder block main bearing cap. If the
outer diameter is less than the minimum value, replace the
whole set of the fixed bolts. 11
Standard outer diameter: 8.80mm~9.00mm
Minimum outer diameter: 8.70mm
8. Visual inspection of flywheel

(a). Check the flywheel working surface for worn groove or
worn ring gear, if any, repair it. If necessary, replace the
flywheel.
(b). Check the flywheel teeth for wear or clash, if any, repair it.
If necessary, replace the flywheel.
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Replace
1. Dismantle ignition coil and spark plug.
Attention:
2. Dismantle vent hose and canister solenoid.

(a). As shown in figure 1, dismantle fixed clamp of PCV valve
(b). As shown in figure 2, disconnect vent hose.
(c). As shown in figure 3, disconnect canister solenoid hose.
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(d). Remove canister solenoid.
11
3. Dismantle fuel guide rail.

(a). Remove the fuel rail fixed bolts, and then remove the fuel
rail.
4. Dismantle intake and exhaust manifold.

(a). Dismantle intake manifold assembly.
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(b). Dismantle exhaust manifold assembly.
5. Removal of cylinder head assembly

(a). Dismantle fixed bolts of cylinder head cover, and remove
(b). Dismantle timing sprocket mechanism.

(c). Dismantle intake, exhaust camshaft with chain wheel
assembly
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(d). Dismantle cylinder head assembly.
11
6. Dismantle oil filter assembly.

(a). Use a special tool to dismantle the oil filter.
7. Dismantle oil pan and oil strainer.

(a). Dismantle fixed bolts of oil pan, and use oil pan detacher to
remove oil pan.
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(b). Remove the fixed bolts of the oil stainer, and then remove
the oil stainer.
8. Dismantle piston and connecting rod assembly.

(a). Dismantle drain bolt, and tilt cylinder head to completely
drain coolant.
△ Hint:
After all coolant in cylinder is drained out, immediately install
drain bolt onto the cylinder block.
(b). Dismantle pistons and connecting rod assembly of each

cylinder.
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9. Dismantle flywheel assembly

(a). Dismantle fixed bolts of flywheel assy, and remove flywheel
assembly
△ Hint:
While dismantling flywheel assy, to avoid rotation of flywheel, it 11
is necessary to firstly fix the flywheel, or use rubber material or
wooden tool to fix crankshaft.
10. Dismantle crankshaft assembly.

(a). Use a "flat-blade" screwdriver or equivalent to dismantle
rear oil seal of crankshaft.
Attention:
Don't reuse the removed oil seal. Be sure to replace it with a
new one when re-installing.
(b). Dismantle fixed bolts of main bearing cap of cylinder head

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(c). Dismantle fixed bolts of upper and lower blocks of cylinder

Attention:
Do not forget to dismantle connecting nuts of oil filter (as
shown in figure 2).
(d). Remove lower block of cylinder.

△ Hint:
Use rubber hammer to slightly strike the lower block of cylinder to
facilitate removing it.
(e). Remove lower bearing of crankshaft from lower block
assembly of cylinder.
Attention:
Follow the sequence to lay the lower bearing of crankshaft to
(f). Remove crankshaft assembly.

(g). Remove upper bearing of crankshaft and 2 thrust plates of
crankshaft from the upper block of cylinder.
Attention:
Follow the sequence to lay the upper bearing of crankshaft to
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11. Installation of crankshaft and flywheel

(a). Use compressed air to blow foreign matters inside upper
and lower blocks of cylinder, coolant and oil.
Attention:
When using compressed air, please wear protective glass or 11
mask, to avoid personal injury.
(b). Install upper bearing of crankshaft onto the upper block of
cylinder.
Attention:
• Follow the laid sequence in dismantling to install them.
• Make sure the back side of bearing bush is clean and
without any scrap. Do not use oil to lubricate the back
side of bearing bush.
• While installing, make sure the position tone of bearing
bush align with positioning tone groove of cylinder
block.
(c). Install 2thrust plates of crankshaft onto the upper block of

cylinder.
Attention:
As shown in figure, make sure that the thrust plates go towards
oil groove and thrust plates are correctly installed.
(d). Install crankshaft assembly.
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(e). Install the lower bearing of crankshaft onto the lower block
of cylinder.
Attention:
• Follow the laid sequence in dismantling to install them.
• Make sure the back side of bearing bush is clean and
without any scrap. Do not use oil to lubricate the back
side of bearing bush.
• While installing, make sure the position tone of bearing
bush align with positioning tone groove of cylinder
block.
(f). Apply a layer of sealant on the mounting surface of lower

block of cylinder.
Attention:
• Before applying new sealant, make sure that old sealant
deposited on cylinder block is cleaned out totally.
• Install lower block assembly of cylinder within 3min
after applying sealant.
(g). Install lower block of cylinder, and tighten 10 fixed bolts of

main bearing cap according to the order shown in figure.
Torque: First 40 N•m
Second 60 N•m
△ Hint:
Tighten the fixed bolts of the main bearing cap twice.
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(h). Tighten fixed bolts of upper and lower blocks of cylinder

and connecting nuts of oil filter according to the order
shown in figure (as shown in figure 2).
Torque : 18 N•m
Torque of connecting nut of oil filter: 20N• m
11
△ Hint:
When fixed bolts, it is necessary to apply a layer of oil uniformly
on the thread of bolt.
Tighten fixed bolts of cylinder block in twice.
(i). Install the crankshaft rear oil seal with the oil seal installer.
Attention:
Be sure to install the seal vertically. Don't install it inclinedly.
△ Hint:
Before installation, coat a layer of clean oil onto the new oil seal
lip.
12. Install flywheel assembly

(a). Install flywheel assy, and tighten fixed bolts of flywheel.
Torque: 80N•m
Attention:
When installing the flywheel, make the flywheel align the
positioning pins of the crankshaft for installation.
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13. Install piston and connecting rod assembly.

(a). Install pistons and connecting rod assembly of each
cylinder.
Torque: 50 N•m
14. Install oil strainer and oil pan.

(a). Install oil strainer onto the cylinder block, and tighten fixed
bolts of oil strainer.
Torque: 25 N•m
(b). Apply a layer of sealant uniformly on the mounting surface

of oil pan.
Attention:
Before applying new sealant, make sure that old sealant
deposited on cylinder block and oil pan is cleaned out totally.
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(c). Install oil pan onto the cylinder block, and tighten fixed
bolts of oil pan.
Torque: 10 N•m
△ Hint:
When installing the fixed bolts, be sure to coat clean oil onto the 11
bolt threads.
Attention:
When tightening the bolts, be sure to start tightening the bolts
in the middle and then work to both sides.
15. Install oil filter assembly.

(a). Use special tool to install oil filter.
Torque: 25 ~ 30 N•m

(a). Install cylinder head cover assembly onto the cylinder
block.
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(b). Install intake, exhaust camshaft with timing sprocket

assembly.
(c). Install timing sprocket mechanism.
(d). Install cylinder head cover assembly and tighten all fixed
bolts.
Torque: 11N•m
17. Install intake and exhaust manifold.

(a). Install exhaust manifold assembly.
Torque : 18 N•m
Torque: 37 N•m
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(b). Install intake manifold with throttle assembly onto the

Torque: 30 N•m
11
18. Install fuel guide rail.

(a). Install fuel guide rail onto the cylinder head, and tighten
Torque: 11N•m
19. Install canister solenoid and vent hole.

(a). Install canister solenoid.
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(b). As shown in figure, install PCV valve hose (as shown in

figure 1), vent hose (as shown in figure 2), and canister
solenoid hose (as shown in figure 3), and tighten clamps of
each hose.
20. Install spark plug and ignition coil.

(a). Use socket or extending rod to install each spark plug.
Torque: 40N•m
(b). Install each ignition coil in order and tighten bolts.

Torque: 11N•m
Attention:
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Cylinder block
Components diagram
11
1 Lower block of cylinder 2 Upper block of cylinder
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Check
1. Inspect the surface warping of upper block of cylinder.
(a). Clean all gasket materials on the cylinder deck, and clean
the cylinder block thoroughly with soft brush and solvent.
Attention:
When cleaning it with solvent, acid or alkaline materials,
follow the manufacturer's recommendations.
(b). Use a ruler or feeler gauge to check the top plan warping of
cylinder block, if the warping value is more than maximum
value, replace cylinder block.
Maximum warping: 0.05mm
2. Inspection of cylinder bore diameter of upper part of

cylinder block
(a). Measure the diameter of the cylinder bore at the A, B and C
positions with the cylinder bore gauge.
Standard diameter: 79.00~79.13mm
△ Hint:
Measure once along the axial direction and the thrust direction at
each position, respectively.
(b). Calculate the difference between the maximum and the
minimum of the six measured values.
Maximum difference: 0.10mm
Attention:
If it exceeds maximum value, replace upper block of the
cylinder.
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Crankshaft oil seal

Replace
1. Removal of crankshaft front oil seal
11
(a). Dismantle front mask assembly.
(b). Use a “flat-blade” screwdriver to pry front oil seal of
crankshaft.
Attention:
Don't reuse the removed oil seal. Be sure to replace it with a
new one when re-installing.
2. Installation of crankshaft front oil seal

(a). Install the crankshaft front oil seal with the oil seal installer.
△ Hint:
lip.
Attention:
(b). Install the front mask assembly
3. Removal of crankshaft rear oil seal

(a). Dismantle fixed bolts of flywheel assy, and remove flywheel
assembly
△ Hint:
While dismantling flywheel assy, to avoid rotation of flywheel, it is
necessary to first fix the flywheel.
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(b). Use a "flat-blade" screwdriver or equivalent to pry rear oil

seal of crankshaft.
4. Installation of crankshaft rear oil seal

(b). Install the crankshaft rear oil seal with the oil seal installer.
△ Hint:
lip.
Attention:
(b). Install flywheel assy, and tighten fixed bolts of flywheel.

Torque: 80N•m
Attention:
When installing the flywheel, make the flywheel align the
positioning pins of the crankshaft for installation.
LIFAN AUTO
Engine control system
Engine control system................................................ 12-1 P0113- Intake temperature sensor circuit has high
Preparation............................................................. 12-1 voltage or open-circuit......................................... 12-91
Repair specifications.............................................. 12-2 P0117-Coolant temperature sensor circuit has low
voltage.................................................................. 12-95
Precautions............................................................. 12-5
P0118- Coolant temperature sensor circuit has high 12
Electronic control system description.................... 12-7
voltage or open-circuit......................................... 12-95
Component layout................................................ 12-18
P0122-Electric throttle position sensor 1# circuit has
Wiring diagram..................................................... 12-20 low voltage........................................................... 12-99
Terminal definition............................................... 12-27 P0123-Electric throttle position sensor 1# circuit has
Basic check........................................................... 12-33 high voltage.......................................................... 12-99
Troubleshooting........................................................ 12-34 P0222-Electric throttle position sensor 2# circuit has
Diagnosis system description............................... 12-34 low voltage........................................................... 12-99
Fault diagnosis procedure..................................... 12-36 P0223-Electric throttle position sensor 2# circuit has
high voltage.......................................................... 12-99
Fault diagnosis analysis........................................ 12-37
P0031- Front oxygen sensor heater has short-circuit or
DTC reading......................................................... 12-39
low voltage......................................................... 12-104
DTC clearing........................................................ 12-43
P0032- Front oxygen sensor heater has short-circuit or
Read data stream.................................................. 12-45 high voltage........................................................ 12-104
I/O Control functional unit................................... 12-48 P0037- Rear oxygen sensor heater has short-circuit to
Problem symptoms table...................................... 12-50 low voltage......................................................... 12-108
DTC (DTC) list.................................................... 12-52 P0038- Rear oxygen sensor heater has short-circuit to
The diagnostic scanner cannot communicate with high voltage........................................................ 12-108
ECM..................................................................... 12-59 P0131- Front oxygen sensor signal has short-circuit to
Crankshaft rotates, but engine can't be started..... 12-60 low voltage......................................................... 12-112
Idle speed is not stable......................................... 12-64 P0132- Front oxygen sensor signal has short-circuit to
Idle speed is too high............................................ 12-67 high voltage........................................................ 12-112
Poor acceleration and performance...................... 12-69 P0133- Front oxygen sensor has slow response..12-112
Accelerated reaction is slow and unbalanced....... 12-71 P0131- Front oxygen sensor signal has open-circuit.....
12-112
The engine will flame out when starting.............. 12-73
P0137- Rear oxygen sensor has short-circuit to low
Engine will flame out when it runs at idle speed in voltage................................................................ 12-117
cold state............................................................... 12-75
P0138- Rear oxygen sensor has short-circuit to high
P0011- Intake VCP phase lag response................ 12-78 voltage................................................................ 12-117
P0012- Intake VCP camshaft phase has big error.12-78 P0140- Rear oxygen sensor has open-circuit..... 12-117
P0016- Intake VCP camshaft gear study exceeds limit P0261- 1# injector circuit has low voltage fault.12-122
range..................................................................... 12-78
P0262- 1# injector circuit has high voltage fault..... 12-
P0026- Intake VCP hydraulic control valve is held..12- 122
78
P0264- 2# injector circuit has low voltage fault.12-122
P0076 - Intake VCP hydraulic control valve coil has
low voltage or short-circuit.................................. 12-81 P0265- 2# injector circuit has high voltage fault..... 12-
122
P0077 - Intake VCP hydraulic control valve coil has
high voltage.......................................................... 12-81 P0267- 3# injector circuit has low voltage fault.12-122
P0105 - Intake pressure sensor signal is held....... 12-86 P0268- 3# injector circuit has high voltage fault..... 12-
122
P0106 - Reasonable failure of intake pressure/throttle
position................................................................. 12-86 P0270- 4# injector circuit has low voltage fault.12-122
P0107 - Intake pressure sensor circuit has low voltage, P0271- 4# injector circuit has high voltage fault..... 12-
open-circuit........................................................... 12-86 122
P0108 - Intake pressure sensor circuit has high P0324-Knock control system fault..................... 12-127
voltage.................................................................. 12-86 P0325-Knock sensor fault.................................. 12-127
P0112- Intake temperature sensor circuit has low P0335-Crankshaft position sensor circuit has no
voltage.................................................................. 12-91 signal.................................................................. 12-131
LIFAN AUTO
P0336-Crankshaft position sensor wire signal Fuel pump........................................................... 12-196
interference......................................................... 12-131
P0340-Status diagnosis of exhaust/ intake VCP
camshaft position sensor.................................... 12-134
P0341- Intake VCP aim wheel diagnostic fault..12-134
P1336-58 Gear error is unstudied....................... 12-138
P0351- Output fault of ignition coil 1#.............. 12-139
P0458- Canister solenoid output has short-circuit to
low voltage to short-circuit................................ 12-144
P0459-Canister solenoid output has short-circuit to
high voltage........................................................ 12-144
P0230- Fuel pump relay fault............................. 12-148
P0480- Low speed fan fault............................... 12-153
P0481-High speed fan fault................................ 12-153
P0562- System voltage is low............................ 12-157
P0563- System voltage is high........................... 12-157
P2122- Electronic accelerator pedal position sensor 1#
circuit has low voltage........................................ 12-162
circuit has high voltage...................................... 12-162
circuit has low voltage........................................ 12-162
circuit has high voltage...................................... 12-162
P2128- Electronic accelerator pedal position sensor
1#, 2# have relative fault................................... 12-162
Sensor actuator....................................................... 12-167
Electronic control unit(ECM)............................. 12-167
Intake air temperature/pressure sensor............... 12-170
Coolant temperature sensor................................ 12-173
Crankshaft position sensor................................. 12-176
CMP sensor........................................................ 12-178
Oxygen sensor.................................................... 12-180
Knock sensor...................................................... 12-182
Electronically-controlled throttle valve housing.12-184
Intake VVT valve............................................... 12-187
Canister control valve......................................... 12-189
Injector............................................................... 12-192
Ignition coil........................................................ 12-194
LIFAN AUTO
Engine Control System-Engine control system 12-1
Engine control system

Preparation
1. Special tool

12
Read DTC and data

1 Diagnostic scanner
flow of EFI system
For measuring voltage

1 Digital multi-meter
and resistance
2 Wiring set For testing circuits
LIFAN AUTO
12-2 Engine Control System-Engine control system
Intake VVT valve working voltage 11 - 14V
Intake VVT valve resistance 9.4~10.6Ω
Working voltage of intake air temperature/pressure sensor 5V±0.1V
Working current of intake air temperature/pressure sensor 12mA (maximum)
Intake air pressure test range 10kPa~110kPa
Intake air temperature test range -40~125℃
Working voltage of canister control valve 8 - 16V
Minimum canister solenoid starting voltage 7V
Working temperature of canister solenoid -30~120℃
Limit working voltage of canister solenoid 25V( ＜ 60s)
Coil inductance of canister solenoid 12~15mH
Canister solenoid impedance 19~22Ω
Operating temperature of exhaust end of oxygen sensor 200~850℃
Working temperature at oxygen sensor mounting position <600℃
Working temperature at connecting position of oxygen sensor cable

≤ 250℃
and metal buckle
Storage temperature of oxygen sensor -40~100℃
Oxygen sensor heater resistance 9.6±1.5Ω
Working gap of crankshaft position sensor 0.25~1.75mm
Crankshaft position sensor coil resistance 560Ω
Working temperature of crankshaft position sensor -40~150℃
Working voltage of coolant temperature sensor 5V
Limit working temperature of coolant temperature sensor -40~135℃
Response time of coolant temperature sensor temperature 17~27s
Resistance when coolant temperature sensor is 20°C 2.3~2.5kΩ
Effective sealing pressure of coolant temperature sensor 145kPa
Working temperature of camshaft position sensor -40~150℃
Working voltage of camshaft position sensor 4.5 - 13V
Peak voltage of camshaft position sensor 24V(1h)
Working gap of crankshaft position sensor 0.3~2mm
Low electric level output of crankshaft position sensor 0 - 700mV
High electric level output of crankshaft position sensor 3.2 - 5V
Working conditions of electrically-controlled throttle valve housing -40~120℃
Diameter of valve hole of electrically-controlled throttle valve

Φ57mm
housing
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Maximum air flow when the throttle fully open (standard

67g/s
atmospheric pressure)
Minimum bypass air flow when throttle is completely closed 1.7g/s
Opening range of throttle position sensor 7% ～ 93%
Working voltage of throttle position sensor 5±0.1V
Throttle position sensor resistance 1.6~2.4kΩ

12
Knock sensor working temperature –40~150℃
Resistance of knock sensor >1MΩ(25℃ )
Knock sensor capacitance 1480~2220pF@25℃ @1000Hz
Frequency response of knock sensor. 3 - 18kHz
Sensitivity to 5kHz signal of new sensor of knock sensor 17~37mV/g
Fuel pump output pressure >350kPa
Fuel pump output flow >10g/s
Fuel pump safety relief <900kPa
Keeping fuel pump pressure ≈ 24kPa
Fuel pump working voltage 8~16V
Fuel pump overpressure protection -13.5~26(<60s)
Fuel pump fuel-free operation <60s
Resistance value of fuel level sensor. <150Ω
Maximum operating current of fuel level sensor <130mA
Suited temperature of electric fuel pump working conditions –40~70℃
Opening voltage range of electric fuel pump 6~14.2V
Rated current of fuel sensor of electric fuel pump 1~80mA
Fuel pressure range of electric fuel pump 300~350kPa
Working temperature of oil track -30~115℃
Fuel pressure regulator has no fuel return system pressure settings 350kPa
Rated resistance of fuel injector at 20°C 12.0±0.4Ω
LIFAN AUTO
Item N•m
ECM Retaining bolts 20
Fixing bolt of intake air temperature/pressure sensor 21~25
Fixing bolt of coolant temperature sensor 20
Fixing Bolts of Crankshaft Position Sensor 6~10
Fixed bolt of camshaft position sensor 6~10
Oxygen sensor 40~60
Knock sensor 15~25
VVT valve fixed bolt 6~10
LIFAN AUTO
Precautions
1. Regardless of whether the engine is running or not, as long as the ignition switch is turned on (ON), never
disconnect any 12V electrical device. When this device is disconnected, any coil will generate highly transient
voltage due to self-inductance. As a result, ECM and sensor is seriously damaged.
2. When the engine is running, it is not allowed to pull out any sensor wire plug (connector). Otherwise, there is
artificial DTC (false code) in ECM, which will affect judgment and troubleshooting of maintenance staff.
3. If it is required to dismantle earth wire of the battery, it is necessary to turn ignition switch to OFF, and all 12
electric load shall be turned off. After negative earth wire is dismantled for 60s, other electrical equipment can be
maintained.
4. Parts of EFI system have high reliability. When complete vehicle or engine has a fault, first check related
mechanical parts, system connector and wire harness, earth wire, spark plug high voltage wire connector.
5. Before installing, use sealant scraper or steel wire brush to remove sundries on mounting surface and confirm
sealing surface is smooth, without oil stain. Do not forget to remove sealant in assembling hole, in thread hole
and on the thread.
6. When installing the sensor and actuator, tighten fixing bolts according to specified torque.
7. When installing and handling the sensor, in order to protect it from being damaged, it shall be handled with care.
Any impact and falling may damage it seriously.
8. Do not use fine needle to puncture wire harness to check electrical signal of the system.
9. When dismantling and replacing oxygen sensor, the sensor shall not contact water or other liquid.
10. Fuel pump cannot run for a long time without gasoline. It cannot run with gasoline in the air.
11. Most of EFI parts cannot be repairable. After any part is damaged, replace it normally.
12. The system should use anti-interference type spark plugs and high-voltage lines. The non-impedance type spark
plugs and high-voltage lines will not only produce the interference waves, but also have a negative impact on the
ECM ignition coil drive-module.
13. Do not disassemble ECM.
14. Do not use test lamp to check electrical control system sensor and ECM control unit (including wire terminal).
15. Except special instructions in testing procedure, normally a pointer type multimeter is not used to check the
resistance of electrical control system. High resistance digit multimeter (above 10MΩ) or special instrument of
electrical control system shall be used.
16. On the vehicle provided with electronic control system, it is forbidden to use grounding test fire or wire removal
striking fire to check the circuit.
17. When a vehicle equipped with electronic control engine is required to bridge power supply of any other vehicle
for starting, first turn off ignition switch and all electrical loads on electronic control vehicle, then dismantle and
install the jumper.
18. When arc welding is made on the vehicle equipped with electronic control system, ECM power supply shall be
disconnected to avoid ECM from being damaged due to high voltage.
19. When repairing the body near ECM or the sensor, please be careful to avoid these electronic components from
being damaged.
20. When dismantling wire joint of electronic control system, first turn off ignition switch (OFF) and dismantle the
battery negative earth wire. If only checking electronic control system, only turn off ignition switch (OFF).
21. Remember all power supply systems on electronic control vehicle are negative earth. When installing the battery,
positive and negative electrodes of the battery shall not be reversed.
22. When installing or removing the ECM, the operator should make himself ground. Otherwise, his body's static
electricity can cause damage to the ECM circuit.
23. Before dismantling any fuel line, first release fuel system pressure. When repairing fuel line system, please keep
away from open fire.
24. Poor contact may be due to connector terminal corrosion, external dirt intruding into the terminal or contact
LIFAN AUTO
pressure reduction between connector plug and socket. Disconnect the connector and then reconnect it. Normal
contact may be restored. When making fault diagnosis, check if wire harness and connector are abnormal and
confirm they are normal. But, after checking, the fault disappears. It may be wiring or connector fault.
25. When washing or overhauling the engine on a rainy day, water shall be prevented from splashing on ECM and
other circuits.
26. Electronic control system faults are mainly wire harness and connector faults. Normally, wire harness is broken,
connector is poor contact, connector terminal is pulled out or not inserted completely or the accessory is earthing.
27. As wire harness is seldom broken in its middle section and often broken at the connector section in most case, it
is necessary to carefully inspect wire at sensor and connector.
28. Before connecting the V30 diagnostic scanner, be sure to turn off the ignition switch (turn it to OFF). After the
completion of connecting the diagnostic scanner, turn on the ignition switch (turn it to ON).
LIFAN AUTO
Electronic control system description

1. Overview
LIFAN 720 equipped LFB479Q EFI engine adopts Delphi MT22.1 EFI system. It is based on torque and
electronic throttle control. Its features lie in computer loop control, multi-point fuel sequence injection, sequence
ignition and post treatment of three-way catalytic converter.
12
2. System function
The main functions of such system:
S/N Function S/N Function
Calculation of thermodynamics air flow and

1 8 VVT control
temperature of engine gas.
ECM built-in ignition drive mode, no distributor

2 Engine torque output control model 9
type sequence ignition
Main power supply relay control of complete

3 10 Knock control
vehicle
Closed loop control multi-point fuel sequence

4 11 Electric throttle control
injection
5 Control of fuel supply method without fuel return 12 cooling fan relay control
6 Fuel pump working control 13 System self-diagnosis
7 Canister solenoid control 14 Overvoltage protection
3. System function introduction

(a). Starting control.
During starting, adopt a special calculation method to control the charging amount, fuel injection and ignition timing.
At the beginning of starting process, air in intake manifold is static. The pressure in intake manifold is shown as
atmospheric pressure. The throttle valve is closed and the idling regulator appoints a fixed parameter that established
according to the start-up temperature. Before starting the engine, when ignition switch is switched on, ECM will
collect relevant parameters to calculate the percentage of total air flow, and then convert into relevant steps of stepper
motor according to the relation between the percentage of air flow and position of stepper motor. The general trend:
the lower the engine start temperature is, the bigger opening of idle air valve. When the percentage of idle air flow
is calculated to be more than 100%, idle air valve will constantly and fully open. After the completion of start, it is
necessary to adjust relevant position of stepper motor to change the idle air flow and improve idle stability. The fuel
injection amount changes with the engine temperature to promote the film formation of the intake manifold and the
cylinder wall, and therefore, it is necessary to enrich the gas mixture before the engine reaches a certain speed.engine
reaches a certain speed. The ignition angle will be adjusted constantly under the starting conditions. It changes with
engine temperature, intake temperature and rotation speed.
(b). Idle speed control system.
• This system adopts electric throttle to achieve high-accuracy idle speed control and make the actual rotation
speed match with aim idle speed.
• Electric load compensation. When electric load is working of cut, engine rotation speed will fluctuate within
some range due to the sudden increase or reduction of engine load. Electric throttle system can adjust air
volume and/ or advance angle of ignition when engine load increases or decreases, to keep the idle speed in
optimal condition.
• Common electric lead compensation includes: air conditioner compressor compensation, engine cooling fan
compensation, blower compensation, battery voltage compensation, boosting steering compensation, canister solenoid
compensation. Whether above compensation works or not depends on system configuration and function requirement.
(c). Calculation of air flow by thermodynamic model of engine gas.
• ECM calculates air flew into cylinder through intake temperature and pressure sensor, and control fuel supply
volume to make the air-fuel ratio meet the requirements of each working condition.
LIFAN AUTO
(d). Torque control mode.

• The system will estimate output torque and control the power output to engine according to signal of
accelerator pedal position sensor.
(e). Baseline of crankshaft position and rotation check.
• The system will judge crankshaft position and check engine rotation speed according to signal of crankshaft
position sensor, and accurately control ignition and fuel injection timing of engine.
(f). Working sequence determination of each cylinder of engine.
• Camshaft position sensor and gear installed on camshaft work together, and send information of the upper
limit point of cylinder of engine to ECM. ECM will judge working sequence of each cylinder of engine
according to this information.
(g). Fuel control.
• Fuel control mainly has 2 modes: closed loop fuel control and open loop fuel control.
• The adoption of closed loop fuel control can accurately control air-fuel ratio of engine, so as to effectively
control emission. Advantage of closed loop control lies that this system is able to eliminate difference of
system and relevant mechanical parts due to fabrication and abrasion during use, to improve consistency of
complete vehicle and reduce emission.
• Open loop fuel control is applicable to the working condition on which closed fuel control is unsuitable to be
used, such as the situations of engine start fault and oxygen sensor fault, etc.
(h). Control of ignition angle.
• Ignition control type is sequence ignition. which means each cylinder ignites fire according to the sequence of
1-3-4-2.The requirement of sequence ignition control lies that the engine has judged the cylinder sequence,
otherwise it will continue to group ignition mode until the engine judges cylinder sequence.
• Under idle speed working condition, ignition angle will conduct closed loop control to control speed rotation
in stable way.
(i). Fuel injection system without fuel return.
• The system adopts multi-point sequence injection without fuel return. Each engine circulation conducts accurate
fuel supply through main pulse width and repair pulse width. It has closed loop control and self-study function.
(j). Control of ignition energy.
• This system supports sequence ignition; the system adopts "fast magnetic recharging and fast release" logic,
which can accurately control magnetic recharging and release time of ignition coil.
(k). Knock control.
• The system detects characteristic vibration produced during knocking through the knock sensor installed on
proper engine position, and change it into signal, so as to input ECM for processing.
• When knock sensor detects that there is a knock, the system will calculate advanced angle of ignition to be
delayed according to information of current working condition, knock strength, and delay the advanced angle
of ignition, so as to avoid or reduce knock.
• Knock control system can independently control ignition timing of each cylinder of engine.
(l). Evaporation emission pollution control.
• The system can control cleaning rate of active canister according to engine working condition.
(m). VVT control.
• VVT control system uses VVT actuator to change the relative position between intake camshaft and crankshaft.
Engine management system will calculate optimal VVT and action of VVT valve according to engine rotation
working condition, to change flow and direction of oil pressure entered into VVT actuator, and finally push the
camshaft to move to the ideal position.
(n). Overvoltage protection.
• When recharging system has fault which causes overvoltage, the system will enters protection condition and
limit engine rotation speed, to avoid damage of ECM.
(o). Air conditioner compressor control.
LIFAN AUTO
• When air conditioner switch is turned on, the system will receive signal of air conditioner request, and make
preparation for adding load for air conditioner according to current engine working condition, and then switch
on air conditioner compressor. The system will control the switching on or switching off of air conditioner
according to the protection requirements of air conditioner. In order to ensure power take-off and protect the
engine, the system will cut off air conditioner under some special conditions.
(p). Three-way catalytic converter.
• The function of three-way catalyst is to convert harmful gas from engine combustion into harmless gas and
then discharge into the atmosphere.
12
• Internal structure of three-way catalyst is designed to be cellular pipe. Palladium, rhodium and platinum coatings on
cellular pipeline wall are used as catalytic reaction agent. Three-way catalyst may make the engine lose 3%~ 5% power.
(q) Overheat protection function of three-way catalytic converter system.
• The system predicts engine exhaust temperature increase trend according to actual working conditions of the engine, and
adopts control method of air-fuel ratio in time to reduce engine combustion temperature and protect three-way catalyst.
(r). Cooling fan relay control.
• The vehicle is equipped with the electric dual-speed engine cooling fan.
• Electric fan control function: ECM will determine whether or not to turn on each fan to reduce the engine's
internal power consumption based on the engine coolant temperature and whether to turn on the air
conditioning and other conditions.
(s). System self-diagnosis.
• Self-diagnosis of system fault is an essential function of engine control system. When one or several parts
work abnormally, the system will remind the user of necessary check and maintenance by lighting fault
indicator lamp. When a fault occurs, the system can adopt emergent plan to control the engine so as to ensure
the driver can drive it to service station.
• When one sensor and actuator are detected to be abnormal, engine fault indicator lamp is lit to remind the driver.
• When one sensor and actuator are detected to be abnormal, corresponding DTC will be output.
• Read RAM data related to sensor and actuator in ECM by fault diagnostic scanner. In addition, in some case,
the actuator can be driven forcedly.
4. Basic principle
① Start control principle.
(a). Turn ignition switch to "ON" position, and fuel pump will run for 2s and then stop.
(b). Engine begins to run. After ECM detects two effective 58X signals, fuel pump begins to run.
(c). In 0.6s after the disappearance of rotation speed signal, fuel pump will stop running.
(d). Pre-injection:
Pre-inject only once during the course of normal starting (if fuel is absorbed by carbon deposit, gas mixture
becomes thinner and it is not easy to start).
Condition to start pre-injection is as follows:
(1). Engine begins to rotate (at least ECM will detect effective signal of 58 gears).
(2). Fuel pump relay is in actuation.
(3). Fuel pump running time exceeds voltage delay time.
(4). No pre-injection is started before.
(5). Once above conditions are met, the starting of pre-injection will be conducted in all cylinders at the same time.
(e). At the initial stage of starting:
The pressure in intake manifold is shown as atmospheric pressure. The throttle is closed. ECM designates one
fixed parameter according to starting temperature.
(f). During the course of starting:
Fuel injection amount changes with engine coolant temperature. Ignition angle is adjusted continuously and
changes with engine coolant temperature, intake air temperature and engine speed.
(g). Starting process is over:
After engine speed exceeds 600r/min, working condition of starting is over.
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② Fuel injection control principle.

(a). ECM controls fuel injector injection time and injection timing so that the engine obtains the optimal air-fuel ratio
gas mixture under various working conditions.
(b). In fuel track, fuel pressure regulator keeps fuel injection pressure stable. Fuel injector injects fuel into air duct of
each cylinder. In each working circulation of engine (crankshaft rotates 2 circles), the cylinder injects fuel once
(injection sequence is 1-3-4-2). This kind of injection method is called sequence injection.
(e). When the engine running in a cold or heavy-duty state, to maintain good engine performance, the ECM will
execute the open-loop control to provide richer gas mixture. When the engine is in the normal working state
(with a small-and-medium load), the ECM will perform the closed-loop control through the feedback signal of
the oxygen sensor to obtain the optimum air-fuel ratio to achieve the best purification efficiency of the catalytic
converter.
(d). Fuel-injection pulse width control.
Input signal ECM Control output
Air-fuel ratio correction
Closed-loop feedback correction
intake manifold Pressure
Air inflation temperature
Air inflation efficiency
Inflation efficiency compensation of VVT
Self-learning correction
Calculate fuel injection amount Intake manifold pressure
Power supply voltage correction
Exhaust gas cycle
Accelerating and stronger
Decelerating and thinner
Decelerating and fuel cut-off.
Protective fuel cut
Fuel injector parameters
Control signal description:
Correction item Contents
• Air-fuel ratio for starting

• Air-fuel ratio when the engine runs
• Air-fuel ratio at low coolant temperature of the engine
Air-fuel ratio includes • Air-fuel ratio at normal coolant temperature of the engine
• Theoretical air-fuel ratio
• Stronger air-fuel ratio
• Overheating protection air-fuel ratio
• Actual air-fuel ratio is controlled around theoretical value through feedback signal of oxygen
Closed-loop feedback correction
sensor.
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Intake manifold pressure • Read directly through MAP installed on intake manifold
• Change of VVT will affect inflation efficiency of engine. Basic inflation efficiency table is
established under the condition where the VVT control system has no action, and relative
Inflation efficiency compensation of
positions of camshaft and crankshaft locates at initial position. When VVT control mechanism
VVT
takes action, the system will give relevant inflation efficiency compensation to ensure accurate
calculation of air flow.
Self-learning • Correct slow change in the engine due to long time running
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Power voltage • When the battery voltage changes, voltage correction can ensure correct fuel injection amount.
• When ECM detects intake manifold pressure and opening value of throttle increases, to avoid
Accelerating and stronger transient thinning of engine mixed gas, fuel injection volume is increased. To improve dynamic
property
• When the ECM detects the intake manifold pressure and the degree of throttle opening
reduces substantially, in order to avoid the instantaneous thickening of air-fuel mixture of the
Decelerating and thinner
engine, the fuel injection quantity will be decreased. In orderto improve emission and driving
performance
• When the system detects that the vehicle goes into decelerating state, it controls fuel cut-off. to
reduce emission and fuel consumption
Decelerating and fuel cut-off.
• When engine speed is higher than the set value, fuel is cut off.
• When ignition system has a fault, fuel is cut off.
When any one of the following conditions is met, the system will stop fuel injection:
• When engine rotation speed exceeds 6500r/min, fuel is cut; when rotation speed is lower than
6300r/min, fuel supply is recovered;
Protective fuel cut • When system detects ignition system fault, fuel supply is cut:
• When system voltage is more than 18V, it enters electric throttle function limit mode (compulsive
idle speed mode).
• Decelerating and fuel cut-off.
Fuel injection parameters • Provide relation between the engine and fuel injection amount
(e). Engine gas mixture correction

• When the engine is at normal working temperature, partial load control is closed-loop fuel control. Now,
the system corrects fuel injection amount at real time by ECM according to voltage signal of oxygen sensor
feedback so that adjusted gas mixture concentration is close to theoretical air-fuel ratio to ensure conversion
efficiency of harmful gas through three-way catalytic converter reaches to optimal state, and a better fuel
economy.
• When the engine is within normal working temperature range, open-loop fuel control is used at full load.
At the moment, to ensure the best power output of the engine, the system will control the fuel injected
with a richer air-fuel ratio, and increase the ignition advance angle moderately without engine knock. The
system can control exhaust temperature through exhaust temperature mathematical model established when
calibrating to protect the engine and three-way catalytic converter.
• The system determines full-load conditions of the engine according to signals provided by throttle position
sensor. Normally, when throttle opening reaches 80%~90%, the system will consider that the engine is in
full-load state. When the driverWhen the driver steps on accelerator pedal, the system will increase fuel
injection amount appropriately to ensure power required by the engine when accelerating. Increased fuel
injection amount is directly proportional to throttle opening change rate. When accelerating, ECM first
delays ignition advance angle appropriately, then restore it gradually in order to avoid increased torque from
impacting drive system when the engine accelerates quickly.
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• When working condition of accelerating is close to full load of the engine, the system will disconnect vehicle
air conditioner system temporarily to ensure power takeoff of the engine when accelerating. No matter in any
condition, when engine rotation speed exceeds maximum speed set in system, the system will cut fuel supply to
resist endless increase of rotation speed, to protect engine and prevent "vehicle flying". When rotation speed returns
to maximum speed limit specified by the system, the system will immediately recover fuel supply.
③ Ignition control principle

(a). Start.
When the engine starts, one fixed ignition advance angle is used to ignite gas in the cylinder and provide positive
torque. After the engine speed increases to a certain degree, ECM calculates ignition advance angle according to
input signals.
(b). Ignition advance angle control.
Correction signal ECM Control output
Coolant temperature correction
Intake air temperature correction
Idle speed correction

Main ignition angle
Calculate ignition advance angle Ignition Advance Angle
Decelerating and fuel cut-off correction
Accelerating correction
Power enrichment correction
Air conditioner correction
(c). Main ignition advance angle:

After the engine reaches to normal value, main ignition angle when the throttle is opened is the minimum ignition
angle at the optimal torque point. When the throttle is closed, ignition angle shall be decreased to obtain idle speed
stability."
(d). Ignition advance angle correction:
• Acceleration correction: when the vehicle is accelerating, ECM detects knock signal, correct ignition angle until
no knock occurs. In addition, it is used to reduce engine speed fluctuation caused by drive system knock.
• Power enrichment corrected: In the vicinity of the engine-performance, to obtain a better power and torque, the
enriched air-fuel ratio can reach the thinnest one with the best torque value, • Decelerating and fuel cut-off
correction: when exiting deceleration and fuel cut-off, correct ignition advance angle to ensure stable transition.
• Air conditioner control correction: when the engine is idling, turn off air conditioner. Correct ignition advance
angle to ensure stable transition.
(e). Acceleration repair
• Acceleration repair of advanced angle of ignition is used to engine rotation speed fluctuation caused by
vibration of drive system. It also can eliminate knock possibly occurred during acceleration, to make a smooth
acceleration process.
(f). Power increase repair
• Around external point, to obtain better power and torque, the air-fuel ratio will be increased to thinnest air-fuel
ratio (LBT) at optimal torque, so as to repair ignition angle and obtain MBT point.
(g). Ignition angle compensation controlled by VVT.
• After VVT control mechanism takes action, engine intake and exhaust overlap angle may change, which will affect
inner waste gas re-circulation rate and temperature inside cylinder. For different VVT, it is necessary to conduct repair of
advanced angle of ignition, to ensure optimal actual advanced angle of ignition under current VVT condition.
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(h). Speed reduction and fuel cut repair

• Before exiting reduction fuel cut, it is necessary to conduct repair of ignition angle to get a smooth process
when closing and exiting throttle.
(i). Air conditioner control repair
• Turn off the air conditioner when engine is in idle speed. It is necessary to conduct repair of advanced angle
of ignition to get a smooth transition process of engine rotation speed.
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④ Idling-speed control principle
(a). Idle speed control
• According to idle speed conditions and engine load changing at idle speed, control throttle bypass air amount
to keep idle speed optimal. According to engine coolant temperature and air conditioner load, ECM drives
idling stepper motor to make the engine run at preset target idle speed. In addition, if turn on or turn off the
air conditioner when engine runs at idle speed, idle air stepper motor will adjust bypass air volume according
to engine loading condition, to avoid unstable idle speed.
(b). Calculate target idle speed.
Input signal ECM Control output
Basic target idle speed
Voltage compensation:
Vehicle speed compensation
Headlamps compensation Calculate target idle speed Target idle speed
Fan compensation
A/C compensation:
Decelerating adjustment
• Voltage compensation:
When the voltage is lower than 12V, if system voltage is lower than 12V and doesn't recover normal condition
within 10s, the system will control and increase aim idle speed to 300r/min, to increase generated electricity
of generator.
At idle speed, when system encounters transient voltage fluctuation caused by external electricity load, the
system will automatically compensate air volume to resist excessive fluctuation of engine rotation speed.
• A/C compensation:
When parking vehicle at idle speed and opening air condition, to compensate power consumption of
compressor, aim idle speed will increase to about 150r/min.
• Headlight compensation:
After the low-beam headlights are turned on to compensate for their power consumption, the target idling-
speed will be increased to 50r/min.
• Fan compensation: when coolant temperature is increasing, the fan is running. In order to compensate power
consumption of fan running, target idle speed will be increased by 50r/min.
(c). Idle speed control parameters:
• Idle speed air amount control.
• Fuel injection amount control.
• Ignition timing control.
(d). Idle speed design control opportunity:
• Idle speed stability calibration.
• Accelerating working condition calibration.
• Decelerating working condition calibration.
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• Decelerating and fuel cut-off.

• Engine transient state transition working condition fuel supply calibration.
• Constant speed driving calibration.
• Mechanical and electrical load increasing / decreasing calibration.
(e). Decisive factors of target idle speed:
• When the engine water temperature is too low, the system will provide high target idle speed to speed up
warming-up process.
• When the additional loads (such as: the headlights, air conditioning, cooling fans and other electrical loads)
are turned on, the system will increase the idling speed to compensate for the increased loads and to maintain
the stability of idling-speed.
⑤ Knock control principle

(a). Knock sensor introduction:
• Knock sensor is a kind of vibration acceleration sensor, which is installed on engine block. Generally
installed between the No. 2 and No. 3 cylinders, which is conducive to the balance of engine knock. ECM
determines if the engine has knock using vibration frequency signal output by the sensor and through filtering
inside ECM. When knock signal is detected, ECM corrects ignition angle until no knock occurs.
(b). Start condition of knock control:
• Vehicle is equipped with knock sensor and knock control function is actuated.
• Engine is running and running time exceeds 2s.
• Engine water temperature exceeds 70°C.
• Engine speed is larger than 800r/min.
(c). Knock control mode:
• Steady knock control: during normal engine running ECM will inspect knock by the way of collecting and
analyzing sounds occurred during engine combustion through knock sensor and after filtering it. Once the
knock strength exceeds allowed limit, the system will quickly delay advanced angle of ignition of cylinder
occurred knock. Knock will be eliminated in subsequent combustion circulation, and advanced angle of
ignition will gradually recover to normal angle.
• Knock is easy to occur during sharp acceleration or sharp change of engine rotation speed. After the system
predicts the possibility of occurring knock, it will automatically delay advanced angle of ignition to avoid
occurring of knock exceeding limit (strength). When the system detects knock, it will quickly delay 3–5°
advanced angle of ignition according to different engine rotation speed, and then recover the normal control
in the subsequent 2~3s.
• Adaptability adjustment of ignition angle:
Due to fabrication error and abrasion during long-time use, there is also difference between engines. At the
beginning of use of system and engine or after re-switching on of ECM, there will be knock when the engine
is working. The system will record it and create a suitable ignition adjustment and repair value (self-study
value) after a few time of run-in. When the engine runs under the same working condition, the system will
automatically adjust advanced angle of ignition and avoid strong knock. Suitability study of the system will
constantly update during running of engine.
⑥ Canister solenoid control principle.

(a). It is used to control washing air flow of the canister. ECM controls Canister valve according to engine load,
engine coolanttemperature, speed and a series of signals. Through an integrated calculation, ECM gives electrical
pulse duration and frequency (i.e. duty cycle) to control EVAP. Excessively-accumulated fuel vapor in the
canister can cause gasoline leak, resulting in environmental pollution. Therefore, the purpose of the canister
control valve is to open at the right time to allow the excessive fuel vapor in the canister to mix with air before
entering into the intake manifold to participate in combustion.
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Canister solenoid will control the volume and time of fuel and evaporation entered into the cylinder through
the control of opening and closing time of passage between active canister and intake pipe, so as to maximally
reduce evaporation emission of the vehicle, meanwhile reduce effect on engine performance.
(b). Working conditions of canister solenoid:
To reduce the effect of fuel and evaporation entered into cylinder to normal combustion of engine. Before
opening of canister solenoid, the following conditions must be met:
• System voltage is lower than 18V. more than 8V;
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• Engine water temperature exceeds 0℃ .
• Engine intake temperature exceeds 0°C;
• Unrelated system fault (fault list is shown as follows):
Fuel system fault
Oil pump fault
Idle speed is too high/ too low
Intake pressure sensor fault
Engine misfire fault
Front oxygen sensor heating fault
Front oxygen sensor signal fault
System voltage is too low/ too high
Crankshaft position sensor fault
Ignition coil fault
Fuel injector fault
Canister solenoid output fault
(c). Working mode of canister solenoid
The opening of canister solenoid will determined by ECM according duty ratio (PWM) signal determined by
engine condition. Under non
Under non idle speed condition, maximum opening of canister solenoid is determined by closed loop air flow.
Maximum value is 100%.
Canister will not attend work during the following conditions:
• Within a period of time after engine cold start.
• Engine cooling water temperature is too low.
• Engine idle.
• Engine load is high.
• Important sensor system faults.
⑦ Electric throttle control.

(a). Compulsive engine flameout mode:
When ECM reports fault, intake system or throttle valve creates problems for the control of air flow, the control
method is to close fuel, ignition and throttle, and engine will flame out and no longer output power.
(b). Management mode of compulsive idle speed power:
When engine is in idle speed condition, ETC system can't reliably use throttle to control engine power. At this moment,
ETC will eliminate control to throttle, and throttle opening will recover its mechanical default value. Engine power
only can be controlled by opening or closing some cylinder injection or delaying advanced angle of ignition.
(c). Compulsive idle speed mode:
When driver's intention can't be obtained reliably, such as all pedal signals are fail, the engine can only work under idle speed
condition to maintain the refrigeration and heating of vehicle environment, power supply and lamp functions When stepping
accelerator pedal, the engine has no any response. Therefore, the vehicle can't be driven under this mode.
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(d). Management mode of limited power:

ETC system can't use throttle to control engine power. Under this mode, the system will judge whether it is
idle speed or acceleration speed according to pedal signal. The engine controls engine power output by closing
or opening some cylinder injection and delay ignition angle. Therefore engine output fluctuation is obvious.
Long time working under this mode will do harm to engine and emission system. This mode can ensure vehicle
inadequate driving, but can't make the vehicle drive or climb slope in normal traffic condition.
(e). When the reliability of confirming driver's intention lowers or big power can't be output:
such as, when 2 pedals have signal output but the signal has large difference, output torque of engine is limited,
the engine delay the response to pedal change, and driver will obviously feel that engine output is weak, but still
can drive normally.
(f). Normal mode: vehicle can drive totally according to the driver's intention.
⑧ Principles of VVT control.

(a). Conditions of conducting action of VVT control mechanism
When the following conditions are met, VVT control mechanism can conduct action according to the
requirements of engine management system, control relative position between camshaft and crankshaft, to make
the engine obtain optimal economy, power and emission performance.
• System voltage should not be more than 16V and less than 10. 5V.
• Engine water temperature should not exceed the specified limit value of 115°C
• Engine rotation speed should not exceed 7000r/min and lower than 900r/min.
• No fault related to VVT control system occurs. (DTC details are shown in fault list)
(b). When the above conditions are met, VVT control system will run and determine suitable VVT according to
current working condition of engine (rotation speed, load) When VVT changes, inflation efficiency and optimal
ignition angle of engine will change: compensation of inflation efficiency is automatically calculated by the
following forma;
⑨ Air conditioner control principles.

ECM monitors A/C request input and A/C evaporator temperature sensor input, and control A/C compressor
clutch through A/C relay. System can automatically identify air-conditioning system with plug-and-play manner.
(a). Operating conditions of air conditioner
When the following conditions are met, air-conditioning system starts to operate:
• Engine is running and running time exceeds 2s.
• Air-conditioning is switched on
• All air-conditioning cutting-off modes do not work
(b). Air conditioner cut-off mode
In some cases, in order to ensure the engine power or protect the engine or protect the Air-Conditioning system,
ECM must stop the air-conditioning compressor or prohibit the air-conditioning system to start. In order to avoid
frequent switching of compressor clutch, once air-conditioning cutting-off mode is activated, ECM permits air-
conditioning clutch to reoperate after a certain period through retardation.
Air-conditioning cut-off modes are listed as follows:
• Air conditioner cut-off mode when the engine speed is too high: protect air conditioner.
When A/C is closed, engine rotation speed is less than 5800r/min and then compressor is allowed to be started.
When A/C is working, engine rotation speed is more than 6000r/min and then cut A/C compressor.
• Air-conditioning cutting-off mode under too high engine cooling water temperature: protect the engine
When A/C is closed, cooling water temperature is less than 105°C, and then compressor is allowed to be started.
When A/C is working, cooling water temperature is more than 108°C, and then cut A/C compressor.
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⑩ Fan control logic

System controls cooling fans of engine and air-conditioning. ECM determines whether to switch on each fan or
not according to engine coolant temperature and conditions for switching on the air-conditioning.
(a). Working mode and conditions of fan
• When air conditioner is off:
Coolant temperature is lower than 91°C. Engine fan is off.
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Coolant temperature is higher than 94°C. Engine fan runs at low speed.
When coolant temperature is higher than 98℃ , engine fan runs at low speed.
After coolant temperature reduces below 94℃ , engine fan runs at low speed again.
After coolant temperature reduces below 89°C, turn off engine fan.
• When air conditioner is turned on:
Coolant temperature is lower than 96°C Engine fan runs at low speed.
When coolant temperature is higher than 96°C, engine fan runs at high speed.
After coolant temperature reduces below 92°C, engine fan runs at low speed again.
No matter how coolant temperature is, engine fan runs at high speed after air conditioner medium voltage
switch is turned on.
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Component layout
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1 Electronic control module (ECM) 8 Rear oxygen sensor
2 Fuel pump 9 Crankshaft position sensor
3 Ignition coil 10 Electronically-controlled throttle valve housing
4 Front oxygen sensor 11 Coolant temperature sensor
5 Injector 12 Knock sensor

12
6 CMP sensor 13 Intake air temperature/pressure sensor
7 Canister control valve 14 Intake VVT valve
△ Hint:
Various sensors and actuators are described in the table below:
S/N Parts Quantity Function
Optimize control system to be appropriate for working

1 Electronic control module (ECM) 1 conditions of the engine according to signals provided by
the sensor
2 Fuel pump 1 Deliver fuel
3 Ignition coil 4 Ignition of the air-fuel mixture.
4 Front oxygen sensor 1 Check oxygen concentration in exhaust gas
5 Injector 4 Inject fuel according to ECM signals
It provides the crank camshaft position information for

the ECM , i.e. to distinguish the top dead center of the
6 CMP sensor 1
compression stroke and the top dead center of the exhaust
stroke of the crankshaft.
Control emission according to ECM digit pulse square

7 Canister control valve 1
wave
8 Rear oxygen sensor 1 Check oxygen concentration in exhaust gas
9 Crankshaft position sensor 1 Check engine crankshaft rotation position and speed
Electronically-controlled throttle
10 1 Controlling the air intake volume.
valve housing
11 Coolant temperature sensor 1 Check engine coolant temperature
12 Knock sensor 1 Check if the engine has knock
Intake air temperature/pressure Check engine intake air temperature, air intake and
13 1
sensor determine compression TDC.
Controlling the engine oil flow into the camshaft position

14 Intake VVT valve 1
actuator.
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ECM power supply, ground, data line
Driver compartment
Engine compartment
central control box
central control box
Engine Control System-Engine control system
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ECM equipment control
Oxygen sensor
Fuel pump and fuel injector
Battery power supply Main relay control Main relay control IG1 PWR ECM ignition system
Wiring diagram
12-20
CAN system
12
12-21

Intermediate voltage
VVT valve control CPV control Steering switch signal A/C request signal switch signal
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High pressure switch
Air-conditioning
Medium pressure
ECM power supply, switch
Pressure Switch
ground, data line
Low pressure switch
PAS switch
Intake VVT Canister control valve
valve
A/C System
PWR, GND, SIG
ECM sensor
Accelerator pedal Intake air
position sensor temperature/pressure sensor
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signal signal signal signal
signal TB Motor - TB Motor + signal signal signal Low level High level High level Low level
12-22
Engine coolant temperature sensor Electronic throttle valve body CMP sensor Crankshaft position sensor Knock sensor
12
12-23
ECM ignition system

Ignition coil control Ignition coil control Ignition coil control Ignition coil control
IgnitiECM power supply,
ground, data lineon coil control
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No. 1 cylinder spark plug No. 2 cylinder spark plug No. 3 cylinder spark plug No. 4 cylinder spark plug
Cooling fan control
Driver compartment
central control box
Engine compartment
central control box
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Fan
A/C compressor
Compressor control FC (high speed) FC (low speed)
12-24
12
12-25
Fuel pump and fuel injector

Driver compartment
central control box
Engine compartment
central control box
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Fuel pump control
Injector control Injector control Injector control Injector control
ECM power supply,
ground, data line
Fuel pump
No. 1 cylinder No. 2 cylinder No. 3 cylinder No. 4 cylinder
injector injector injector injector
Oxygen sensor
Front oxygen sensor Rear oxygen sensor
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ECM power supply,
ground, data line
signal heating signal heating
12-26
Terminal definition
E01 to ECM
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Terminal Terminal
No. Color Function No. Color Function
1 LgW No. 3 cylinder ignition coil control 42 Gr APS signal
2 B Power ground 43 YW VVT valve control
3 B Power ground 44 WB Main relay control
4 LgR No. 1 cylinder ignition coil control 45 - -
5 RG Main relay power supply 46 - -
6 OB No. 1 cylinder injector control 47 OY Front HO2S signal
7 PY No. 3 cylinder injector control 48 GO Rear HO2S signal
8 YR No. 2 cylinder injector control 49 YB CTS signal
9 GrY Pump relay control 50 - -
10 GrBl Air conditioner compressor control 51 OG VSS signal output
11 Bl CPS low voltage level signal 52 BlG TPS signal
12 - - 53 - -
13 - - 54 P MAPS signal
14 - - 55 - -
15 - - 56 - -
16 - - 57 - -
17 GrV High speed fan control 58 - -
18 - - 59 WB Weak acceleration sensor signal
19 - - 60 BlG Power steering switch signal
20 V TB motor(-) 61 - -
21 Y TB motor(+) 62 Br No. 4 cylinder ignition coil control
22 - - 63 - -
23 GV Rear HO2S heating (-) 64 WG CPV control
24 VW Front HO2S heating 65 GrO Low speed fan control
25 GY No. 4 cylinder injector control 66 RW 5V Reference Voltage
26 - - 67 R ECM battery power supply
27 P TPS signal 68 RG Ignition switch power supply
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28 - - 69 GrW Brake switch
29 - - 70 RB 5V Reference Voltage
30 G CPS high voltage level signal 71 Bl IATS signal
31 - - 72 - -
32 - - 73 VB HO2S signal GND
33 GrR Brake lamp 74 W Signal GND
34 - - 75 GrG KW2000 communication
35 - - 76 WB Signal GND
36 W KS high electric-level signal 77 LgW CMPS signal
37 B KS low electric-level signal 78 - -
38 WB CAN_H 79 RG A/C request signal
39 W CAN_L 80 - -
40 G Intermediate voltage switch signal 81 PG No. 2 cylinder ignition coil control
41 RY APS signal
E02 to accelerator pedal sensor E04 to fuel injector of No.2cylinder
Terminal Terminal
1 Gr APS signal 1 RG Power supply of 12V.
2 WB Grounding 2 YR Injector control
3 RY APS signal
4 W Grounding E05 to fuel injector of No.3 cylinder

5 RB APS sensor (+)
6 RW APS sensor (+)
E03 to fuel injector of No.1 cylinder Terminal

No. Color Function
1 RG Power supply of 12V.
2 PY Injector control
Terminal
No. Color Function E06 to fuel injector of No.4 cylinder
2 OB Injector control
Terminal
No. Color Function
2 GY Injector control
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E07 to ignition coil of No.1 cylinder E11 to canister solenoid
Terminal
No. Color Function
Terminal
No. Color Function 1 BlR Power supply of 12V.
1 LgR Ignition coil control 2 WG CPV control 12

2 B Grounding
3 BW IG1 PWR
E13 to reversing lamp switch
E08 to ignition coil of No.2cylinder

Terminal
No. Color Function
1 WBl Switch signal
2 B Grounding
Terminal
No. Color Function
1 PG Ignition coil control

E14 to crankshaft position sensor
2 B Grounding
3 BW IG1 PWR
Terminal
No. Color Function
E09 to ignition coil of No.3 cylinder
1 G CPS high-voltage level
2 Bl CPS low-voltage level
3 B Grounding
Terminal
No. Color Function
E15 to engine coolant temperature sensor
1 LgW Ignition coil control
2 B Grounding
3 BW IG1 PWR
Terminal
No. Color Function
1 WB Power supply of 5V.

E10 to ignition coil of No.4 cylinder
2 - -
3 YB Temperature signal
E16 to camshaft position sensor

Terminal
No. Color Function
1 Br Ignition coil control
2 B Grounding
Terminal
No. Color Function
3 BW IG1 PWR
1 BW Power supply of 5V.
2 WB Signal GND
3 LgW CMPS signal
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E17 to electric control throttle E22 to engine oil pressure warning switch
Terminal Terminal
1 W Signal GND 1 GGr Oil pressure signal
2 BlG TPS signal
3 P TPS signal
E23 to generator adjuster
4 RB Power supply of 5V.
5 Y TB motor(+)
6 - -
7 - - Terminal
No. Color Function
8 V TB motor(-)
1 R Battery power supply
2 R IG1 PWR
E19 to knock sensor Charging indicator lamp
3 WR
E24 to air conditioner magnetic switch
Terminal
No. Color Function
1 B KS low-voltage level
2 W KS high-voltage level Terminal

No. Color Function
1 RV A/C compressor (+)

E20 to intake temperature/pressure sensor
E25 to intake VVT valve
Terminal
No. Color Function
1 P MAPS signal Terminal

No. Color Function
2 RW Power supply of 5V.
3 Bl IATS signal
2 OR VVT valve control
4 RB Signal GND
E26 to boosting steering switch

E21 to starter magnetic switch
Terminal
Terminal No. Color Function
No. Color Function
1 BlG Switch signal
1 W Starter (+)
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E27 to front oxygen sensor EI1 to dashboard harness
Terminal
No. Color Function
1 BlR Power supply of 12V.
2 VW HO2S heating 12
3 OY HO2S signal
Terminal
4 VB Signal GND No. Color Function
1 WB CAN_L
2 W CAN_H
E29 to air conditioner pressure switch
3 GrG K communication cable
4 GB Rear HO2S GND
5 RG Main relay power supply

Terminal
No. Color Function
6 - -
1 B Grounding
7 OG Vehicle signal
2 YG A/C request signal
8 RW VSSIG1 power supply
3 G Middle pressure switch
9 GV Rear HO2S heating (-)
4 RG High/low pressure switch
10 GO Rear HO2S signal
11 - -
I01 to fault diagnostic interface 12 WR Charging indication
13 GGr Oil pressure signal
14 WBl Reversing lamp switch signal

Terminal 15 YG A/C request signal
No. Color Function
1 - - 16 RG ECM ignition switch power supply
2 - - 17 R Generator power output
3 - - 18 - -
4 B Grounding 19 GrW Auxiliary brake signal
5 B Grounding 20 GrR Main brake signal
6 W CAN_H 21 - -
7 GrG KW2000 communication cable 22 - -
8 RW Ignition switch power supply
9 - -
10 - -
11 - -
12 - -
13 - -
14 WB CAN_L
15 - -
LIFAN AUTO
EU1 to central control box of engine compartment I38 to rear oxygen sensor
Terminal
No. Color Function
1 RG Heater
2 GV Heater (-)
Terminal
No. Color Function 3 GO Sensor signal
1 GrV High speed fan control 4 GB Grounding
2 GrBl A/C compressor control
3 GrY Fuel pump control
4 GrO Low speed fan control
5 WB Main relay control
7 W Starter (+)
8 - -
9 - -
10 - -
11 - -
12 R ECM battery power supply
13 - -
14 - -
15 - -
16 - -
17 RG Main relay power supply
18 - -
19 - -
20 - -
21 - -
22 - -
LIFAN AUTO
Basic check
△ Hint:
If the DTC isn't determined during inspection of DTC, all possible circuits must be considered as possible fault cause
to analyze and eliminate fault. In most cases, basic check for the engine in the following table will be made to find fault
location quickly and efficiently.
Step No. Inspection item Recommended action 12

Check the battery voltage
YES Go to step 2
1 • The battery voltage shall be ≥9.6V.
Inspect if the result is normal NO Charge or replace the battery.
Check if the engine starts

YES Go to step 3
2 • Engine starting
Inspect if the result is normal NO Go to step 6
Check air filter

YES Go to step 4
• Take out air filter
3 • Check if air filter is polluted or oily excessively
visually.
NO Clean or replace air filter
Inspect if the result is normal
Check idle speed Go to step 5

YES
• Engine starting
4
• Let the engine in idling state. See chapter 12 engine control system – fault
NO
diagnosis, fault phenomenon table
Check ignition timing

YES Go to step 6
• Using the timing light check method or ignition
5
timing tester Check ignition timing
See chapter 12 engine control system – fault
NO
Inspect if the result is normal diagnosis, fault phenomenon table
Inspect fuel pressure YES Go to step 7

6 • Check fuel pressure with fuel pressure gauge.
See chapter 12 engine control system – fault
Inspect if the result is normal NO
diagnosis, fault phenomenon table
Inspection of sparks
YES Basic check is over
• Dismantle spark plugs one by one.
7
• Test spark plug.
NO Replace spark plug
LIFAN AUTO
12-34 Engine Control System-Troubleshooting
Troubleshooting
Diagnosis system description
1. System overview
The engine EFI diagnosis system refers to the on-board (OBD) system for emission control. It can identify possible
faults and store DTC into electronic control unit memory.
2. Information storage
(a). After a fault occurs and the system confirms it, each fault is stored in electronic control module (ECM) as a
separate DTC.Middle
(b). Store fault information and engine state parameters when the fault occurs, including load value, engine speed,
fuel pressure and correction, vehicle speed, coolant temperature, etc.
3. Information reading
(a). Connect a diagnostic scanner with the vehicle through diagnosis interface or a computer to read DTC and engine
state parameters when the fault occurs.
(b). Diagnosis interface:

16-pin interface, located below the left lower of the
dashboard.
(c). Diagnosis interface description:
Terminal code Function description Inspection of data
4 Grounding (-) Resistance : about 1Ω or less
5 Grounding (-) Resistance : about 1Ω or less
6 CAN_H 0~5V voltage
7 KW2000 communication cable Pulse Signal
8 IG1 PWR Ground voltage 9~14V
14 CAN_L 0~5V voltage
16 Battery positive terminal (+) Ground voltage 9~14V
LIFAN AUTO
Engine Control System-Troubleshooting 12-35
4. Malfunction indicator light

(a). Position and Symbol
Positions and symbols on dashboard include two
malfunction indicator lights. One is malfunction indicator
light "SVS" (a).of the system, and the other is OBD
malfunction indicator light MIL (b). Both are controlled
by ECM calibration. The difference is that OBD MIL is
mandatory by national laws and regulations. When it is lit, 12
it means there is a fault in electronic control system that
deteriorates emission of complete vehicle. SVS light means
there are other faults in electronic control system. During
the course of normal running for the engine, when a fault
occurs, both lights are lit according to respective rule.
5. Lighting type of malfunction indicator light

△ Hint:
• Before starting vehicle, turn key to ON position and hold for 2s, and observe whether indicator lamp self-inspect.
Start the vehicle at least 5s after turning off ignition switch.
• The SVS and MIL lamps installed on the dashboard are to Hint the user whether the fault is related to the
electronic control system. Their illumination will be controlled by the ECM internal calibration data.
(a). When the system has no fault
• Turn ignition switch to ON, and MIL is always lit, SVS goes out after self check.
• After starting, MIL lamp and SVS go out;
• After flameout, turn ignition switch to OFF, and then MIL and SVS go out.
(b). When the system has a fault.
• Turn ignition switch to ON, and MIL is always lit, SVS goes out and then is lit after self check.
• After starting, if MIL in fault classes is defined to be lighting mode, MIL goes out and is lit after MIL lighting
condition is met; if SVS in fault classes is defined to be lighting mode, SVS is continuously lit after SVS lighting
condition is met.
• After flameout, turn ignition switch to OFF, and all go out after AFTERRUN process (the longest time is 90s).
6. Fault classes in engine electronic control system

(a). Light OBD malfunction indicator lamp. When OBD malfunction indicator lam of OBD lights up, according
relevant requirements of nation law, the user must immediately go to service station authorized by LIFAN and let
the professional technicians to deal with it.
(b). Light up SVS malfunction indicator light. This fault will not affect emission. But it also shows that the system
works abnormally. The user shall go to service station authorized by LIFAN for check at the right time.
△ Hint:
The two faults require the user to go to the service station authorized by LIFAN to have them checked with the
diagnostic scanner or the special equipment with the equivalent function.
LIFAN AUTO
Fault diagnosis procedure
Ask users for time, symptom, situation, condition, occurrence

reason, troubleshooting condition and moved part.
Visual inspection: if each system part lost, and wire connector

and harness get loose; if the wire and hose are wrong
connected; if the part box sensor is damaged apparently
Basic check: perform the basic idle check and ignition timing
check; check the fuel pressure; check the battery, etc.
Search and draw fault code
Verify fault code: 1. if the code fault exists; 2. if the fault has
been eliminated while the fault code displays uncleared.
Not read out Read out
Use fault symptom simulated test to verify fault
Use fault code to determine

fault part
When the code is normal but the fault
still exists, diagnose the fault according
to the "fault diagnosis table" and
"common fault judgment method"
Treatment as per single fault
code trouble shooting
method
Perform the maintenance according to the identified fault reason
Verify if the fault is excluded
LIFAN AUTO
Fault diagnosis analysis

△ Hint:
Electronic control engine has common faults: difficult to start, flameout after starting, unstable idling, idle speed too
high, driving poor, accelerating poor, backfire blasting, shaking gasp, smoking and high fuel consumption. Fault reasons
are very complicated. So it is very important to analyze faults carefully.
12
1. Analyzing and determining whether there is a fault in the engine
To determine whether there is a fault in the engine, the general methods include:
• When the engine cannot start or cannot run normally after starting, or the engine runs with exhaust pipe
blasting, has exhaust pipe backfire and obvious knock, it means the engine has a fault.
• Whether engine malfunction indicator light of engine electronic control system is lit. If this light is lit, it
means engine electronic control system has a fault;
• If the engine performance changes a lot in a short time, it means the engine has a fault. For example, the
engine power decreases obviously and fuel consumption increases obviously.
• Engine performance changes a little, the following method can be used to test it: when the engine runs under
various working conditions, check if exhaust pipe and intake pipe have abnormal noise; check if the engine
has obvious shaking or metal knock, and engine speed changing.
Attention:
• Step on the pedal slowly to increase engine speed gradually and check the above-mentioned phenomenon
exists.
• If it exists, it means the engine may have a fault. It is necessary to make tests repeatedly and provide a
basis to determine faults correctly.
• Step on accelerator pedal suddenly; check if the above-mentioned phenomenon exists and engine speed
increases correctly. If any abnormal condition occurs or engine speed increase is slow, it means the engine
has a fault.
• In both cases, if the engine has no abnormal phenomenon, release accelerator pedal and check engine
running at idle speed: check if idle speed is too high, unstable, and if the engine shakes seriously.
△ Hint:
After the completion of the above operation, if no abnormal phenomenon has been detected, it is an indication that the
engine works normally. If you want to carefully inspect dynamic performance, economy and emission condition of
engine, it is necessary to use inspection line or special detector to inspect and diagnose fault.
2. Analyzing and determining type of fault

When there is a trouble in the electronically controlled engine, firstly observe the condition of the engine
electronic control system's self-diagnostic fault indicator "CHECKENGINE (check the engine)" . If the light is
lit during the course of running the engine, it means electronic control engine has a fault that can be monitored
by fault self-diagnosis system. The fault normally relates to electronic control system. Now DTC stored in the
computer can be called out. Then find out the fault reason according to DTC. If the engine really has a fault and
engine "malfunction indicator light" on dashboard is not lit when the engine runs, it means the engine fault is
not identified by electronic control unit self-diagnosis system. Now, according to traditional engine and fault
phenomenon, you analyze possible fault reasons based on a principle from external to internal and from simple
to complicated. In this case, do not dismantle electronic control system at random. Only when the fault is in
electronic control system, it is necessary to check electronic control system. Otherwise, check other parts.
3. Analyzing and determining the exact location of the fault

To reduce the workload of troubleshooting, after abnormal engine reaction occurs, you can use the method for
subtracting 1/2, that is, narrowing the objects of suspicion to the range of 1/2. To achieve that end, first
LIFAN AUTO
of all, it is necessary to determine that the fault is in the oil ways or in the circuits. Most of engine faults arise
from fuel line or electrical circuit. Therefore, when the engine has a fault, you can reduce work amount by 1/2 if
you are sure that the fault arises from fuel line or electrical circuit. Therefore, the following procedure shall be
observed:
(a). Determine if fuel line or electrical circuit has a fault.
Because it is simple and easy to diagnose electrical circuit fault. Therefore, first check electrical circuit. First
make spark-over test on cylinders. If no high voltage spark is found or spark is weak, it means the ignition
system has a fault. After the above-mentioned check, if spark for each cylinder and electrical circuit are normal,
the fault may arise from fuel line.
(b). Determine if individual cylinder or all cylinders work abnormally.
If the engine works abnormally, individual cylinder or all cylinders work abnormally. If individual cylinder
does not work or works abnormally, it is necessary to analyze and check individual cylinder. If each cylinder of
the engine works normally and any fault is not obviously displayed, it is necessary to check and analyze each
cylinder of the engine to reduce work amount by 1/2. The following procedures shall be observed: start the
engine and run idly. After the temperature is normal, make fire cutoff test of distributing live line for each
cylinder discontinuously to check running conditions of the engine. If discontinuous fire cutoff and refiring tests
are made on single cylinder, the engine runs normally. It means this cylinder works abnormally. So it is necessary
to analyze and check this cylinder. If discontinuous fire cutoff and refiring tests are made on all cylinders, the
engine runs normally. It means working conditions of all cylinders are the same. It is necessary to check all
cylinders that are abnormal.
LIFAN AUTO
DTC reading
1. Description
(a). So-called "DTC" refers to "vehicle computer self diagnosis DTC". When the vehicle computer makes
performance test for each part before starting and during the course of driving, it finds a fault and then stores the
information in the computer by means of DTC. For example, when water temperature sensor circuit is open, the
computer will detects that water temperature sensor interface signal changes suddenly or deviates from normal
value. Now, the computer will record this state. So, "reading DTC" means reading DTC information in vehicle 12
computer and explains it correctly.
(b). Contents of DTC. Normally, DTC of the instrument indicates fault position and fault character. For example,
DTC "P0107", "intake pressure sensor" is fault position, and "low voltage and open-circuit" is the nature of fault.
For some vehicles, fault characters defined in DTC are detailed, including short to ground, short to power supply,
open circuit, poor contact, signal too high, signal too low, rapid change and slow change.In this way, maintenance
staff can differentiate these items easily.
Attention:
• Through reading DTC, possible reasons and locations for most of faults can be determined correctly.
Sometimes, wrong judgment is made, which gives rise to misleading.
• In fact, DTC is only a conclusion, which does not give detailed reason of the fault. In order to determine
fault location, it is necessary to make further analysis and check according to the engine fault symptom.
• Self diagnosis system cannot display all sensor faults. When ECM detects sensor signal, it only receives
abnormal signal beyond the range (sensor) to determine whether the sensor has a fault or not. Normally,
after reading DTC, check corresponding sensor, wire connector and wire to find out and eliminate fault
points of open circuit and short circuit. But, if the sensor sensitivity reduces due to some reason (although
it is within the range set by ECM, it responds slowly. Output characteristic deviates), self diagnosis system
cannot detect it.
• Although the engine really has a fault, self diagnosis system outputs normal code without any fault. Now, it
is necessary to analyze and determine the engine fault symptom, and then check the sensor to find out and
make troubleshooting of the sensor. For example, when engine idle speed is unstable and engine running
condition is imbalance during driving and the system outputs no DTC, first it is worthy of considering that
intake manifold pressure sensor has fault. As performance directly affects basic fuel injection volume, it is
necessary to conduct inspection even when no DTC appears.
• Self diagnosis system may display wrong DTC. This is caused by working condition signal error. For
example, DTC displays "water temperature sensor short circuit or open circuit" fault; but engine fault
symptom: whenever the engine is cold or hot, it is difficult to start, with backfire and unstable idling. The
engine speed cannot be increased all the time. It is obvious that these faults don't have tight relation with
coolant temperature sensor (after inspecting coolant temperature sensor, no fault is found).
• It is suggested to compare DTC with actual fault symptom of the engine to get an appropriate judgment.
Do not regard DTC as only one basis.
• Improper maintenance will cause wrong DTC. For example, during the course of running, if one sensor
plug is pulled out for testing at random, ECM will record one DTC of the sensor.
• If old DTC is not cleared completely due to improper operation after repairing EFI engine, the remaining
old DTC is still displayed again, which leads to confusion of maintenance staff.
• Before reading DTC, first execute "DTC clearing" operation.
• When the system has a fault, diagnostic scanner is used to clear the DTC. If the system fault is eliminated,
the DTC will still appear when executing DTC operation again until the fault is eliminated.
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2. Reading procedure
△ Hint:
Fault LIFAN 720 engine electric control system is read by special diagnostic scanner provided by LIFAN. If fault is
read by diagnostic scanner not provided by LIFAN, the result is unreliable. The diagnostic scanner used for reading and
removing the following DTCs is a LIFAN special V30 diagnostic scanner.
(a). Connect the LIFAN V30 diagnostic scanner to the

diagnostic interface.
(b). Turn on the diagnostic scanner, and enter into "Chongqing

Series selection
LIFAN diagnosis system".
LIFAN Others
Dedicated
Chongqing Lifan
System Help About Power off

configuration
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(c). Select the diagnostic program V5.0 version, and then click
"OK".
Choose the version of diagnosis program
Demo
Confirm
Cancel
12
Software of this version can test the engine, transmission, ABS,
airbag and anti-theft system of Lifan models.
Service help info not found.
Please choose a version, and then click "OK" to start diagnosis.
(d). Select and enter "Power Train".
Chongqing Lifan LIFAN Dedicated\Chongqing Lifan\V5.0\
Power system Previous page

Anti-lock braking system
Airbag system Next page
Anti-theft system
Instrument system Print
Vehicle body system
A/C System Return
Electrical power steering system
(e). Select and enter"Engine System(Delphi VVT ETC)".
Power system LIFAN Dedicated\Chongqing Lifan\V5.0\Power system\Engine
Engine system (DELPHI) Previous page

Engine system (SUN-TECK)
Automatic clutch system (ACS) Next page
Engine system (DELPHI MT20U2/CNG)
Continuously Variable Transmission system (CVT) Print
Engine system (DELPHI VVT ETC)
Engine system (UMC M797) Return
LIFAN AUTO
(f). Select and enter "Read DTC".
Engine system (DELPHI VVT ETC) LIFAN Dedicated\Chongqing Lifan\V5.0
Read fault code Previous page

Clear fault code
Read data stream
Next page
Version info
Write car information
Print
I/O Control functional unit
OBD Vehicle off-assembly line inspection
Return
(g). Read engine DTC information.
Read fault code
Fault code Description

Relevant fault of brake switch
Previous page Next page Help Print Return
LIFAN AUTO
DTC clearing
1. Description
(a). "Clearing DTC" means clearing DTC information in vehicle computer.
(b). The DTC can be erased only after the vehicle fault has been troubleshot.
(c). After the completion of erasing the DTC, the tester will perform the operation of reading the DTC once
automatically. If the tester can still read a DTC, it is an indication that there is still a certain fault which has not 12
been eliminated.
(d). The current hard DTCs can not be removed. For the technical DTCs, such as oxygen sensor, knock sensor,
mixture correction and cylinder misfiring, they can be removed immediately, but they will recur in a certain
period. Only after troubleshooting, the DTC will not appear.
2. Clearing procedure
△ Hint:
The usual methods for removing DTCs include: using instrument, disconnecting the battery negative cable and
disconnecting the master fuse of electrical control system.DTC of LIFAN 720 model is cleared by special V30
diagnostic scanner.
(a). Connect the LIFAN V30 diagnostic scanner to the diagnostic interface.
(b). Turn on the diagnostic scanner, and enter into "Chongqing Lifan diagnosis system".
(c). Select the diagnostic program V5.0 version, and then click "OK".
(f). Click "Erase DTC" to erase the DTCs.

Clear fault code
Read data stream Next page
Version info
Write car information Print
Return
LIFAN AUTO
(g). Select "Confirm" to clear DTC.

△ Hint:
Information If the DTC cannot be removed, it is an indication that the fault has
not been troubleshooted. You should remove the fault based on the
Do you want to clear all the fault codes? Confirm DTC before trying to remove the DTC again.
Cancel
LIFAN AUTO
Read data stream

1. Description
The so-called data stream refers to the electrical signals sent out by the auto computer in a continuous manner
based on various operating parameters and work status of a certain system. There are many data streams.
Common data stream in engine system as follows:
• Ignition Advance Angle
12
• Throttle Position
• Number of steps of idling-speed control motor
• Intake manifold pressure
• Coolant temperature
• Inlet air temperature
• intake manifold Pressure
• Atmospheric Pressure
• Fuel injection start angle
• The battery voltage.
Attention:
Reading the data table displayed on the diagnostic scanner, you can check the data values, including switches,
sensors, actuators and other parts, without removing any part. First read data table so as to shorten diagnosis
time.
2. Reading procedure
(b). Turn on the diagnostic scanner, and enter into "Chongqing Lifan diagnosis system".
(c). Select the diagnostic program V5. 0 version, and then click "OK".
(f). Click "Reading data stream".

Clear fault code
Version info
Write car information Print
OBD Vehicle off-assembly line inspection Return
LIFAN AUTO
(g). Click to "read data public ID".
Read data stream LIFAN Dedicated\Chongqing Lifan\V5.0\Power system\Engine
Read data local ID Previous page

Read data public ID
Next page
Print
Return
Cancel
(h). . Click the content required to be read.
Read data public ID
Fuel system status (Group 1) Previous page

Fuel system status (Group 2)
Current calculated load value Next page
Coolant temperature
Short-term fuel adjustment (Group 1) Confirm
Long-term fuel adjustment (Group 1)
Manifold absolute pressure Print
Engine speed
Vehicle velocity Cancel
指令点火正时提前角汽缸#1
(i). Select "common mode".
Please select mode
Common mode Self-study mode
Comparison mode
Confirm Cancel
LIFAN AUTO
(j). Read data.
Data stream
Enable data stream memory playback
Name Current value Unit

Current calculated load value
Coolant temperature
Short-time fuel adjustment (Group 1)
12
Long-term fuel adjustment (Group 1)
Manifold absolute pressure
Previous page Next page Waveform Playback

Return
Help Print Channel Record
LIFAN AUTO

1. Description
Input and output control function unit is a kind of self-study process of components. It doesn't need dismantle any part,
and study of test and other special operation of components including relay and actuator.
2. Test procedures
(b). Turn ignition switch to "ON" position.
(c). Turn on the diagnostic scanner, and enter into "Chongqing Lifan" diagnosis system.
(d). Select V5. 0 diagnostic procedure version, and click "confirm".
(e). Select and enter "Power Train"
(f). Select and enter"Engine System(Delphi VVT ETC)".
(g). Click to "input and output control function unit".

Clear fault code
Read data stream
Next page
Version info
Write car information
Print
Return
(h). When using "input and output control function unit" function to inspect engine components, if there is any
abnormal condition, inspect and repair relevant wire harness or components.
(i). After repair, clear DTC.
(j). Re-start engine and use V30 diagnostic scanner to confirm that fault is eliminated.
(k). Turn ignition switch to "OFF" position.
(i). Disconnect connection of V30 diagnostic scanner and diagnostic interface.
3. Test items
S/N Name Test mode Description
Test if engine malfunction indicator light works

1 Malfunction indicator lamp (MIL) ON/OFF
normally
Starting the engine, test whether the canister

2 Canister purge 0~100 (percentage)
solenoid is working properly.
3 Fuel pump ON/OFF Test whether oil pump relay works normally.
Test whether the low-speed fan is working

4 Fan low-speed ON/OFF
properly.
Test whether the high-speed fan is working

5 Fan high-speed ON/OFF
properly.
LIFAN AUTO
Start engine and test whether air conditioner

6 A/C clutch ON/OFF
relay works normally.
Start the engine to input the numerical value.

7 Control IAC valve by steps 0~255(Steps) Turn off ignition switch to recover original
position.
0~255(RPM Start the engine to input the numerical value.

8 Control IAC valve by rpm Turn off ignition switch to recover original
position.
=13.7*N+1000) 12
When engine isn't started, click to enter idle air
9 Idle air control valve reset
control valve reset
Start the engine to input the numerical value.

10 Ignition advance/delay 0~255 Turn off the ignition switch and restore the
original settings
Start engine and "open" error study of aim gear

Aim gear of crankshaft position
11 ON/OFF of crankshaft position sensor. "Close" means to
sensor has error study.
cancel operation
Start engine to control fuel injector working

12 Fuel injector open/ forbidden
condition.
Start engine to "open" BLM study of fuel unit.

13 Fuel unit BLM Learn ON/OFF
"Close" means to cancel operation
Start engine to select "open/ close" fuel opening

14 Fuel opening circulation ON/OFF
circulation
15 Fuel unit reset BLM Reset If engine isn't started, click direct run
Start engine, and "open" means beginning of

16 Catalytic converter offline diagnosis ON/OFF catalytic converter offline diagnosis; "close"
means to cancel operation.
Start engine, and "open" means beginning of

17 Oxygen sensor offline diagnosis ON/OFF oxygen sensor offline diagnosis; "close" means
cancel operation
LIFAN AUTO

△ Hint:
The causes of EFI engine failure phenomenon are various and complex. The common potential locations of the
corresponding faults are listed in the following table. Following the described locations to troubleshoot one by one can
allow most problems to be solved.
1. Power supply (ECM power supply circuit Check the battery voltage and make troubleshooting for
is poor) power supply circuit
The diagnostic scanner
cannot communicate with
ECM 2. The circuit between ECM and diagnostic
Make troubleshooting for the circuit
scanner (open circuit)
3. ECM (damaged) Replace.
1. Intake air system (air leakage) Check and eliminate system leakage
2. Fuel pressure (too low) Check fuel pressure and eliminate fuel system fault
3. Air filter (clogging) Clean and eliminate clogging
4. Coolant temperature sensor (damaged) Inspection and replacement
5. Electronically controlled throttle valve

Inspection and replacement
housing (damaged)
The engine cannot be started
6. Injector (oil leakage) Replace fuel injector
7. Ignition timing (Incorrect) Adjust ignition timing
8. Connection from the ignition lock to ECM

(open-circuit)
Check cylinder pressure and eliminate mechanical fault

9. Cylinder compression pressure (too low)
of the engine
1. Intake air system (air leakage) Check and eliminate system leakage
2. Fuel pressure (too low) Check fuel pressure and eliminate fuel system fault
3. Air filter (clogging) Clean and eliminate clogging
4. Coolant temperature sensor (damaged) Inspection and replacement

It is difficult to start a cold Replace.
housing (damaged)
engine and the vehicle is
shaking
6. Injector (oil leakage) Replace fuel injector
7. Ignition timing (Incorrect) Adjust ignition timing
8. Connection from the ignition lock to ECM

(open-circuit)

of the engine
1. Ignition system (fault) Check and eliminate ignition system fault
2. Idle air stepper motor (poor) Repair or replace

Idle speed is not stable
of the engine
4. Front and rear oxygen sensors (reversal) Re-connect them properly.
1. Intake air system (vacuum leakage) Check and eliminate system leakage

Idle speed is too high Replace.
housing (damaged)
LIFAN AUTO
2. Fuel supply system (fault) Check fuel pressure and eliminate fuel system fault
Poor acceleration and Check cylinder pressure and eliminate mechanical fault
performance of the engine
4. Exhaust system (blocked) Clean and eliminate clogging

12
1. Fuel supply system (fault) Check fuel pressure and eliminate fuel system fault
Accelerated reaction is slow Check cylinder pressure and eliminate mechanical fault
and unbalanced of the engine

Replace.
housing (damaged)
2. Fuel injector (damaged) Replace fuel injector

The engine will flame out
when starting 3. Ignition system (fault) Check and eliminate ignition system fault
4. Load signal (poor) -
2. Intake air system (fault) Check and eliminate intake air system fault
Engine will flame out when
it runs at idle speed in cold 3. Cylinder compression pressure (too low)
of the engine
state
4. Discharge control system (fault) Check and eliminate emission control system fault
LIFAN AUTO
DTC (DTC) list

Attention:
In check mode, if a certain DTC is displayed, it is necessary to check electrical system associated to the code
listed in the following table.
DTC (DTC) DTC description Suspected area
• Valve timing
• VVT solenoid valve
P0011 Intake VCP lag response • Solenoid valve filter element
• VVT actuator assembly
• ECM
• Intake VVT valve

P0012 Intake VCP camshaft phase with large error • Intake VVT valve harness
• ECM
• Valve timing
Intake VCP camshaft study error exceeds
P0016 • Solenoid valve filter element
specified range
• ECM
• Valve timing
P0026 Intake VCP hydraulic control is held • Solenoid valve filter element
• ECM
• Front oxygen sensor

Front oxygen sensor heater has short-circuit
P0031 • Front oxygen sensor wire harness
to low voltage
• ECM

Front oxygen sensor heater has short-circuit
to high voltage
• ECM
• Rear oxygen sensor

Rear oxygen sensor heater has short-circuit
P0037 • Rear oxygen sensor wire harness
to low voltage
• ECM

Rear oxygen sensor heater short-circuit to
high voltage
• ECM
VVT solenoid valve

Intake VCP hydraulic control valve coil has
P0076 • VVTsolenoid valve wire harness
low voltage or short-circuit
• ECM
VVT solenoid valve

Intake VCP hydraulic control valve coil high
P0077 • VVTsolenoid valve wire harness
voltage
• ECM
LIFAN AUTO
• Intake air temperature/pressure sensor

P0105 Intake pressure sensor signal is held • Intake air temperature/pressure sensor wire harness
• ECM

Intake pressure/throttle position rationality
P0106 • Intake air temperature/pressure sensor wire harness
fault
• ECM
12
Intake pressure sensor circuit has low
voltage, short-circuit
• ECM

Intake pressure sensor circuit has high
voltage
• ECM

Intake temperature sensor circuit has low
voltage
• ECM

Intake temperature sensor circuit has high
voltage or short-circuit
• ECM
• Coolant temperature sensor

Coolant temperature sensor circuit has low
P0117 • Coolant temperature sensor wire harness
voltage
• ECM
• Coolant temperature sensor

Coolant temperature sensor circuit has high
P0118 • Coolant temperature sensor wire harness
voltage or short-circuit
• ECM
• Throttle position sensor (TAPS)

Electric throttle position sensor 1# circuit
P0122 • Throttle position sensor wire harness
has low voltage
• ECM

has high voltage
• ECM

Front oxygen sensor signal has short-circuit
to low voltage
• ECM

Front oxygen sensor has short-circuit to high
voltage
• ECM
P0133 Front oxygen sensor has slow response • Front oxygen sensor

P0134 Front oxygen sensor has short-circuit • Front oxygen sensor wire harness
• ECM
LIFAN AUTO

Rear oxygen sensor heater has short-circuit
to low voltage
• ECM

Rear oxygen sensor has short-circuit to high
voltage
• ECM

P0140 Rear oxygen sensor has short-circuit • Rear oxygen sensor wire harness
• ECM
• Injector
• Canister control valve
Fuel system is thinner at non idle speed
P0171 • Intake air temperature/pressure sensor
working condition
• Front oxygen Sensor
• Injector
Fuel system is thicker at non idle speed
working condition

has low voltage
• ECM

has high voltage
• ECM
• Fuel pump relay

P0230 Fuel pump relay fault • Fuel pump relay wire harness
• ECM
• No. 1 cylinder fuel injector

P0261 Low voltage of 1# injector circuit has fault • Fuel injector wire harness
• ECM

P0262 High voltage of 1# injector has fault • Fuel injector wire harness
• ECM

• ECM

• ECM
LIFAN AUTO

• ECM

• ECM
12
• ECM

• ECM
• Engine harness
• Injector
• Ignition system
• Fuel pressure
• Intake pressure and temperature sensor
Single cylinder or multiple cylinders misfire • Compression pressure
(catalytic converter damaged misfire)
P0300 • Valve mechanism timing
Single cylinder or multiple cylinders misfire
(emission damaged misfire) • Valve clearance
• Cylinder head
• Vent valve pipe
• Air intake system
• Vacuum hose
• ECM
• Knock sensor
P0324 Knock control system fault • Knock sensor wire harness
• ECM
• Knock sensor
P0325 Knock sensor fault • Knock sensor wire harness
• ECM
• Crankshaft position sensor

• Crankshaft position sensor wire harness
P0335 Crankshaft position sensor circuit no signal
• ECM
• Sensor signal disc
• Crankshaft position sensor
Crankshaft position sensor circuit signal • Crankshaft position sensor wire harness
P0336
interference • ECM
• Sensor signal disc
LIFAN AUTO
• CMP sensor
Status diagnosis of intake VCP camshaft • Camshaft position sensor wiring harness
P0340
position sensor • Camshaft signal wheel
• ECM
• CMP sensor
• Camshaft position sensor wiring harness
P0341 Diagnosis of fault of intake VCP aim wheel
• Camshaft signal wheel
• ECM
• Ignition coil
P0351 Output of ignition coil 1# has fault • Ignition coil wire harness
• ECM
• Ignition coil
• ECM
• Ignition coil
• ECM
• Ignition coil
• ECM
• Three way catalytic converter
Catalytic converter has low convention • Front oxygen Sensor

P0420
efficiency • Rear oxygen Sensor
• Exhaust leakage
• Canister control valve wire harness

Canister solenoid output has short-circuit,
P0458 • Canister control valve
low voltage or short-circuit
• ECM
• Canister control valve wire harness

Canister solenoid output has short-circuit,
P0459 • Canister control valve
high voltage
• ECM
• Low-speed fan relay

• Low speed fan relay wire harness
P0480 Low speed fan fault
• Cooling Fan
• ECM
• High-speed fan relay

• High speed fan relay wire harness
P0481 High speed fan fault
• Cooling Fan
• ECM
• Speed sensor
P0502 Speed sensor has no signal • Speed sensor wire harness
• ECM
LIFAN AUTO
• Brake switch
P0504 Brake switch related fault • Brake switch wire harness
• ECM
• ETC throttle valve assembly

• Air Intake System
P0506 Idle speed rotation is low
• Exhaust system
• ECM 12
• ETC throttle valve assembly
• Air intake system
P0507 Idle speed rotation is high
• Exhaust system
• ECM
• Power steering switch

Power steering switch circuit voltage range/
P0551 • Power steering switch wire harness
performance fault
• ECM
• Battery
P0562 System voltage is low • Engine harness
• ECM
• Battery
P0563 System voltage is high • Engine harness
• ECM
P0602 ECM processor fault • ECM
P0604 RAM is error • ECM
P0606 ECM processor fault • ECM
P060A ECM programming is error • ECM
• Ignition key
• Ignition key excitation coil
P0633 Fault of anti-theft device non-study • Chip anti-theft module
• Ignition key excitation coil
• ECM
• Injector
It becomes thicker when front oxygen sensor
cuts fuel during speed reduction.
• Injector
It becomes thinner when front oxygen
sensor adds fuel during speed acceleration.
LIFAN AUTO
• It is necessary to re-study after replacing ECM or

crankshaft gear ring, or adjusting relative position
between gear ring and 58X sensor
P1336 58 gear error isn't studied • Crankshaft position sensor connector has bad
connection, and sensor wire harness has open-circuit or
short-circuit.
• ECM
P1516 electric throttle stability diagnosis error • ECM
Electric throttle drive second step diagnosis

P2101 • ECM
error
• Electric throttle is dirty

P2119 Throttle recovers to default position fault
• Electric throttle has mechanical fault
• Accelerator pedal position sensor

Electric accelerator pedal position sensor 1#
P2122 • Electric accelerator pedal position sensor wire harness
circuit has low voltage
• ECM

circuit has high voltage
• ECM

circuit has low voltage
• ECM

circuit has high voltage
• ECM
• Electric throttle valve assembly

Fault related to electric throttle position
sensor 1#, 2# wire harness
• ECM
• Accelerator pedal assembly

Fault related to electric accelerator pedal
position sensor 1#, 2# wire harness
• ECM
• Injector
Fuel system is thinner at idle speed working
P2187 • Intake Air Temperature/Pressure Sensor
condition
• Injector
Fuel system is thicker at idle speed working
P2188 • Intake Air Temperature/Pressure Sensor
condition
LIFAN AUTO
The diagnostic scanner cannot communicate with ECM

Step No. Diagnosis YES NO
Check engine data

• Turn ignition switch to "OFF" position.
• Connect diagnostic scanner to fault diagnosis connector (16-pin) on the bottom left of
dashboard. Intermittent 12
1 To Step 2
• Turn ignition switch to ON, and turn on the diagnostic scanner- use the latest software fault exists
version.
• Read engine data displayed on the diagnostic scanner.
• Inspect whether diagnostic scanner can enter into engine system to read data flow.
Inspection of data of other modules

• Read system data of airbag and ABS shown by diagnostic scanner.
2 To Step 4 To Step 3
• Inspect whether diagnostic scanner can enter into airbag system or ABS system to read
data flow.
Check ECM diagnosis communication circuit

• Disconnect ECM connector E01.
• Use a digital multimeter to check the connection between No.7 terminal of diagnostic
interface I01 and No.75 terminal of ECM connector E01.
Resistance: ≤2Ω
• Turn ignition switch to "ON" position, and use a digital multimeter to check the voltage
of No.7 terminal of diagnostic interface I01.
Voltage: battery voltage
• Inspect if the result is normal
Check ECM power supply and earthing

4 • Disconnect ECM connector E01. To Step 5 To Step 6
• Check if ECM power supply works normally?
• Check whether the ECM grounding wire is short-circuited.
Replace ECM
• Replace ECM. (See chapter 12 engine control system - sensor actuator, electronic control Recheck
5 unit) To Step 6 according to
• Read engine data displayed on the diagnostic scanner. the sequence
• Confirm whether V30 diagnostic scanner and ECM have normal communication.
6 Eliminate detected fault and test if the fault is eliminated? Diagnosis is completed.
LIFAN AUTO
Crankshaft rotates, but engine can't be started.

Check engine malfunction indicator light and DTC

Refer
• Connect diagnostic scanner to fault diagnosis connector (16-pin) on the bottom left of to DTC
dashboard. list and
1 execute To Step 2
• Turn ignition switch to ON, and turn on the diagnostic scanner- use the latest software DTC
version. diagnosis
procedure.
• Read engine DTC.
• Check if DTC exists.
Check ignition system

• Remove the pen-type ignition coil, and remove the spark plug.
• Dismantle high-voltage line and spark plug, and insert spark plug into the high-voltage
wire for grounding. Use diagnostic scanner drive actuator to drive ignition coil to take
action and observe ignition spark. If the spark is not normal, inspect high-voltage line
2 and spark plug and replace the leaked high-voltage line and spark plug. Otherwise, To Step 4 To Step 3
continue to next step.
• If there is no diagnostic scanner available, While dismantling high-voltage line and spark
plug and inserting spark plug into high-voltage line for grounding, it is also necessary to
test fuel injector plug before starting engine for trying fire
Attention: it is forbidden to directly start engine for trying fire after unplugging
high-voltage line.
Check mechanical fault of ignition system

• Check the resistance of ignition coil, and clean the connector terminals.
Secondary resistance: 9840±980 Ω
• Inspect whether there is carbon, carbon sign deposited on spark plug, and whether
ceramic insulation section has cracks or electricity leakage, whether clearance is normal,
whether positive and negative poles are burned. And then clean the spark plug.
• Check if the above-mentioned condition is normal?
Inspect crankshaft position sensor.

• With the diagnostic scanner, read the data streams of the engine crankshaft position
sensor displayed by the diagnostic scanner.
• When starting the engine, check if data stream reaches to specified value To Step 5 To Step 15
4
Hint:
If the data flow of crankshaft sensor can't be read due to the software version of LIFAN
V30 diagnostic scanner, (See Chapter 12Engine Control System - sensor Actuator,
Crankshaft Position sensor).
Check the throttle

5 • Step on accelerator pedal slightly and start the engine. To Step 6 To Step 15
• Check if the engine starts.
Check coolant temperature sensor and intake air temperature/pressure sensor

• Check if intake air temperature/pressure sensor is installed correctly.
• Dismantle intake air temperature/pressure sensor.
• Check if gaging hole is blocked and the resistance between terminals conform to the
6 standard. To Step 7 To Step 15
• Check if temperature sensor is dirty.
• Ignition switch: ON, read the data streams of the engine intake temperature / pressure
sensor and coolant temperature sensor displayed by the diagnostic scanner.
LIFAN AUTO
Inspection of circuits of fuel system

7 • Ignition switch: ON To Step 8 To Step 16
• Check whether the fuel pump relay and the fuel pump can work.
Check fuel system pressure

8 • Check if fuel system pressure is normal? (See Chapter 13 Fuel System - fuel System, To Step 9 To Step 15
Onboard Inspection").
Check fuel system supply 12

9 • Check if inlet pipe leaks or is blocked? To Step 16 To Step 10
• Check the fuel filter for clogging.
Check fuel injector

• Pull out fuel injector connector.
• Dismantle fixing bolt of fuel distribution pipe and pull out fuel distribution pipe and fuel
injector together.
• Apply the battery 12V voltage on the fuel injector directly.
• Check if each fuel injector can inject fuel that conforms to standard flow and atomize it
uniformly.
• If it is not qualified, clean fuel injector, recheck if working condition of fuel injector is
normal?
Hint:
When checking the injector's injection state, if the injection shape is columnar instead of
10 tapered, or if the quantity of fuel injected by each injector of the four cylinders under the To Step 11 To Step 15
same conditions is different significantly(>5ml), replace the injector. Check fuel injector
nozzle has colloids. If it has, it is immersed in cleaning agent and washed. Otherwise, fuel
injection amount is insufficient or the acceleration is poor.
Attention:
When testing the fuel system,
• Place a "Be careful: inflammable" mark in working area.
• Be sure to work at the ventilated area equipped with a carbon dioxide fire
extinguisher.
• It is forbidden to smoke when fuel system is used. Working area shall keep away
from open fire and spark.
• Place discharged fuel in a explosion proof contain.
Check cylinder pressure

• Perform cylinder compression pressure tests.
• Each cylinder reference pressure: 1. 2MPa
• Each cylinder reference limit value: 1. 0MPa
• Each cylinder phase-difference reference limit value: 0.1MPa
• Check whether all is normal.
Check engine valve timing

12 • Check if engine timing gear mark is aligned and damaged, if the belt is loose or has To Step 13 To Step 15
"jumping over teeth"?
Check mechanical part of the engine

• Dismantle and eliminate the fault inside the engine, clean carbon deposit or dismantle
engine cylinder head.
13 • Check valve and intake manifold carbon deposit. For example: clearance between piston To Step 14 To Step 15
ring and cylinder block is big and untight, cylinder pad has air leakage; valve guide pipe
is loose; valve is not tightly closed, valve has carbon deposit.
LIFAN AUTO
Replace ECM
Recheck
• Replace ECM. (See chapter 12 engine control system - sensor actuator, electronic control
according
14 unit) To Step 15
to the
• Check engine data stream and confirm engine fault does not exist. Check if the system is sequence
normal?
It is difficult to start a cold engine and the vehicle is shaking


Refer
dashboard. list and
1 execute To Step 2
version. diagnosis
procedure.
Inspect the battery.

• When starting the engine, check if the battery voltage is ≥9.6V.
Check the starter

• Check starter or starter circuit has a fault.
Inspect crankshaft position sensor.

• With the diagnostic scanner, read the data streams of the engine crankshaft position
sensor displayed by the diagnostic scanner.
• When starting the engine, check if data stream reaches to specified value

Check intake air system

• Inspect whether joints of intake pipe, bushing, vacuum hose and fuel evaporation system
are damaged.
• Check if air filter element is clogged.
Check the throttle

7 • Step on accelerator pedal slightly and start the engine. To Step 16 To Step 8
• Check if the engine starts.
LIFAN AUTO
Inspection of idle-speed stepping motor

• Turn ignition switch to "ON" position, and inspect whether idle air stepper motor is
8 telescopic. To Step 9 To Step 16
• Turn ignition switch to "OFF" position, and inspect whether idle air stepper motor takes
action. If normal, the opening should be maximum value.

Onboard Inspection"). 12
Check fuel system supply
Check fuel injector

injector together.
uniformly.
normal?
Hint:
Attention:
extinguisher.

• Each cylinder reference pressure: 1.2MPa
• Each cylinder reference limit value: 1.0MPa


LIFAN AUTO
Replace ECM
• Replace ECM. (See chapter 12 Engine Control System - Sensor Actuator, Electronic
15 Control Unit) To Step 16
• Check engine data stream and confirm engine fault does not exist. Check if the system is
normal.
Idle speed is not stable


Refer
dashboard. list and
1 execute To Step 2
version. diagnosis
procedure.
Visual check and external check

• Start the engine and observe engine running conditions and shaking degree.
• Observe engine tachometer pointer swing and the speed at the time of flameout.
• Observe if the engine flames out at normal idle speed or at loading idle speed . (turn on
air conditioner, lights, put into gears and turn steering wheel, etc.)
2 • Check if external parts of the engine are abnormal. Check if vacuum pipe is loose or To Step 3 To Step 16
damaged. Check if the connector is loose.
• Check if the engine has fuel, water, gas and electricity leakage.
• Check the exhaust pipe for chug (an indication of poor burning), black smoke, fresh
gasoline smell and other abnormal phenomena.
• Check if the above-mentioned conditions are normal.
Inspection of electronic control throttle valve housing

• Check if the throttle has oil stain and carbon deposit, is smooth, if inlet duct around the
throttle has oil stain and carbon deposit, and if stepper motor has carbon deposit.
• Start the engine and make it idle.
• When the diagnostic scanner controls the idle air stepper motor extending and rotating,
3 the engine speed will change synchronously. To Step 4 To Step 16
telescopic.
action.
• Check if the above-mentioned conditions are normal.
LIFAN AUTO

12
high-voltage line.

• Check if the above-mentioned condition is normal.
Check fuel injector

injector together.
uniformly.
normal.
Hint:
Attention:
extinguisher.

7 • Check if fuel system pressure is normal? (See Chapter 13 Fuel System - Fuel System, To Step 9 To Step 16

8 • Check if inlet pipe leaks or is blocked. To Step 9 To Step 16
LIFAN AUTO
Check intake/exhaust system

• Check if engine intake air system leaks.
• Check if intake air pipe connection is loose, cracked or deformed, or sealing is aged.
• Check if intake air pipe has air leakage when the engine is running.
• Check the positive crankshaft ventilation valve (PCV) hoses for leak, and check whether
9 the PCV opens excessively. To Step 12 To Step 11
• Check if evaporation emission control system vacuum pipe leaks.
• Check if three-way catalytic converter is blocked.
• Check if the throttle body seal leaks.
• Check if intake manifold seal gasket leaks.
• Check if the above-mentioned condition is normal.

Check oxygen sensor

• Check if pre/rear oxygen sensor is installed correctly.
• Keep the engine at idle speed running condition, and inspect data flow of diagnostic
scanner. After coolant temperature reaches to normal value of actuated closed loop
control condition,, observe whether oxygen sensor works normally.


"jumping over teeth".

Replace ECM
• Replace ECM. (See chapter 12 Engine Control System - Sensor Actuator, Electronic
15 Control Unit) To Step 16
normal.
LIFAN AUTO
Idle speed is too high


Refer
dashboard. list and 12
1 execute To Step 2
version. diagnosis
procedure.
• Check if DTC exists?

• Observe if the engine flames out at normal idle speed or at loading idle speed ? (turn on
2 • Check if external parts of the engine are abnormal? Check if vacuum pipe is loose or To Step 3 To Step 10
damaged? Check if the connector is loose?
• Check if the above-mentioned conditions are normal?

• Check if engine intake air system leaks?
• Check if intake air pipe has air leakage when the engine is running?
• Check if intake air pipe connection is loose, cracked or deformed, or sealing is aged?
Check related accessories

• Check if canister control valve vacuum hose is connected reliably or damaged?
• Check if crankcase forced vent vacuum pipe is installed reliably or damaged?
• Check if brake system vacuum boosting pipe is installed reliably or damaged?

throttle has oil stain and carbon deposit, and if stepper motor has carbon deposit?
telescopic.
action.
LIFAN AUTO


7 • Check if fuel system pressure is normal? (See Chapter 13 Fuel System - Fuel System, To Step 8 To Step 10
Check fuel injector

injector together.
uniformly.
normal?
Hint:
Attention:
extinguisher.
Replace ECM
9 unit) To Step 10
normal?
LIFAN AUTO
Poor acceleration and performance


Refer
dashboard. list and 12
1 execute To Step 2
version. diagnosis
procedure.

• Observe if the engine flames out at normal idle speed or at loading idle speed ? (turn on
2 • Check if external parts of the engine are abnormal? Check if vacuum pipe is loose or To Step 3 To Step 14
damaged? Check if the connector is loose?
Check the throttle position

3 • Check the diagnostic scanner and check the throttle is normal? To Step 4 To Step 14
• Check if throttle opening change is normal when stepping on accelerator pedal?



LIFAN AUTO
Check fuel injector

injector together.
uniformly.
normal?
Hint:
Attention:
extinguisher.

high-voltage line.



LIFAN AUTO

Replace ECM 12
13 unit) To Step 14
normal?
Accelerated reaction is slow and unbalanced


Refer
dashboard. list and
1 execute To Step 2
version. diagnosis
procedure.

• Inspect whether joints of intake pipe, bushing, vacuum hose and fuel evaporation system
are damaged.
• Check if air filter element is clogged.
Check idle speed

• Check if idle running of the engine is normal?


LIFAN AUTO
Check fuel injector

injector together.
uniformly.
normal?
Hint:
Attention:
extinguisher.


Inspect the exhaust system.

9 • Check if exhaust system and three-way catalyst are normal? To Step 14 To Step 10
• Check if exhaust pipe is blocked?



LIFAN AUTO
Replace ECM
13 unit) To Step 14
normal?
12
The engine will flame out when starting

Refer
dashboard. list and
1 execute To Step 2
version. diagnosis
procedure.

2 • Observe if the engine flames out at normal idle speed or at loading idle speed ? (turn on To Step 3 To Step 14
• Check if external parts of the engine are abnormal? Check vacuum pipe is loose or
damaged; check if the connector is loose?

telescopic.
action.

LIFAN AUTO

high-voltage line.

Check fuel injector

injector together.
uniformly.
normal?
Hint:
Attention:
extinguisher.


LIFAN AUTO

Check engine valve timing 12


Replace ECM
13 unit) To Step 14
normal?
Engine will flame out when it runs at idle speed in cold state

Refer
dashboard. list and
1 execute To Step 2
version. diagnosis
procedure.

2 • Observe if the engine flames out at normal idle speed or at loading idle speed ? (turn on To Step 3 To Step 13
• Check if external parts of the engine are abnormal? Check vacuum pipe is loose or
damaged; check if the connector is loose?
LIFAN AUTO

telescopic.
action.
Check coolant temperature sensor

• Check if the resistance between coolant temperature sensor terminals conforms to the
standard?
4 • Check if coolant temperature sensor is dirty? To Step 5 To Step 13
• Turn ignition switch to ON, read diagnostic scanner coolant temperature sensor data
stream.
• Check if data stream is normal?
Check intake air temperature/pressure sensor

• Inspect whether resistance value between terminals of intake temperature/ pressure
sensor meets standard.pressure sensor meets standard.
5 • Inspect whether intake temperature/ pressure sensor is stained. To Step 6 To Step 13
• Turn ignition switch to "ON" position, and read data flow of intake temperature/ pressure
sensor from diagnostic scanner.
• Check if data stream is normal?
Check fuel injector

injector together.
uniformly.
normal?
Hint:
Attention:
extinguisher.

LIFAN AUTO


9
To Step 11 To Step 10 12


Replace ECM
12 unit) To Step 13
normal?
LIFAN AUTO
P0011- Intake VCP phase lag response

P0012- Intake VCP camshaft phase has big error
P0016- Intake VCP camshaft gear study exceeds limit range
P0026- Intake VCP hydraulic control valve is held.
Wiring diagram
Engine compartment central control box

Intake VVT valve
VVT valve control
Main relay control
Description of intake VVT valve

1. The intake camshaft position (CMP) actuator is connected to the intake camshaft and operated by the hydraulic
pressure. The hydraulic pressure is provided by the oil pump in order to change the angle of the intake camshaft
relative to the crankshaft position (CKP).
2. The intake VVT solenoid valve is powered by the main relay, and the ECM is grounded with the pulse width
control signal. Thereby, the oil flow of the engine to the actuator of the camshaft position is controlled.
3. The engine oil pressure will drive a safety slide valve inside the camshaft position actuator mechanism fixed
at the front of the camshaft to move. When the safety slide valve moving, the engine oil will be led into the
camshaft position actuator to make the camshaft rotate.
4. The intake camshaft position actuator can allow the cam working angle to change 50 °maximally.
LIFAN AUTO
Diagnostic steps
Attention:
Before carrying out this diagnosis steps, you should observe the data list on the fault diagnostic scanner and
analyze the accuracy of the data to help quick troubleshooting.
1. Inspect whether control system has other DTCs except for the codes of P0011, P0012, P0016, P0026
12
(a). Connect fault diagnostic scanner to a datalink connector.
(b). Turn the ignition switch to ON.
(c). Press the fault diagnostic scanner power button.
(d). Select the follow menu: power system/ engine system
(Delphi VVT ETC)/ read DTCs.
(e). Read DTCs.
Whether the displayed DTC is other DTCs except for P0010, P2088, P2089, P000A, P0012?
Yes ＞ Go to the DTC list.
No ＞ Go to Step 2.
2. Inspect resistance of intake VVT valve
(a). Disconnect VVT valve wire harness connector E25.

(b). Use a digital multimeter resistance scale to check the
resistance between No.1 and No.2terminals of intake VVT
valve E22.
Standard resistance: 9.4 ~ 10.6Ω (20°C)
Is check result normal?

Yes ＞ Go to Step 3.
No ＞ Replace the intake VVT solenoid valve.
Attention:
To avoid explosion, fire or other danger, don't connect the two cables together directly in the process of testing.
LIFAN AUTO
3. Inspect action of VVT valve.
(a). Connect the battery positive cable to the Terminal 1 of the

intake VVT solenoid valve, and the battery negative cable
to the Terminal 2 of the intake VVT solenoid valve.
(b). Check the valve core for movement.

Yes ＞ to engine mechanical system
4. Use fault diagnostic scanner to confirm if DTC is stored again
(a). Use a diagnostic scanner to execute DTC confirmation procedure.

(b). Execute reading sensor data stream procedure. Confirm no DTC exists and data is normal.
LIFAN AUTO
P0076 - Intake VCP hydraulic control valve coil has low voltage or
short-circuit.
P0077 - Intake VCP hydraulic control valve coil has high voltage.
Wiring diagram
12

Intake VVT valve
VVT valve control
Main relay control
Description of intake VVT valve

1. Engine ECM confirms whether control circuit has open-circuit, grounding short-circuit or voltage short-circuit
according to monitoring feedback signal.If engine ECM detects that control circuit voltage is in preset range
when control circuit is cut by command, it will set this fault diagnostic code.
2. Hydraulic control valve coil and 12V power supply has short-circuit. this is determined as a fault and DTC is
P0076. VVT function can't be effective, engine runs in stable condition, and vehicle can be driven.
3. Hydraulic control valve coil and grounding short-circuit or cut. This is determined as a fault and DTC is P0077.
VVT function can't be effective, engine runs in stable condition, and vehicle can be driven. For grounding short-
circuit, because OCV value constantly opens and VVT is in maximum opening condition, it may cause vehicle
hard to start or start at idle speed or flame out.
Diagnostic steps
1. Primary check
(a). Before executing the following procedures, ensure ECM grounding is good.
(b). Before executing electronic diagnosis and test, refer to Wiring diagram and component information.
(c). Before measuring, first check if connector terminal is broken, loose or corrosive, ensure the terminal contact is
good.
LIFAN AUTO
2. Read DTC on the diagnostic scanner

(e). Read DTCs.
Whether the displayed DTC is P0076, P0077?

No ＞ Go to DTC (DTC) list.
3. Inspect resistance of intake VVT valve
(a). Disconnect VVT valve wire harness connector E25.

(b). Use a digital multimeter resistance scale to check the
resistance between No.1 and No.2terminals of intake VVT
valve E25.
Resistance: 9.4 ~ 10.6 Ω (20 °C)

LIFAN AUTO
4. Inspect voltage of VVT valve grounding terminal.
(a). Turn the ignition switch to the "OFF" position;

(b). Disconnect intake VVT valve wire harness connector
E25.
(c). Turn ignition switch to "ON" position.
(d). Use a digital multimeter to check the voltage between No.1 12
terminal of wire harness connector E25 and grounding.
Voltage: 11~14V

5. Inspection of power circuits of intake VVT solenoid valve
(a). Turn the ignition switch to OFF.
Disconnect Normal (b). Open the central control box of the engine compartment.
(c). Inspect whether fuse SB09 is in good condition.
(d). Pull out the relay RL03, and apply the battery voltage
between the terminals 1 and 2 of the RL03. C h e c k f o r
the continuity between the terminals 3 and 5 of the RL03
with the digital millimeter.

No ＞ Replace the fuse or relay.
6. Inspection of connection between intake VVT solenoid valve and main relay
(a). Disconnect front oxygen sensor connector E25.

(b). Disconnect the connector EU1.
(c). Use a digital multimeter to check the resistance between
No.1 terminal of E25 and No.17 terminal of EU1.
Resistance: ≤2Ω
LIFAN AUTO
(d). Measure the resistance between terminal 1 of E13 and the

ground with a digital multimeter.
Resistance: ＞ 1MΩ

No ＞ Repair or replace faulty wire harness.
7. Inspect wire harness and connector between intake VVT valve and ECM.

(b). Disconnect intake VVT valve wire harness connector
E25.
(c). Disconnect the ECM connector E21.
(d). Use a digital multimeter to check the resistance between
No.2terminal of intake VVT valve wire harness connector
E25 and No.43 terminal of ECM wire harness connector
E01.
Resistance: ≤2Ω
(e). Use a digital multimeter to check the resistance between

No.2terminal of intake VVT valve wire harness connector
E25 and grounding.
Resistance: > 1 MΩ
(f). Turn ignition switch to "ON" position, and use a digital

multimeter to check the voltage between No.2 terminal of
VVT valve wire harness connector E25 and grounding.
Voltage: 0V
Attention:
At this moment, E01, E22connectors must be in disconnection
position.
LIFAN AUTO

(8). Replace the ECM
12
(a). Replace ECM.
(b). Use a diagnostic scanner to execute DTC confirmation procedure.
(c). Execute reading sensor data stream procedure. Confirm no DTC exists and data is normal.
LIFAN AUTO
P0105 - Intake pressure sensor signal is held.

P0106 - Reasonable failure of intake pressure/throttle position
P0107 - Intake pressure sensor circuit has low voltage, open-circuit.
P0108 - Intake pressure sensor circuit has high voltage.
Wiring diagram
signal
Intake Air Temperature/Pressure Sensor

signal
Intake air pressure sensor description
1. The intake pressure sensor (MAPS) is a type of sensor for indirect measurement of the engine intake volume.
Its function is to detect the engine working condition through measuring the intake pressure between the throttle
valve and the intake manifold, and to convert the pressure signal into the electric signal to input the engine ECM
for the ECM to calculate and determine the fuel injection time and ignition timing.
2. Sensor circuit consists of: 5V reference voltage circuit, low reference voltage circuit, sensor signal circuit.
3. ECM will provide 5V reference voltage to No.2terminal of sensor wire harness connector E20 through No.66
terminal of ECM wire harness connector E01. And, a low reference voltage through EM01 terminal No.76 to
EM30 terminal No.4.
4. Sensor can be used to determine atmospheric pressure. When the ignition switch is turned on and the engine is
turned off. As long as the engine running with the throttle fully open, atmospheric pressure readings will also be
updated.
5. The ECM monitors the sensor signal to determine whether the voltage exceeds the normal range.
LIFAN AUTO
Diagnostic steps
△ Hint:
Intake air temperature/pressure sensor consists of intake air pressure sensor and intake air temperature sensor.
1. Primary check
12
good.

(c). Start the engine and run for a period of time.
(d). Press power supply key of fault diagnostic scanner.
(e). Select the following menu: power system/ engine system
(Delphi VVT ETC)/ read DTC.
(f). Read fault diagnosis code.
Check whether the displayed DTC is P0105, P0106, P0107 or P0108.

3. Check intake air pressure sensor power supply voltage

(b). Disconnect intake air temperature/pressure sensor connector
E16.
(d). Use a digital multimeter to check the voltage between
No.2terminal of E20 wire harness connector and grounding.
Voltage: 4.5~5.5V

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4. Inspect 5V reference power supply circuit of intake pressure sensor.

(a). Disconnect intake temperature/ pressure sensor connector
E20.
(c). Disconnect ECM connector E01.
(d). Measure the resistance between the Terminal 2 of the
connector E27 of the intake temperature/ pressure sensor
and the Terminal 66 of E01 with the digital multimeter.
Resistance: ≤2Ω
(e). Measure the resistance between the Terminal 2 of connector

E27 of the intake temperature/ pressure sensor and ground
with the digital multimeter.
Resistance: > 1 MΩ

No ＞ Repair or replace wire harness or connector.
5. Inspection of low reference voltage line of intake pressure sensor

(b). Disconnect intake air temperature/pressure sensor connector
E16.
No.4 terminal of intake temperature/ pressure sensor wire
harness connector E20 and No.76 terminal of E01.
Resistance: ≤2Ω
(e). Turn ignition switch to "ON" position

(f). Use a digital multimeter to check the voltage between No.4
terminal of intake temperature/ pressure sensor wire harness
connector E20 and grounding.
Voltage: 0V
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No ＞ Repair or replace wire harness or connector.
6. Check intake air pressure sensor signal wire
12
(a). Turn ignition switch to "OFF" position.
E20.
No.1 terminal of intake temperature/ pressure sensor
connector E20 and No.54 terminal of E01.
Resistance: ≤2Ω
(e). Measure the resistance between the Terminal 1 of connector

E27 of the intake temperature/ pressure sensor and ground
with the digital multimeter.
Resistance: > 1 MΩ

7. Check intake air pressure sensor

(b). Turn ignition switch to "ON" position, press power supply
key of fault diagnostic scanner.
(c). Select the follow menu: power system/ engine system
(Delphi VVT ETC)/ rear data flow/ manifold absolute
pressure.
Standard value: 101kPa (specific value is related to air
pressure at the moment)
(d). Start engine and run it until water temperature reaches to
85°C, and then read the pressure value.
Standard value: 40±10kPa
(e). Pressure reading may have slight change. If reading and
standard value has big difference or pressure value is fixed
without any change and other parts are in normal condition,
replace intake pressure sensor.
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No ＞ replace intake air temperature/pressure sensor.
(a). Replace ECM.

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P0112- Intake temperature sensor circuit has low voltage.

P0113- Intake temperature sensor circuit has high voltage or open-
circuit.
Wiring diagram
12
signal
Intake Air Temperature/Pressure Sensor

signal
Intake air temperature sensor description

1. The intake air temperature sensor (IATS) undertakes to detect the intake air temperature and convert the intake
air temperature signal into electric signal which will then be transmitted to the engine control module (ECM),
so that the ECM could correct the time for fuel injection and ignition to make the engine working in the best
condition.
2. Intake air temperature sensor adopts thermistor with negative temperature coefficient (NTC). Its resistance value
decreases with the temperature increasing.ECM provides 5V reference voltage to No.2terminal of intake pressure
and temperature sensor wire harness connector E20 though No.66 terminal of E01. When intake air temperature/
pressure sensor is in cold state, thermistor resistance value used to measure the temperature is high.When air
temperature increases, resistance value decreases. When resistance value is high, ECM will detect that signal
circuit voltage is high. With resistance value decreasing, ECM detects that intake air temperature signal circuit
voltage decreases.
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Diagnostic steps
1. Primary check
good.
2. Check if intake air temperature is normal

(c). Select the follow menu: power system/ engine system / rear
data flow/ intake air pressure.
Temperature: it is the same as actual intake air
temperature

Yes ＞ to inspect intermittent fault.
No ＞ if the reading is -40°C, go to step 3. If the reading is 130°C or more, go to step 4.
3. Inspect open-circuit of signal cable.

E20.
(b). Use fine wire to connect No.3 and No.4 terminals of intake
temperature/ pressure sensor connector E20.
(c). Start the engine.
(d). Read intake temperature value shown in diagnostic scanner.
Temperature: 130°C or more

Yes ＞ Replace intake temperature/ pressure sensor.
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4. Inspect short-circuit condition
(a). Disconnect intake temperature/ pressure sensor connector E20.

(c). Read intake temperature value shown in diagnostic scanner.
Temperature: -40°C or less 12

Yes ＞ Replace intake temperature/ pressure sensor.
5. Inspect wire harness and connector of intake temperature/ pressure sensor
(a). Turn the ignition switch to the OFF position.

E20.
No. 3 terminal of intake temperature/ pressure sensor
connector E20 and No.71 terminal of E01 and grounding.
Resistance: ≤2Ω

Resistance: ≤2Ω
(f). Use a digital multimeter to check the resistance between

Resistance: > 1 MΩ
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(g). Turn ignition switch to "ON" position.

(h). Use a digital multimeter to check the voltage between No.4
terminal of intake temperature/ pressure sensor connector
E20 and grounding.
Voltage: 0V

(a). Replace ECM.

LIFAN AUTO
P0117-Coolant temperature sensor circuit has low voltage

P0118- Coolant temperature sensor circuit has high voltage or open-
circuit
Wiring diagram
12
Coolant temperature sensor
ECT signal
Engine coolant temperature sensor description
1. Coolant temperature sensor (ECT) function is to transfer engine coolant temperature signal into electrical signal
and then sends it to ECM so that ECM corrects fuel injection time and ignition time to ensure the engine is in
optimal working state.
2. Coolant temperature sensor adopts thermistor with negative temperature coefficient (NTC). Its resistance value
decreases with the temperature increasing.
3. ECM will always record the length of time the ignition switched off. When starting, if the ignition switched off
time reaches the pre-set time, the engine control module will compare the engine coolant temperature and intake
air temperature in order to determine whether the difference between the two is in normal working range.
4. Coolant temperature sensor is often install on the main water pipe of engine.
LIFAN AUTO
Diagnostic steps
1. Primary check
good.
2. Inspect and check whether coolant temperature value is normal

(c). Select the following menu: power system/ engine system/
read data flow/ read data public ID/ common mode/ coolant
temperature (start).
Te m p e r a t u re : i t i s t h e s a m e a s a c t u a l c o o l a n t
temperature

Yes ＞ Check transient fault.
No ＞ if the reading is -40°C, go to step 3. If the reading is 130°C or more, go to step 4.
3. Inspect open-circuit of signal cable.
(a). Disconnect coolant temperature sensor connector E15.

(b). Use a fine wire to connect No.1 and No.3 terminals of
coolant temperature sensor connector E15.
(d). Read the coolant temperature value shown in diagnostic
scanner.
Temperature: 130°C or more

Yes ＞ Replace coolant temperature sensor.
LIFAN AUTO
4. Inspect short-circuit condition
(a). Disconnect coolant temperature sensor connector E15.

(c). Read coolant temperature value shown in diagnostic scanner.
Temperature: -40°C or less 12

Yes ＞ Replace coolant temperature sensor.
5. Inspect signal cable of engine coolant temperature sensor.

(b). Disconnect coolant temperature sensor connector E06.
No.1 terminal of coolant temperature sensor connector E15
and No.74 terminal of E01.
Resistance: ≤2Ω

and No.49 terminal of E01 and grounding.
Resistance: ≤2Ω

Resistance: ＞ 1MΩ
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terminal of coolant temperature sensor connector E15 and
grounding.
Voltage: 0V

Yes ＞ Replace ECM.
(a). Replace ECM.

LIFAN AUTO
P0122-Electric throttle position sensor 1# circuit has low voltage.

P0123-Electric throttle position sensor 1# circuit has high voltage
P0222-Electric throttle position sensor 2# circuit has low voltage
P0223-Electric throttle position sensor 2# circuit has high voltage
12
Wiring diagram
TB Motor -
TB Motor +
Electronic throttle valve body
TPS signal
TPS signal
Throttle position sensor description

1. Throttle position sensor (TPS) is applied to change the throttle opening (engine load) size into electric signal and
input it into engine ECU, to determine air-fuel ratio.
2. The actual throttle position will be compared with the that determined according to the engine load. Engine
Control Module (ECM) detects the engine load by intake manifold absolute pressure sensor (MAP) signal. With
a further comparison, you can determine whether the sensor is failed and set the corresponding DTC.
LIFAN AUTO
Diagnostic steps
1. Primary check
good.

(e). Read DTC codes.
Whether the displayed DTC is P0122, P0123, P0222, P0223?

3. Inspect power supply voltage of throttle position sensor
(a). Disconnect connector E17.

(c). Use a digital multimeter to check the voltage between No.1
and No.4 terminal of connector E17.
Voltage: 5V

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4. Check throttle position sensor
(a). Disconnect electric throttle valve connector E17.

(b). Use a digital multimeter to check the resistance between
No.1 and No.4 terminals of electric throttle valve.
Resistance: 1.6 ~ 2.4 kΩ
(c). Rotate the throttle valve slowly from one end to the other, 12
use a digital multimeter to detect the resistance between
Terminal 3 and Terminal 1 of the connector E08, and its
resistance will feature a linear variation with the changes of
the throttle valve openness. The resistance change between
1# and 3# terminals is the opposite.

No ＞ Electric throttle valve assembly.
5. Check throttle position sensor earth circuit
(a). Disconnect electric throttle valve connector E17.

No.1 terminal of electric throttle valve connector E17 and
grounding.
Resistance: ≤2Ω

6. Check throttle position sensor wire harness and connector

(b). Disconnect electric control throttle valve connector
E17.
No.3 terminal of electric control throttle valve connector
E17 and No.27 terminal of E01.
Resistance: ≤2Ω
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E17 and No. 70 terminal of E01.
Resistance: ≤2Ω

Resistance: ≤2Ω
(g). Use a digital multimeter to check the resistance between

Resistance: > 1 MΩ
(h). Use a digital multimeter to check the resistance between

No.3 and No.74 terminals of electric control throttle valve
connector E17.
Resistance: > 1 MΩ
(i). Use a digital multimeter to check the resistance between

E17 and grounding.
Resistance: > 1 MΩ
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(j). Use a digital multimeter to check the resistance between

No.2terminal of electric control throttle valve connector
E17 and No.52terminal of E01.
Resistance: ≤2Ω
12
(k). Use a digital multimeter to check the resistance between

Resistance: > 1 MΩ
(i). Use a digital multimeter to check the resistance between

Resistance: > 1 MΩ

(a). Replace ECM.

LIFAN AUTO
P0031- Front oxygen sensor heater has short-circuit or low voltage.

P0032- Front oxygen sensor heater has short-circuit or high voltage.
Wiring diagram
Main relay control
box
central control
compartment
Engine
Front oxygen sensor

signal
heating
Front oxygen sensor description
1. Front heated oxygen sensor is used for fuel control.

2. The sensor compares the oxygen content in ambient air with
the oxygen content in exhaust flow.
Sensor
voltage 3. Each heated oxygen sensor has an internal heating element
for sensor heating.
4. The ECM controls the heated oxygen sensor's heating
control circuit.This makes the system enter into the closed-
Theoretical air-fuel ratio Air fuel ratio
loop control mode earlier, so that ECM can calculate Air-
Thin
Dense
fuel ratio earlier.
5. Engine control model can control the switching on or switching off of heater through command, to let the heated
oxygen sensor keep the specified working temperature range. Engine control module detects the temperature by
Measure the heater current. The working voltage of the heating coil of the front oxygen sensor is supplied by
the main relay controlled by the ECM, that is, when the ignition switch is turned to the ON position, the battery
voltage will be applied to the No.4 terminal of the harness connector E04. E CM controls the working time of
heater through No.23 terminal of ECM wire harness connector E01.
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Diagnostic steps
1. Primary check
(b). Before executing electronic diagnosis and test, refer to Wiring diagram and component information. 12
good.

Displayed DTC is P0031, P0032?

3. Check front oxygen sensor heater resistance value

No.1 and No.2terminals of connector E27.
Resistance: 9.6±1.5Ω(20°C)

No ＞ Replace front oxygen sensor.
LIFAN AUTO
4. Check the voltage between front oxygen sensor terminal and the ground

(c). Measure the voltage between the terminal 1 of the
front oxygen sensor E04 and grounding with the digital
millimeter.
Voltage: 11~14V

5. Check front oxygen sensor heater power supply circuit

6. Check connection between front oxygen sensor and main relay

(b). Disconnect the connector EU1.
No.1 of E27 and No.17 of EU1.
Resistance: ≤2Ω
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Resistance: > 1 MΩ
12

7. Check connection between front oxygen sensor and ECM

(b). Disconnect ECM connector E01.
No.2of front oxygen sensor E27 and No.24 of E01.
Resistance: ≤2Ω

Resistance: > 1 MΩ


LIFAN AUTO
P0037- Rear oxygen sensor heater has short-circuit to low voltage.

P0038- Rear oxygen sensor heater has short-circuit to high voltage.
Wiring diagram
Main relay control
compartment
Engine
central control box
Rear oxygen sensor

signal
heating
Rear oxygen sensor description

1. The post-catalytic heated oxygen sensor (HO2S) is used for monitoring three-way catalytic converter working
status.
2. The sensor compares the oxygen content in ambient air with the oxygen content in exhaust flow.
3. Each heated oxygen sensor has an internal heating element for sensor heating.
4. The ECM controls the heated oxygen sensor's heating control circuit. This makes the system enter into the
closed-loop control mode earlier, so that ECM can calculate Air-fuel ratio earlier.
5. Engine control model can control the switching on or switching off of heater through command, to let the heated
oxygen sensor keep the specified working temperature range. Engine control module detects the temperature by
Measure the heater current. The working voltage of the heating coil of front oxygen sensor is provided by the
main relay controlled by the ECM, that is, when turning the ignition switch to the ON position, the voltage of the
Terminal 1 of the sensor of the harness connector E12 is equal to the battery voltage. ECM controls the working
time of heater through No.23 terminal of ECM wire harness connector E01.
LIFAN AUTO
Diagnostic steps
1. Primary check
12
good.

Displayed DTC is P0031, P0032?

3. Check rear oxygen sensor heater resistance value
(a). Disconnect rear oxygen sensor connector I38.

No.1 and No.2terminals of connector I38.
Resistance: 9.6±1. 5Ω(20°C)

NO ＞ Replace rear oxygen sensor.
LIFAN AUTO
4. Check the voltage between rear oxygen sensor terminal and ground

terminal of rear oxygen sensor I38 and grounding.
Voltage: 11~14V

5. Check rear oxygen sensor heater power supply circuit

6. Check connection between rear oxygen sensor and main relay

(b). Disconnect connector IE1.
No.1 terminal of I38 and No.5 of IE1.
Resistance: ≤2Ω
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No.1 terminal of I38 and grounding.
Resistance: > 1 MΩ
12

7. Check connection between front oxygen sensor and ECM
(a). Disconnect front oxygen sensor connector I38.

No.2terminal of front oxygen sensor I38 and No.23 terminal
of E01.
Resistance: ≤2Ω

Resistance: > 1 MΩ


LIFAN AUTO
P0131- Front oxygen sensor signal has short-circuit to low voltage.

P0132- Front oxygen sensor signal has short-circuit to high voltage.
P0133- Front oxygen sensor has slow response.
P0131- Front oxygen sensor signal has open-circuit.
Wiring diagram
Main relay control
box
central control
compartment
Engine
Front oxygen sensor

signal
heating
Front oxygen sensor description

1. The work of the oxygen sensor is achieved by changing the oxygen ion concentration difference inside and
outside the sensing ceramic tube into a voltage signal output.
2. When the temperature of the sensing ceramic tube reaches 350°C, it owns the characteristics of solid electrolyte.
The oxygen ions can pass through the ceramic tube freely because of its special textures. It is also this texture
that the concentration difference can be changed into potential difference and then forms electrical signal output.
3. When the air-fuel mixture is richer, the difference of the oxygen ion concentration inside and outside the ceramic
tube is larger and the potential difference is higher, resulting in a large amount of oxygen ions moving from the
inside to the outside, so that the output voltage is higher (nearly 800 to 1000mV).
4. When the mixed gas is relatively thin, the oxygen ion concentration difference inside and outside the ceramic
tube will be lower and the potential difference will be relatively low so that only a little of oxygen ions will move
from the inside to the outside, resulting in a lower output voltage.
LIFAN AUTO
Diagnostic steps
1. Primary check
good.

Check whether the DTC is P0130, P0131, P0132, P0133, or P0134.

No ＞ Go to DTC list.
3. Check front oxygen sensor wire harness and connector

(c). Measure the resistance between the Terminal 3 of the
connector E12 and the Terminal 47 of E01 with the digital
multimeter.
Resistance: ≤2Ω
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(d). Use a digital multimeter to measure the resistance between

Terminal 4 of the connector EI2 and Terminal 73 of
E01.
Resistance: ≤2Ω

4. Check front oxygen sensor signal circuit

(d). Select the following menu: power system/ engine system
(Delphi VVT ETC)/ read data flow/ read data public ID/
B1-S1 O2voltage/ common mode.
Voltage: 0.35~0.45V

No.4 terminal of E28 and grounding.
Resistance: > 1 MΩ

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5. Check front oxygen sensor earth circuit

(b). Use a digital multimeter to check the voltage between No.4
terminal of E27 and grounding.
Voltage: 0V
12

Resistance: ≤2Ω

6. Check front oxygen sensor

(c). Select the following menu: power system/ engine system
(d). Keep the engine rotation speed at 2500r/min for about
2min, and first keep the oxygen sensor in working condition
and make its temperature reach to more than 400°C. When
switching on ignition switch, voltage should be about
0.5V. When starting the engine and providing thick mixed
gas (completely step the accelerator pedal), signal voltage
should be about 0.8V. When providing engine with thin
mixed gas, signal voltage should be about 0.1V. Otherwise,
it indicates that the oxygen sensor is fail and should be
replaced.

No ＞ Replace front oxygen sensor.
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P0137- Rear oxygen sensor has short-circuit to low voltage.

P0138- Rear oxygen sensor has short-circuit to high voltage.
P0140- Rear oxygen sensor has open-circuit.
Wiring diagram
12
Main relay control
compartment
Engine
central control box
Rear oxygen sensor

signal
heating
Rear oxygen sensor description

1. After the vehicle starting, the ECM will work at the open-loop mode, in which the ECM will ignore the
signal voltage of the heated oxygen sensor when calculating the air-fuel ratio. The control module provides
approximately 450mV reference voltage to the heated oxygen sensor.
2. The heated oxygen sensor will be heated to generate a voltage of 00.1V when the engine running. Once the
control module detects that the heated oxygen sensor voltage exceeds a threshold voltage, it will immediately
enter into the closed-loop mode.
3. The control module will determine the air-fuel ratio with the heated oxygen sensor voltage. If the heated type
oxygen sensor voltage is increased to above the reference voltage (tend to 1 V), the mixture is too thick. If the
heated oxygen sensor voltage decreases to below the reference voltage (tend to 0mV), it indicates that the air fuel
mixture is too lean.
LIFAN AUTO
Diagnostic steps
1. Primary check
good.

Whether the DTCs are P0137, P0138, P0140?

3. Check rear oxygen sensor wire harness and connector

(b). Disconnect connector IE1.
No.3 terminal of connector I38 and No.10 terminal of
IE1.
Resistance: ≤2Ω
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No.4 terminal of connector I38 and No.4 terminal of
IE4.
Resistance: ≤2Ω
12

4. Check rear oxygen sensor signal circuit

(d). Select the following menu: power system/ engine system
(Delphi VVT ETC)/read data stream/read data common
voltage ID/B1-S2O2/common mode.
Voltage: 0.35~0.45V

Resistance: > 1 MΩ

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5. Check rear oxygen sensor earth circuit

(b). Use a digital multimeter to check the voltage between No.4
terminal of I38 and grounding.
Voltage: 0V

Resistance: ≤2Ω

6. Check rear oxygen sensor

(c). Select the following menu: power system/ engine system
(d). Keep the engine rotation speed at 2500r/min for about 2min,
and first keep the oxygen sensor in working condition and
make its temperature reach to more than 400°C. The normal
voltage should be as follows: When turning on the ignition
switch, the voltage should be about 0.45V. When starting
the engine and supplying it with rich air-fuel mixture
(pressing the accelerator pedal to its extreme position), the
signal voltage should be about 0.9V. When supplying the
engine with thin air-fuel mixture, the signal voltage should
be about 0.1V. Otherwise, the oxygen sensor would be
failed and be sure to replace it.
NO ＞ replace rear oxygen sensor.
LIFAN AUTO

12
LIFAN AUTO
P0261- 1# injector circuit has low voltage fault

P0262- 1# injector circuit has high voltage fault
Fuel injector description

1. The fuel injector operating voltage is provided by the ECM-controlled main relay and the battery voltage is
delivered to Terminal 3 of each fuel injector connector through Terminal 5 of the main relay. ECM controls fuel
injectors of No.1 cylinder, No.2 cylinder, No.3 cylinder and No. 4 cylinder through 6, 8, 7 and 71# terminals,
respectively.
2. The ECM monitors the state of each injector drive circuit. If the
ECM detects the voltage corresponding to the drive circuit command state is not correct, it will set a fault diagnosis
code for the injector control circuit fault.
Attention:
Before carrying out this diagnosis steps, you should observe the data list on the fault diagnostic scanner and
analyze the accuracy of the data to help quick troubleshooting.
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12
12-123

Engine Control System-Troubleshooting
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Main relay control
Injector control Injector control Injector control Injector control
Wiring diagram
No. 1 cylinder No. 2 cylinder No. 3 cylinder No. 4 cylinder injector

injector injector injector
Diagnostic steps
1. Primary check
good.
(d). If it is good connection, move the connector and harness to observe the sensor signal voltage. If there is a trouble,
the voltage displayed on the diagnostic scanner will change.
Attention:
Here, No.1 cylinder fuel injector is set as an example. No.2 cylinder, No.3 cylinder and No. 4 cylinder fuel
injectors are the same.

Whether the DTCs are P0261, P0262, P0264, P0265, P0267, P0268, P0270, P0271?
LIFAN AUTO
3. Inspect resistance value of fuel injector assembly
(a). Disconnect No.1 cylinder injector wire harness connector

E03.
No.1 and No.2terminals of E03.
Reference resistance value: 12.0~17Ω
12

No ＞ Replace fuel injector assembly.
4. Inspect working power supply of fuel injector.
(a). Disconnect No.1 cylinder injector wire harness connector

E03.
(c). Use a digital multimeter to check the voltage between
No.1 terminal of No.1 cylinder injector connector E03 and
grounding.
(d). Turn ignition switch to "OFF" position.

No.1 terminal of No.1 cylinder injector connector E03 and
grounding.
Resistance: > 1 MΩ

LIFAN AUTO
5. Check fuel injector control circuit

(b). Disconnect No.1 cylinder injector connector E03 and ECM
connector E01.
(c). Use a digital multimeter to measure the resistance between
Terminal 2 of the connector E12 and Terminal 6 of the
connector E01.
Resistance: ≤2Ω

Resistance: > 1 MΩ
(e). Use a digital multimeter to check the voltage between

No.2terminal of E03 and grounding.
Voltage: 0V

(a). Replace ECM.

(c). Execute reading sensor data stream procedure.
(d). Confirm no DTC exists and data is normal.
LIFAN AUTO
P0324-Knock control system fault

P0325-Knock sensor fault
Wiring diagram
12
High level
Knock sensor
Low level
Knock sensor description
1. Knock sensor is a kind of vibration acceleration sensor, which is installed on engine cylinder block.
2. The sensitive element of the sensor is a piezoelectric element, the engine cylinder block vibration is transferred
to the piezoelectric crystal through the mass block in the sensor, and the piezoelectric crystal will have voltage
produced between its two pole faces under the pressure generated due to vibration of the mass block to change
the vibration signal into the output of alternating voltage signal.
3. Its purpose is to detect the engine for knock, and output the voltage signal to the ECM to determine the working
condition of the engine.
Diagnostic steps
1. Primary check
good.
LIFAN AUTO

(c). After starting the engine, and keeping the engine run at the
speed of no less than 1600r/min for a moment.
Whether the DTCs are P0324, P0325?

3. Check knock sensor
(a). Disconnect knock sensor connector E19.

(b). Measure the resistance between 1# and 2# terminals of
knock sensor with a digital multimeter.
Resistance: > 1 MΩ

No ＞ Inspect or replace knock sensor.
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4. Inspect wire harness and connector of knock sensor.
(a). Disconnect ECM connector E01.

(b). Disconnect knock sensor connector E19.
No.1 terminal of E19 and No.36 terminal of E01.
12
Resistance: ≤2Ω

No.2of E19 and No.37 of E01.
Resistance: ≤2Ω

No.1 and No.2terminals of E19 and grounding.
Resistance: > 1 MΩ
(f). Turn ignition switch to "ON" position.

(g). Use a digital multimeter to check the voltage between No.1
Voltage: 0V
LIFAN AUTO
(h). Use a digital multimeter to check the voltage between

No.2terminal of E19 and grounding.
Voltage: 0V

(a). Replace ECM.

LIFAN AUTO
P0335-Crankshaft position sensor circuit has no signal

P0336-Crankshaft position sensor wire signal interference
Wiring diagram
12
Low level
Crankshaft position sensor

High level
Crankshaft position sensor description

1. Crankshaft position sensor (CPS) is a magnetic sensor which is installed near the crankshaft and works together
with 58x gear ring. When crankshaft rotates, 58X gear top and groove pass through the sensor with different
clearance, the sensor will sense the change of magnetic reluctance. This AC magnetic reluctance will produce
AC output signal and ECM will make full use of this signal to determine the rotation position and speed of
crankshaft.
2. The ECM determines the specific location of the piston before top dead center (TDC) through the signal of the
crankshaft position sensor. Using the signal of the camshaft position sensor, the ECM can determine which
cylinder is at the top dead center of which working stroke. Therefore, when ECM determines which cylinder is
at exhaust stroke and the piston moves to some specific position before TDC according to cylinder signal and
crankshaft position signal, it will output fuel injection control command to drive fuel injector.
Diagnostic steps
1. Inspect the resistance of crankshaft position sensor

No.1 and No.2terminals of crankshaft position sensor
E14.
Resistance: 560Ω(20°C)

No ＞ Replace crankshaft position sensor.
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2. Check crankshaft position sensor wire harness and connector

(b). Disconnect crankshaft position sensor connector E14.
No.1 terminal of crankshaft position sensor E14 and No.30
terminal of E01.
Resistance: ≤2Ω
(e). Use a digital multimeter t o check the resistance between

No.2 terminal of crankshaft position sensor connector E14
Resistance: ≤2Ω
(f). Use a digital multimeter t o check the resistance between

No.3 terminal of crankshaft position sensor E14 and
grounding.
Resistance: ≤2Ω

No.1 terminal of crankshaft position sensor connector E14
and grounding.
Resistance: > 1 MΩ
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No.2terminal of crankshaft position sensor connector E14
and grounding.
Resistance: > 1 MΩ
12
(i). Turn ignition switch to "ON" position.

(j). Use a digital multimeter to check the voltage between No.1
terminal of crankshaft position sensor connector E14 and
grounding.
Voltage: 0V
(k). Use a digital multimeter to check the voltage between

No.2terminal of crankshaft position sensor connector E14
and grounding.
Voltage: 0V


LIFAN AUTO
P0340-Status diagnosis of exhaust/ intake VCP camshaft position

sensor
P0341- Intake VCP aim wheel diagnostic fault.
Wiring diagram
CMP sensor
signal
Descriptions of the camshaft position sensor

The camshaft position sensor (CMPS) is also called a cylinder identification sensor, and its function is to collect the
position signal of the gas distribution camshaft and input it to the ECM in order to determine the piston is at the TDC
position of the compression (or exhaust) stroke and ultimately determine when to inject fuel into the cylinder.
Diagnostic steps
1. Primary check
good.
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12

3. Inspect power supply voltage of camshaft position sensor.

terminal of connector E16 and grounding.
Voltage: 5V

No ＞ After repair, replace the fault wire harness.
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4. Check the camshaft position sensor wire harness and connectors.

(b). Disconnect camshaft position sensor connector E16.
E01.
Resistance: ≤2Ω

No.2terminal of connector E16 and No.74 terminal of
E01.
Resistance: ≤2Ω

No.3 terminal of connector E16 and No.77 terminal of
E01.
Resistance: ≤2Ω

No.1 terminal of connector E16 and grounding.
Resistance: > 1 MΩ
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Resistance: > 1 MΩ
12
(i). Turn ignition switch to "OFF" position.

Voltage: 0V
(k). Use a digital multimeter to check the voltage between No.3

Voltage: 0V

5. Replace camshaft position sensor
(a). Replace the camshaft position sensor.

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P1336-58 Gear error is unstudied.
Fault descriptions
When replacing crankshaft position sensor, replacing ECM and installing engine and after the repair related to the
change of crankshaft position sensor and gear disc position, it is necessary to conduct self-study on crankshaft position
sensor; otherwise, fault may occur. Meanwhile, ECM will record "P1336 58 gear error unstudied" DTC!
Diagnostic steps
1. Connect diagnostic scanner

Attention:
Before conducting gear study, the following conditions must be
met:
• Make sure that engine coolant temperature is above 60°C
• Air conditioner switch isn't turned on.
• Engine is started for 10s.
(Delphi VVT ETC)/ input and output control function unit/
aim gear error study of crankshaft position sensor.
2. Aim gear study of crankshaft position sensor.
(a). Click "open", and depress the pedal completely. Engine rotation speed circulates 2~5 times from 1300 to 4500,
and final will fluctuate around 4500r/min.
(b). Loosen accelerator pedal and click "close", and turn ignition switch to "OFF" position, then the study is finished.
3. Confirmation of DTC
(a). Connect diagnostic scanner to diagnostic interface, and turn ignition switch to "ON" position.
(b). Use diagnostic scanner, and carry out "clear DTC" step.
(c). Use diagnostic scanner and carry out "read DTC" step to confirm that there is no DTC. If there is DTC, go to
fault diagnostic list.
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P0351- Output fault of ignition coil 1#

12
Ignition coil description
1. Each rod type ignition coil corresponds to a cylinder. Under the control of computer ECM, recharge the
preliminary coil for accumulating magnetic energy, and secondary coil winding will sense high voltage, to make
the spark plug connected to the coil jump spark, which can control output voltage energy from ignition coil of
each cylinder to spark plug.
2. The ignition coil is connected to the automobile engine control assembly, in order to control the ignition time,
pause time and spark progress. The ignition function can be completed with the current flow to the primary coil
within the ignition system. This switch is controlled by the electronic spark timing signal from the pulse code
modulation. When the electronic spark timing signal falls below a particular threshold voltage level, the primary
current will be interrupted so that the electrical energy will be transferred from the primary winding to the
secondary winding. The electrical energy generated in the secondary winding will be directly transmitted to the
spark plug.
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Driver
compartment
central control box
Ignition coil control Ignition coil control Ignition coil control Ignition coil control
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No. 1 cylinder spark plug No. 2 cylinder spark plug No. 3 cylinder spark plug No. 4 cylinder spark plug
Wiring diagram
12-140
Diagnostic steps
1. Primary check
(c). Before measuring, first check if connector terminal is broken, loose or corrosive, ensure the terminal contact is good.
Attention:
Here takes the ignition coil of the No. 1 cylinder as an example. The principle is also applied to the ignition coil of
the No.2, 3, and 4 cylinder, respectively.

Whether the DTCs are P0351, P0352, P0353, P0354?

3. Check ignition coil

No.1 and No.3 terminals of ignition coil E07.
Resistance: 0.5±0.05Ω(20°C)

No ＞ replace ignition coil.
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4. Check ignition coil power supply circuit

Voltage: 11~14V

5. Check ignition coil wire harness and connector

(b). Disconnect ignition coil connector E07.
No.1 terminal of connector E07 and No.4 terminal of
E01.
Resistance: ≤2Ω

No.2terminal of connector E07 and grounding.
Resistance: ≤2Ω

No.1 terminal of connector E07 and grounding.
Resistance: > 1 MΩ
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(g). Turn the ignition switch to the ON position.

Voltage: 0V
12


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P0458- Canister solenoid output has short-circuit to low voltage to

short-circuit.
P0459-Canister solenoid output has short-circuit to high voltage.
Wiring diagram
Canister control valve
Main relay control

CPV control
box
central control
compartment
Engine
Canister control valve description
1. ECM controls gasoline evaporation volume entering to intake manifold from canister through canister solenoid.
ECM will output pulse square wave. Air flow and duty ratio which controlled the pulse square wave have linear
relation.
2. ECM will change working time and rate for cleaning of canister according to engine rotation speed and load
condition.
Diagnostic steps
1. Primary check
good.
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12

3. Check canister control valve power supply voltage
(a). Disconnect the canister solenoid connector E24.

Voltage: 11~14V

No ＞ Inspect ECM power supply circuit.
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4. Inspect wire harness and connector of canister solenoid.

(b). Disconnect canister solenoid connector E11.
No.2terminal of connector and No.64 terminal of E01.
Resistance: ≤2Ω

Resistance: > 1 MΩ

Resistance: ≤2Ω

(h). Use a digital multimeter to check the voltage between
Voltage: 0V

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5. Check canister control valve
(a). Disconnect canister solenoid connector E11.

No.1 and No.2pins of canister solenoid
Resistance: 19 ~ 22 Ω (20 °C)
(c). Reconnect connector E11
12
(e). Turn ignition switch to "ON" position
(f). Press power supply key of fault diagnostic scanner.
(g). Select the following menu: power system/ engine system
(Delphi VVT ETC)/ input and output control function unit/
cleaning of canister.
(h). Start the engine, and test whether canister solenoid is in
normal working condition
No ＞ replace canister control valve.
(a). Replace ECM.

LIFAN AUTO
P0230- Fuel pump relay fault
Wiring diagram
central control box

compartment
Driver
Fuel pump control
Fuel pump
box
central control
compartment
Engine
Description of electric fuel pump

1. Electric fuel pump is used to provide fuel with pressure of more than intake manifold pressure to fuel injector.
It consists of fuel pump, bracket and fuel level sensor, fuel tank (optional) and fuel pressure adjustor (limit fuel
return system).
2. Fuel pump is a kind of one-step electric fuel pump. Its working condition is controlled by ECM through fuel
pump relay. There is a one-way valve on the opening of fuel pump. When the engine doesn't work, fuel deposited
inside fuel pipe will not return to fuel tank, so as to ensure next start performance.
Attention:
• Old fuel pump can't be tried in dry condition: when fuel pump is dismantled, there still has residual
gasoline inside pump housing. If switching on for test on this condition, once the electric brush has bad
connection with commutator and creates spark, it will cause explosion due to the combustion of gasoline
inside fuel pump housing. The consequence is very serious.
• Don't perform the drying test on the new fuel pump, either. Because the fuel pump motor in the pump
housing is sealed, once being energized, the heat generated in the drying test can not be distributed.
The overheated armature can burn out the motor. Therefore, to perform the test, dip the fuel pump in
gasoline.
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Diagnostic steps
1. Primary check
good.
2. Inspect power supply voltage of fuel pump control circuit

(d). Use a digital multimeter to check the voltage between No.9
Voltage: 11~14V

3. Inspect fuel pump control power supply circuit
(a). Ignition switch: OFF

(b). Open the central control box in the driving compartment.
(c). Take out IG1 fuse FS31.
Attention:
It is required to a special fuse detacher to dismantle the fuse. Do not pull it out manually because it is easy to
damage the fuse.
(d). Inspect whether IG1 fuse FS31 is burned out.
Disconnect Normal
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(e). Open engine compartment fuse box.

(f). Inspect fuel pump relay RL11.
Standard value:
The multimeter is
Condition connected with a Specified value
terminal
Normal State 1-2 breakover
Normal State 3-5 No continuity
Apply power supply

voltage between 3-5 breakover
terminal 1 and

No ＞ Replace corresponding specification fuse or relay.
4. Inspect wire harness and connector of fuel pump control circuit.
(a). Disconnect the connector EU1.

(b). Disconnect the connector E01.
multimeter.
Resistance: ≤2Ω

5. Inspect fuel pump power supply voltage.

(b). Disconnect fuel pump connector B10.
terminal of B10 and grounding.
Voltage: 11~14V

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6. Inspect wire harness and connector of fuel pump circuit.
(a). Disconnect fuel pump connector B10.

(b). Disconnect connector B12.
No.1 terminal of connector B10 and No.9 terminal of
connector B12. 12
Resistance: ≤2Ω

No.4 terminal of fuel pump connector B10 and grounding.
Resistance: ≤2Ω

7. Inspection of fuel tank
(a). Release the fuel pressure.

(b). Dismantle fuel pump assembly.
(c). Connect temporary power supply wire harness to fuel
pump.
Attention:
Only connect power supply wire harness to fuel pump, and do
not connect wire harness to battery terminal. Keep the fuel
pump switch off.
(d). Put the fuel pump into a clean fuel container and install fuel
pressure gauge onto fuel outlet hose of fuel pump.
Attention:
When overhauling, keep away from fire source, to avoid fire
accident.
(e). Connect temporary power supply to switch on fuel pump
circuit.
(f). Obverse the reading of pressure gauge.
Output pressure: ＞ 350kPa
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No ＞ Repair or replace fuel pump.
(a). Replace ECM.

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P0480- Low speed fan fault.

P0481-High speed fan fault.
Wiring diagram
12
control box
central
compartment
Driver
FC (high speed)
FC (low speed)
Fan
box
central control
compartment
Engine
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Diagnostic steps
1. Primary check
good.
2. Check cooling fan control power supply voltage

Voltage: 11~14V
(e). Measure the voltage between 2# terminal of E01 and the

Voltage: 11~14V

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3. Check cooling fan control power supply circuit

(b). Open the central control box in the driving compartment.
(c). Take out IG1 fuse FS31.
Attention: 12
damage the fuse.
(d). Inspect whether IG1 fuse FS31 is burned out.
Disconnect Normal
(e). Open engine compartment fuse box.

(f). Inspect relay RL13, RL14, RL15.
Standard value:
The multimeter is
terminal
Normal State 85-86 breakover
Normal State 30-87a breakover
Normal State 30-87 No continuity
Apply the voltage 30-87 breakover

between terminal 85 and
86 30-87a No continuity

4. Check cooling fan control circuit wire harness and connector
(a). Disconnect connector UI1.

(c). Use a digital multimeter to check the resistance between No.7 terminal of connector UI1 and No.17 and No.65
terminals of E01.
Resistance: ≤2Ω
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Terminal 17 of E01 and the ground.
Resistance: > 1 MΩ
(e). Measure the resistance between 50# terminal of E01 and the
Resistance: > 1 MΩ

(a). Replace ECM.

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12
12-157
Engine Driver compartment

compartment central control box
central control box
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P0563- System voltage is high
P0562- System voltage is low
Battery power supply Main relay control Battery power supply PWR
Wiring diagram
Diagnostic Steps
1. Primary check
good.
2. Check ECM power supply voltage

(d). Measure the voltage between 2# terminal of E01 and the
Voltage: 11~14V
(e). Measure the voltage between 2# terminal of E01 and the

Voltage: 11~14V

3. Check ECM power circuit fuse and relay

(b). Open the central control box of the engine compartment.
(c). Take out fuse FS26, SB09.
Attention:
damage the fuse.
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(d). Inspect whether fuse FS26, SB29 is burned out.
Disconnect Normal
12
(e). Inspect relay RL09.

Standard value:
The multimeter is
terminal
Normal state 1-2 Breakover
Normal state 3-5 No continuity
Apply the voltage

3-5 Breakover
between terminal 3 and 5

4. Check ECM power supply circuit wire harness and connector
(a). Disconnect the connector EU1.

multimeter.
Resistance: ≤2Ω

E01.
Resistance: ≤2Ω
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No.17 terminal of EU1 and No.5 terminal of E01.
Resistance: ≤2Ω
(f). Use a digital multimeter to measure the resistance between

Terminal 5 of E01 and the ground.
Resistance: > 1 MΩ

5. Check the battery.
(a). Inspect battery.

Voltage: 11~14V

No ＞ Charge or replace the battery.
6. Check the battery terminal
(a). Check the battery terminal is loose or corrosive.

OK: the battery terminal is not loose or corrosive

No ＞ Repair or replace the battery terminal.
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7. Check engine wire harness earth point
(a). Inspect wire harness grounding point G01.

OK: grounding point is not loose and body connection is good.
Is check result normal? 12

No ＞ Repair or replace grounding terminal.
(a). Replace ECM.

LIFAN AUTO
P2122- Electronic accelerator pedal position sensor 1# circuit has low voltage.
P2123- Electronic accelerator pedal position sensor 1# circuit has high voltage.
P2127- Electronic accelerator pedal position sensor 2# circuit has low voltage.
P2128- Electronic accelerator pedal position sensor 2# circuit has high voltage.
P2128- Electronic accelerator pedal position sensor 1#, 2# have relative fault.
Wiring diagram
signal
Accelerator pedal position sensor

signal
Description of electronic accelerator pedal position sensor

1. Electronic accelerator pedal position sensor is a sliding type potentiometer. When stepping accelerator pedal,
sensor will send feedback voltage signal to ECM.
2. ECM will drive motor to rotate by controlling output voltage signal, so as to adjust throttle opening. Sensor
signal voltage changes within a range of 0~5V. It is proportional to throttle opening.
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Diagnostic steps
1. Primary check
good.

(e). Read DTCs.
Check whether the displayed DTC is P2122, P2123, P2127, P2128 or P2138.
3. Inspect power supply voltage of accelerator pedal position sensor.
(a). Ignition switch: OFF

(b). Disconnect the connector E02 of the accelerator pedal
position sensor.
terminal of accelerator pedal position sensor connector
E02and grounding.
Voltage: 5V
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(e). Use a digital multimeter to check the voltage between No.5

terminal of accelerator pedal position sensor connector
E02and grounding.
Voltage: 5V

4. Inspect accelerator pedal position sensor.
(a). Disconnect the connector E02 of the accelerator pedal

position sensor.
(b). Use a digital multimeter resistance scale to check whether
No.6 terminal and No.2terminal of accelerator pedal
position sensor are connected.
(c). Use a digital multimeter resistance scale to check whether

No.5 terminal and No.4 terminal of accelerator pedal
position sensor are connected.

No ＞ Replace the accelerator pedal position sensor assembly.
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5. Inspect electric wiring and connector of accelerator pedal position sensor.
(a). Disconnect the connector E02 of the accelerator pedal position sensor.
(c). Use a digital multimeter to check the resistance between No.6 terminal of accelerator pedal position sensor
connector E02and No.66 terminal of ECM connector E01, No.1 terminal of E02and No.42terminal of E01,
No.2terminal of E02AND No.76 terminal of E01, No.4 terminal of E02and No.74 terminal of E01, No.3 terminal 12
of E02and No.41 terminal of E01, No.5 terminal of E02and No.70 terminal of E01, No.6 terminal of E02and
grounding, No.1 terminal of E02and grounding, No.2terminal of E02and grounding, No.5 terminal of E02and
grounding, No.3 terminal of E02and grounding, and No.4 terminal of E02and grounding.
The multimeter is connected with a terminal Resistor
Terminal 6 of E02 and the Terminal 32 of E01 ≤ 2Ω
Terminal 6 of E02 and ground ＞ 1MΩ
Terminal 2 of E02 and ground ≤ 2Ω
Terminal 4 of E02 and ground ≤ 2Ω

LIFAN AUTO
6. Inspect the condition of accelerator pedal position sensor signal to power supply short-circuit.
(a). Disconnect the connector E02 of the accelerator pedal position sensor.
(d). Use a digital multimeter to respectively check the voltage between No.1 terminal and No.3 terminal of E02and
grounding.
Voltage: 0V

7. Replace the ECM
(a). Replace ECM.

LIFAN AUTO
Engine Control System-Sensor actuator 12-167
Sensor actuator
Electronic control unit(ECM)
1. Parts drawing
12
2. ECM installation position

3. Working principle
The ECM is the core of the engine electronic control
system. The ECM consists of a microprocessor and is
provided with an interface for sensor signal input and an
engine electronic control center of actuator drive circuit. It
receives and treats the engine state signals input by various
sensors and sends control signals to the actuators so that
the engine can run according to the predefined procedures
to enable the engine to be in the optimum working state in
order to ensure good power, economy and emissions.
4. Replace
(b). Disconnect the battery negative cable.
Attention:
When disconnecting and re-connecting negative cable of
battery, please turn off ignition switch and all electric load
switches first. And loosen the fastening nut of the battery
negative terminal. Don't pry up the cable terminal when
performing such operation.
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12-168 Engine Control System-Sensor actuator
(c). Remove the glove box. (See Chapter 84 Dashboard and

Console - Glove Box, Replacement)
(d). Disconnect ECM connector.

Attention:
After disconnecting the connector, make sure the connector
does not contact dirt, water and other impurities.
(e). Dismantle the 4 fastening bolts of the ECM.

(f). Take down ECM.
Attention:
After dismantling ECM, do not immerse it in the water. When dismantling ECM, handle it with care.
(g). Install the ECM.
Torque: 20 N•m
Attention:
When installing, electrostatic protection shall be made.
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(h). Connect ECM connector.
12
(i). Install glove box. (See Chapter 84 Dashboard and Console -

Glove Box, Replacement)
(j). Connect the battery negative cable.
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Intake air temperature/pressure sensor

1. Simplified diagram of parts and pins
(a). Intake air temperature/pressure sensor diagram
(b). Intake temperature/pressure sensor terminal.
Terminal No. Function
1 MAPS signal
2 Power supply of 5V.
3 IATS signal
4 Signal GND
2. Mounting position for the intake air temperature /

pressure sensor
The intake manifold absolute pressure sensor is composed of a piece of silicon chip. A piece of pressure
diaphragm is etched on the silicon chip. Four piezo resistances are on the pressure diaphragm and they, as a strain
element, form a Wheatstone bridge. Besides this pressure diaphragm, a signal processing circuit is also integrated
on the silicon chip. (Remove the connector) switch the digital multimeter to ohmmeter mode and connect the two
test pens respectively to 1# pin and 2# pin of the sensor. The rated resistance is 2. 5kΩ±5% at 20 ° C and
other relevant resistance values can be measured out from the characteristic curve of the figure above. Therefore,
a micro electro mechanical system is formed. The active side of the silicon chip is under the pressure approaches
to zero and its reverse side is under the intake manifold absolute pressure that is introduced by a connecting
pipe and needs to be measured. The thickness of silicon chip is only few microns (m), therefore, the changes of
the intake manifold absolute pressure can cause mechanical transformation of silicon chip, then the four piezo
resistances transform and the resistance value changes. Voltage signals that are linear to pressure are formed after
the circuit processing through the signal processing circuit of silicon chip.Intake temperature sensing element is
the resistance of a negative temperature coefficient (NTC). The resistance will change with intake temperature.
This sensor inputs a voltage showing intake temperature change to controller.
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4. Possible faults and reasons

(a). Fault phenomenon: Misfiring, poor idle, increased fuel consumption and emissions and so on.
(b). General fault reason:
Abnormal high voltage or large reverse current occurs in the process of use.
Vacuum components can be damaged in the process of maintenance.
5. On-Vehicle inspection 12
(a). Start the engine and make it run to reach its normal working
temperature.
(b). Turn ignition switch to "OFF" position.
(c). Connect diagnostic scanner to fault diagnosis connector
(16-pin) on the bottom left of dashboard.
(d). Turn ignition switch to "ON" position, and turn on the
diagnostic scanner - use the update software version.
(e). Select item of "intake air temperature" in menu of "read

data flow".
Data stream
Items
displayed by Check conditions (range) Normal value
Enable data stream memory playback the diagnostic
scanner
Intake air sensor
Inlet air
temperature:
-20℃
-20℃
Inlet air
Previous page Next page Waveform Playback temperature:
Return
0℃
0℃
• Ignition
Inlet air
Intake air switch: ON
temperature:
20℃
• Engine
Temperature
20℃
running
Inlet air
temperature:
40℃
40℃
Inlet air
temperature:
80℃
80℃
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(f). Select diagnostic item of "manifold absolute pressure",

there should have pressure output.
(e). If the result does not comply with relevant provisions,
Data stream
check the intake manifold pressure / temperature sensor,
Enable data stream memory playback wire harness or ECM.
Manifold absolute pressure

Return
6. Inspection and replacement

(b). Open engine hood.
(c). Disconnect the battery negative cable.
Attention:
When disconnecting and re-connecting negative cable of battery,
please turn off ignition switch and all illumination switches first.
And loosen the fastening nut of the battery negative terminal.
Don't pry up the cable terminal when performing such operation.
(d). Disconnect intake air temperature/pressure sensor
connector.
(e). Dismantle the hold-down bolts and take down the intake air
pressure / temperature sensor.
Attention:
After dismantling, clean mounting surface and the sensor to
make sure no oil stains and contaminants.
(f). Inspect resistance value of intake temperature sensor.

Switch the digital multimeter to the resistance function,
and connect the two probes to the Terminal 3 and 4 of the
sensor, respectively. Analogous method can be used during
the measurement, that is, to supply air towards the sensor
with the electric blower (Hint: don’t be too closed to it),
observe the changes of the sensor resistance, and at the
moment, the resistance shall drop off.
(g). If the result doesn't meet requirement, replace intake
temperature/ pressure sensor.
(h). Install intake temperature/ pressure sensor, and tighten fixed bolts.
Torque: 21~25 N•m
Install it by pressing method. Do not use any impact tool
(like a hammer) to knock the sensor into mounting hole.
(h). Connect intake air temperature/pressure sensor connector.
LIFAN AUTO
Coolant temperature sensor

1. Parts drawing
12
2. Coolant temperature sensor installation position
Coolant temperature sensor is installed on engine body or cylinder head. It contacts with coolant. It is used to
check the temperature of engine circulation coolant and send the check result to electric control unit to repair
fuel injection value and ignition timing. The water-temperature sensor is usually made of the thermostat which
is very sensitive to temperature change. In general, the thermostat uses the NTC resistance. The lower the water
temperature, the larger the thermostat resistance. According to such signal, the electronic control unit can enable
the quantity of fuel injection to increase so as to enrich the air-fuel mixture.

(a). Fault phenomenon: engine fuel consumption and exhaust pollution is increasing, it is difficult to start a cold
engine or the engine cannot start, engine flames out intermittently and idle speed is unstable.
• Engine temperature sensor has open-circuit.
• Engine temperature sensor has internal short-circuit.
• Engine temperature thermistance has short-circuit to the housing.
LIFAN AUTO
5. On-Vehicle inspection
temperature.
(e). Select "reading data stream" menu item.
Items
displayed by
Data stream Check conditions (range) Normal value
the diagnostic
scanner
Name Current value Unit Coolant
Engine Idling Speed 80℃～ 100℃
Coolant temperature temperature
(f). If the result does not conform to the specification, check

coolant temperature sensor, wire harness or ECM.

Return
6. Inspection and replacement

(b). Open the engine hood.
Attention:
battery, please turn off ignition switch and all illumination
(d). Discharge engine coolant.
LIFAN AUTO
(e). Disconnect coolant temperature sensor connector.

(f). Dismantle coolant temperature sensor.
Attention:
Clean mounting surface after dismantling. Clean up the
mounting hole threads after removal. Clean up the mounting
threads after the sensor is dismantled. When removing or
installing it, be careful not to let the tool touch the linker (the 12
resin part).

No.1 and No.3 terminal s of ECT sensor.
(h). If the check result doesn't meet requirement, replace ECT
sensor.
Measuring conditions Standard resistance (Ω)
0℃ 9098~9700
10℃ 5494~5822
20℃ 2184~2296
(i). Install ECT sensor and tighten it.

Torque: 20N•m
(j). Install the ECT sensor connector.
(k). Refill the engine with the recommended coolant.
(l). Check the coolant for leak.
(m). Connect the battery negative cable.
LIFAN AUTO
Crankshaft position sensor

1. Parts drawing
2. Crankshaft position sensor installation position
Engine rotation and crankshaft position sensor is a magnetic sensor which is installed near the crankshaft and
works together with 58X gear ring. When crankshaft rotates, 58X gear top and groove pass through the sensor
with different clearance, the sensor will sense the change of magnetic reluctance. This AC magnetic reluctance
will produce AC output signal; while notch position of 58X gear ring corresponds to upper limit point. When it is
on the limit point of No.1 cylinder, sensor will point to the 20th gear of 58X gear ring. ECM will make full use
of this signal to determine the rotation position and speed of crankshaft.

(a). Fault phenomenon: the engine cannot start or it flames out after starting.
• In wire harness, this signal doesn't use shielded wire or shield layer of shielded wire has bad grounding
connection.
• Magnetic core absorbs plenty of metal and dust;
• Distance between sensor and gear ring exceeds limit value;
• Relative position between gear ring and crankshaft is incorrect or has displacement.
LIFAN AUTO
5. Overhaul and replace

Attention:
When disconnecting and re-connecting negative cable of 12
(d). Disconnect the crankshaft position sensor connector.
(e). Remove the crankshaft position sensor.
Attention:
After dismantling, clean mounting surface to ensure no oil
stain.
(f). Check the crankshaft position sensor.

(g). Adjust a digital multimeter to resistance scale, 3 meter
probes are connected respectively to No.1 and No.2terminal
of sensor, and check the resistance between 2 terminals.
Standard resistance: 560 Ω (20°C)
(h). If the check resistance value doesn't meet requirement,
replace sensor. (i). Install crankshaft position sensor, and
tighten fixed bolts.
Torque: 6 ~ 10N•m
Attention:
Install it by pressing method. Do not use any impact tool (like a
hammer) to knock the sensor into mounting hole.
(j). Connect crankshaft position sensor connector.
(k). Connect the battery cathode cable.
LIFAN AUTO
CMP sensor
1. Parts drawing
2. Mounting position for the camshaft position sensor

This sensor is coupled with the pulse plate and used
in the distributorless system to provide the ECM with
the crankshaft camshaft position information, namely,
distinguish the crankshaft compression TDC and exhaust
TDC. This sensor consists of a Hall sensor (HS) and a steel
rotor. The Hall sensor is fixed, while the rotor is arranged
on a camshaft. The rotor is a cylindrical steel blade with
the range of 180° , and when the blade covers up the Hall
sensor, there will be no output signal; otherwise, there will
be output signal. If closed together, the two semi-circles
of the camshaft are equivalent to two whole circles of the
crankshaft, by which the crankshaft compression TDC can
be distinguished from the exhaust TDC.
(a). Fault phenomenon: Excessive emissions, increased fuel
consumption, or other.
• The camshaft position sensor is open circuit;
• The camshaft position sensor is subject to an internal
short circuit;
• The camshaft position sensor Hall element circuit is
shorted to the ground;
• The camshaft position sensor Hall element circuit is
shorted to the system reference voltage signal line.
LIFAN AUTO

Attention:
When disconnecting and re-connecting negative cable of 12
(d). Disconnect camshaft position sensor connector.
(e). Remove the camshaft position sensor.
Attention:
After dismantling, clean mounting surface to ensure no oil
stain.
(f). Check the camshaft position sensor. (See fault diagnosis

P0340, P0341)
(g). Install camshaft position sensor, and tighten fixed bolts.
Torque: 6 ~ 10N•m
Attention:
Install it by pressing method. Do not use any impact tool (like a
hammer) to knock the sensor into mounting hole.
(h). Connect camshaft position sensor connector.
(i). Connect the battery cathode cable.
LIFAN AUTO
Oxygen sensor
1. Parts drawing
2. Mounting position of oxygen sensor

Oxygen sensor has a sensing element, which is a porous
ceramic tube, the outer wall surrounded by the engine exhaust
and inside connecting to the atmosphere. Sensing ceramic pipe
wall is a solid electrolyte that contains electric heating pipes.
The function of oxygen sensor is realized through changing the
concentration difference of oxygen ions inside and outside the
sensing ceramic tube into the voltage signal output. When the
temperature of the sensing ceramic tube reaches to 350° C, it
owns the characteristics of solid electrolyte. The oxygen ions
can pass through the ceramic tube freely because of its special
textures. It is also this texture that the concentration difference
can be changed into potential difference and then forms
electrical signal output. When the mixed gas is relatively rich.
The oxygen ion concentration inside and outside the ceramic
tube will be higher, resulting in a higher electric potential
difference. Therefore, a great deal of oxygen ion will move to
the outside from the inside, resulting in a higher output voltage
(about 800~1000mV). If the air-fuel mixture is thinner, the
oxygen ion concentration inside and outside the ceramic tube
will be lower, resulting in a lower electric potential difference.
As a result, only a little of oxygen ion will move to the outside
from the inside, resulting in a lower output voltage (about
100mV).

(a). Fault phenomenon: engine fuel consumption and exhaust pollution increasing, idle speed unstable, misfire, shaking etc.
• Lead poisoning, for use of leaded gasoline. At high temperature, the lead will attach onto the surface of the
oxygen sensor so that the oxygen cannot produce normal signals.
• Deposited carbon. If the carbon deposits onto the surface of the oxygen sensor platinum, the oxygen sensor
will not produce normal voltage signals.
• Internal circuit of oxygen sensor is poor contact or open circuit so that no signal voltage is output.
• Due to damage to the ceramic components of the oxygen sensor, the oxygen sensor cannot produce normal
voltage signals.
• The resistance wire of the heater of the oxygen sensor is blown or the circuit is open-circuited so that the
oxygen sensor cannot reach its normal working temperature quickly.
LIFAN AUTO
temperature.
Data stream

Name Current value Unit (c). Connect diagnostic scanner to fault diagnosis connector
(d). Turn ignition switch to "ON" position, and turn on the 12
Return Items
displayed by Inspection conditions Normal value
the diagnostic
scanner
Group 1,
oxygen sensor
Engine running 0.1 - 0.9V
voltage (sensor
1, sensor 2)
(f). If the voltage is not in conformity with the provisions,

check the sensor, wire harness and ECM.
Attention:
When disconnecting and re-connecting negative cable of battery,
please turn off ignition switch and all illumination switches first.
And loosen the fastening nut of the battery negative terminal.
Don't pry up the cable terminal when performing such operation.
(d). Remove the connectors of front and rear oxygen sensors.
Attention:
exhaust pipe is hot, operate after exhaust pipe is cooled completely.
(e). Remove front and rear oxygen sensors.
(f). Check front and rear oxygen sensors.

Standard resistance: 9.6±1.5Ω (20°C)
△ Hint:
Measuring methods of front/rear oxygen sensors are the same.
(h). If the check resistance value doesn't meet requirement, replace sensor.
(i). Install front and rear oxygen sensors, and tighten fixed bolts.
Attention:
Before installing, apply a layer of antirust oil on the threads to prevent corrosion.
LIFAN AUTO
Knock sensor
1. Parts drawing
2. Knock sensor installation position
Knock sensor is a kind of vibration acceleration sensor, which is installed on engine cylinder block. Sensing
element of the sensor is a piezoelectric element. Engine cylinder block vibration is transferred to piezoelectric
crystal through weight block in the sensor. Because piezoelectric crystal bears pressure generated by weight
block vibration, the voltage is generated on both pole faces to convert vibration signal into AC voltage signal
output. Vibration signal frequency caused by engine knock is higher than normal vibration signal frequency of
the engine. Therefore, ECM filters knock sensor signals and differentiate knock signal and non-knock signal.
(a). Fault phenomenon: bad acceleration.
• If various liquid such as engine oil, coolant, brake fluid, water contacts with sensor for a long time, it may
cause corrosion of sensor.
• In wire harness, this signal doesn't use shielded wire or shield layer of shielded wire has bad grounding
connection.
LIFAN AUTO
temperature.
(c). Disconnect knock sensor connector.
(d). Adjust a digital multimeter to voltage scale, and check the
voltage between 2 terminals. 12
(e). Use a small hammer to slightly strike the cylinder block
near knock sensor, at this moment, the knock sensor should
have 0~1V voltage signal output.
(f). If there is no voltage signal output, replace the knock
sensor.

(d). Remove intake manifold. (See Chapter11 Engine
Mechanical System--Intake Manifold, Replacement)
(e). Disconnect the knock sensor connector.
(f). Remove the fixed bolt and the knock sensor.
Attention:
Clean mounting surface after dismantling. After dismantling,
do not contact various liquids, such as engine oil, coolant,
brake fluid etc. The sensor will be subject to corrosion due to
long-term exposure to these fluids.
(g). Check the knock sensor. Switch the digital multimeter to

the resistance function and check whether the resistance
between the two terminals is infinite.
(h). If the check result doesn't meet requirement, replace knock
sensor.
(i). Install knock sensor, and tighten fixed bolts.
Attention:
Make sure knock sensor direction is right. Install it by pressing
method. Do not use any impact tool (like a hammer) to knock
the sensor into mounting hole. Metal face of the sensor shall
be very close to cylinder block. When installing, any type of
washer is not allowed. When laying the sensor signal cable,
signal cables shall not have resonance to avoid breaking.
(j). Connect the knock sensor connector.
(k). Install the intake manifold. (See Chapter11Engine
(l). Connect the battery negative cable.
LIFAN AUTO
Electronically-controlled throttle valve housing

1. Parts drawing
2. Mounting position of electrically-controlled throttle

valve housing
The throttle opening of the electrically-controlled throttle valve housing assembly is regulated by the ECM.
Based on the input signal of the accelerator pedal controlled by the driver as well as other input signals of various
sensors, the ECM can calculate the desired engine output power at the moment and in the state. On this basis,
the ECM will control the quantity of fuel injection of the engine, and correct the control parameters according to
the feedback signals to ensure the engine to work in the optimum state. The electrically-controlled throttle valve
housing is additionally equipped with a drive motor, gear drive mechanism and other components as well as the
throttle position sensor with more function and reliability.

(a). Fault phenomenon: high idle speed, idle at idle speed and so on.
• Dust and gasoline accumulation blocks bypass air duct. As a result, idle speed adjustment of stepper motor is
abnormal.
LIFAN AUTO
temperature.
(d). Turn ignition switch to "ON" position, and turn on the 12
Items
displayed by Normal
Data stream the diagnostic Inspection conditions conditions
scanner
Name Current value Unit Idling position 12%±5%
The throttle
• Ignition is gradually
switch: ON Throttle is proportional
Absolute throttle to the increase
opening
position • Engine of the throttle
gradually
doesn't run opening
Previous page Next page Waveform Playback angle.
Return
Fully open 83%~93%
(f). If the signal value is inconsistent with the specified value or

there is no signal output, check the electrically-controlled
throttle valve hosing, harness and ECM.

(d). Remove the intake manifold assembly. (See Chapter 11
Engine Mechanical System--Intake Manifold, Replacement)
(e). Remove the electrically-controlled throttle valve housing
assembly.
LIFAN AUTO
(f). Check the resistance of the electrically-controlled throttle

valve housing. Check the resistance between No.1 and No.3
terminals of connector of throttle element.
Connection of digital Specified conditions

multimeter
The throttle opens gradually from

the idling position up until it opens
Terminal 1 and Terminal 3 fully. The resistance changes
steadily and proportionally with
the throttle opening angle.
(g). If the resistance is beyond the standard range or the

resistance changes unsteadily, replace the throttle valve
housing.
(h). Check the stepping motor of the electrically-controlled

throttle valve. Connect positive and negative cables of
battery to No.5 and No.8 terminals of electric control
throttle, stepper motor should take action. Otherwise,
replace the electrically-controlled throttle valve housing.
(i). Install the electrically-controlled throttle valve housing
assembly.
(j). Install the intake manifold assembly. (See Chapter 11
LIFAN AUTO
Intake VVT valve

1. Parts drawing
12
2. Mounting position of intake VVT

The working power supply of the intake VVT solenoid
valve is provided by the main relay. The ECM controls
grounding through pulse-width-modulated signal. Thereby,
controlling the engine oil flow to the camshaft position
actuator. The oil pressure actuates a safety sliding valve,
which is inside the camshaft position actuator mechanism
fixed at the front of the camshaft to operate. When the
safety sliding valve operates, the oil will be led into the
camshaft position actuator to make the camshaft rotate.
(a). Fault phenomenon: engine idle speed unstable, poor
acceleration. It is impossible to drive the vehicle normally.
(b). General cause of fault: The oil way has not been cleaned
thoroughly.
temperature.
(c). Open the engine hood.
(d). Disconnect the battery negative cable.
(e). Disconnect the VVT solenoid valve connector.
LIFAN AUTO
(f). Measure the resistance between the two terminals of the

VVT solenoid valve with the digital multimeter.
Standard resistance:9.4~10.6Ω(20°C)
(g). If the measured resistance is inconsistent with the standard
value, replace the VVT solenoid valve.

(d). Disconnect the VVT solenoid valve connector.
(e). Remove the VVT solenoid valve.
(f). Check the VVT solenoid valve filter for clogging or
damage. If there is , replace the filter.
(g). Connect the battery positive cable to the Terminal 1 of the

VVT solenoid valve, and connect the battery negative cable
to the Terminal 2 of the VVT solenoid valve.
Attention:
To avoid explosion, fire or other danger, don't connect the two
cables together directly in the process of testing.
(h). Check the valve core for operation. If it doesn't work,
replace the VVT solenoid valve.
(i). Install the VVT solenoid valve and tighten it.
Torque: 6 ~ 10N•m
(j). Connect the VVT solenoid valve connector.
LIFAN AUTO
Canister control valve

1. Parts drawing
12
2. Mounting position of canister solenoid

There is a solenoid valve mechanism inside canister
solenoid. Digital pulse square sent from ECM will control
the opening of solenoid valve. The opening of canister
solenoid varies with engine working conditions. When
engine is in heavy load and idle speed, to ensure output
power of engine, canister doesn't work.
(a). Fault phenomenon: function failure, excessive accumulation
of gasoline vapor in the canister, resulting in gasoline leak
and environment pollution.
• Canister solenoid and other relevant circuit fault;
• Read system diagnosis fault through diagnostic scanner;
• Connector falls off.
• Internal damage.
LIFAN AUTO
temperature.
(e). Touch the canister solenoid of the evaporative emission
control system (EVAP) with your hand.
(f). Use the function of "input and output control function unit"
of diagnostic scanner to carry out function of "purification
of canister".
(g). Canister solenoid should have slight vibration. If the
canister solenoid has no slight vibration, inspect solenoid
valve, wire harness and ECM.
6. Overhaul and replacement

(d). Remove the intake manifold assembly. (See Chapter 11
(e). Disconnect canister solenoid connector.
(f). Loosen the clamp of the air inlet of the canister solenoid
and disconnect the connection of hose (to the canister).
Attention:
For a vehicle with a long mileage, when disconnecting a hose,
first twist the hose to confirm it has been loose.
(g). Loosen the clamp of the air outlet of the canister solenoid
and disconnect the connection of hose ( connected to the
lower intake manifold of the throttle housing).
(h). Remove the canister solenoid.
LIFAN AUTO
(i). Check the canister solenoid.

(j). Use battery power supply to switch on canister solenoid.
When switching on or off canister solenoid, a "tick" sound
should be produced. At this moment, blow air into air inlet
(to canister). If there is air flowing from air outlet (to intake
manifold), it indicates that canister solenoid has good
working condition. otherwise, replace solenoid valve.
(k). If solenoid valve is not energized, it shall keep closed and 12
air cannot go through it.
(l). Check the resistance of the canister solenoid. Switch the

digital multimeter to the resistance function, connect the
two probes to the Terminal 1 and Terminal 2 of the solenoid
valve, respectively, and then measure the resistance between
the two terminals.
Standard resistance:19~22Ω(20°C)
(m). If the resistance is inconsistent with the specified value,
replace the solenoid valve.
(n). Connect the clamp of the air outlet of the canister solenoid
and disconnect the connection of hose ( to the lower intake
manifold of the throttle housing).
(o). Connect the clamp of the air inlet of the canister solenoid
and disconnect the connection of hose (to the canister).
(p). Connect the connector of the canister solenoid.
(q). Install intake manifold assembly. (See Chapter 11 Engine
(r). Connect negative cable of battery.
LIFAN AUTO
Injector
1. Simplified diagram of parts and pins
2. Mounting position of injector

The nozzle structure is a ball valve device of the
electromagnetic switch. Two poles leading from coil are
connected to ECM and power supply through engine wire
harness. After coil, being controlled by ECM, to system
grounding , the produced magnet will overcome spring
force, fuel pressure and vacuum absorption of manifold
and absorb valve core. Fuel will spray out from guide hole
through valve seat hole. Fuel forming fog type to spray onto
the intake valve. After being switched off, fuel injector will
close under the effect of spring force and fuel pressure.
(a). , Fault phenomenon: poor idling and acceleration, it is
difficult to start.
• Impurity blockage;
• Fuel gumming after evaporation;
• Seal ring is damaged, which leads to oil leakage or air
leakage;
• Connector falling off, wire harness or itself damaged.
LIFAN AUTO
(a). After warming up the engine, make it run at idle speed.
(b). Touch the injector with a spin tool (screwdriver) or
stethoscope (touch-rod type).
(c). When the engine operating, you can hear rhythmic "rattling"
sounds from the injectors - These are the fuel injection sounds
of the injectors under the action of electric pulses. 12
(d). If the working sound of the injector of each cylinder is clear
and uniform, it is an indication that each injector is working
properly. If the working sound of the injector of a cylinder
is very small, it indicates that the injector of the cylinder
is not working properly. It is possible that its needle valve
is seized up, be sure to perform further examination on it.
If you hear no working sound of the injector of a cylinder
injector, it is clear that the injector in the cylinder is not
working, be sure to check the injector and its control circuit.

Attention:
(d). Dismantle fuel rail assembly.
(e). Remove the injector.
(f). Check fuel injector.
Standard resistance: 12.0±0.4Ω (20°C)
(h). If the resistance value doesn't meet requirement, replace
fuel injector.
LIFAN AUTO
Ignition coil
1. Parts drawing
2. Mounting position of ignition coil

The ignition coil is mainly composed of a primary coil,
a secondary coil and an iron core. In the ignition system,
the ignition coil is used to change a low voltage into a
high voltage to enable the spark plugs to generate sparks.
Delphi rod type ignition coil only corresponds to one
cylinder. Under the control of computer ECM, recharge
the preliminary coil for accumulating magnetic energy, and
secondary coil winding will sense high voltage, to make
the spark plug connected to the coil jump spark, which can
control output voltage energy from ignition coil of each
cylinder to spark plug.
(a). Fault phenomenon: engine idle speed unstable, intermittent
flameout, the engine cannot start.
• Ignition coil winding is short circuit, open circuit or
grounding. As a result, ignition coil generates low
voltage or does not generate voltage, which leads to
insufficient ignition energy or misfire.
• Insulation material of ignition coil is ageing which make
the insulation performance bad. Ignition system has
weak spark or doesn't ignite due to electricity leakage of
ignition coil.
LIFAN AUTO

(a). Remove the fixing bolts of the high-voltage ignition coil,
and then remove the high-voltage ignition coil.
12
(e). Check the surface of the high-voltage ignition coil for crack
or damage. If there is , replace the ignition coil.
(f). Adjust a digital multimeter to resistance scale to check the

resistance between No.1 and No.3 terminals of high-voltage
ignition coil.
Standard resistance: 0.52±0.05Ω (Preliminary)
Secondary: 9840±980Ω
(g). If the check resistance doesn't meet requirement, replace
ignition coil.
(h). Install the ignition coil and tighten its fixed bolts.
LIFAN AUTO
Fuel pump
1. Parts drawing
2. Mounting position of fuel pump

The electric fuel pump consists of a DC motor, a vane
pump and an end-cover (integrated with a check valve, a
pressure relief valve and anti-electromagnetic interference
components) and so on. Both the pump and the motor are
installed on the shaft and sealed inside the same housing.
Gasoline is filled around the pump and motor inside the
housing and is used for cooling and lubricating. The battery
powers the electric fuel pump through the fuel pump relay.
Only when the engine starts and operates, the relay can
allow the electric fuel pump circuit to have good continuity.
When the engine stops running due to any accident, the fuel
pump will stop operating automatically.
4. Possible faults
(a). Fault phenomenon: noisy operation, poor acceleration,
unable to start (difficult to start), etc.
(b). General cause of fault: due to use of poor fuel.
temperature.
LIFAN AUTO
(e). Use the function of "input and output control function unit"
of diagnostic scanner to carry out function of "fuel pump".
(f). The fuel pump relay should operate, and the fuel pump
O Control functional unit LIFAN Dedicated\Chongqing Lifan\V5.0\Power should produce a slight pumping sound. If there is on
Malfunction indicator light (MIL) Previous page operation of the fuel pump relay or no pumping of the fuel
Canister purge pump, be sure to check the fuel pump, harness and ECM.
Fuel pump Next page
Fan low-speed
Fan high-speed Print 12
A/C clutch
Control IAC valve by steps Return
Control IAC valve by rpm
Idle air control valve reset
Ignition advance/delay

(d). Disconnect the fuel pump connector.
(e). Remove the fuel pump. (See Chapter 13 Fuel System-Fuel
Pump, Replacement)
(f). Check the fuel pump. Put fuel pump into fuel container, and
use a wire to connect fuel pump and battery.
Attention:
Separate the battery from the container with a wooden plate to
prevent fire from igniting the fuel.
(g). Make sure that the fuel pump can pump fuel normally. If
not, replace the fuel pump.
(h). Install the fuel pump. (See Chapter 13 Fuel System-Fuel
Pump, Replacement)
(i). Connect fuel pump connector.
LIFAN AUTO
• Memo •
LIFAN AUTO
Fuel system
Fuel system................................................................. 13-1
Preparation............................................................. 13-1
Repair specifications.............................................. 13-2
Precautions............................................................. 13-3
Schematic diagram................................................. 13-4
Component diagram (I).......................................... 13-5 13
Component diagram ( Ⅱ )..................................... 13-6
On-Vehicle check................................................... 13-7
Fuel tank................................................................... 13-11
Check.................................................................... 13-11
Replace................................................................. 13-12
Fuel pump................................................................. 13-17
Check.................................................................... 13-17
Replace................................................................. 13-18
Fuel filter................................................................... 13-21
Check.................................................................... 13-21
Replace................................................................. 13-22
Fuel pipeline............................................................. 13-25
Check.................................................................... 13-25
Canister..................................................................... 13-26
Replace................................................................. 13-26
LIFAN AUTO
13-1
Fuel System - Fuel system
Fuel system
Preparation
S/N Tools Contour Drawing No. Description
13
1 Bracket Lift parts
Remover for fuel Remove and install the

2 pump compression fuel pump compression
nuts nuts
Measure fuel system

3 Fuel pressure gauge
fuel pressure
Measure current,
4 Digital multi-meter voltage and resistance
value
LIFAN AUTO
13-2
Fuel tank capacity 55L
Normal pressure of fuel 0.25~0.35MPa
Oil level sensor resistance value (the highest point) 40.9Ω
Oil level sensor resistance value (the lowest point) Infinity
2. Torque Specifications
Item N•m
Fuel tank fixed bolt 40~50
Fuel tank support fixed bolts 65~85
Fixed bolts of heat insulator of fuel tank 6~12
Fixed bolts of fuel filter assembly 6~12
Fixed bolts of canister sleeve 6~12
LIFAN AUTO
13-3
Precautions
1. Whether the gasoline engine runs or not, with ignition switch ON, any component is not allowed to be plugged,
such as any cable of the battery, fuel injector, fuel pump, ignition system wire, electronic control unit (ECU)
circuit, air conditioner circuit.
2. When fuel system is working, smoking strictly prohibited and keep away from open fire. At maintenance site,
keep good ventilation and provide fire extinguisher.
3. After the engine flames out, there is still high pressure remaining in the fuel system. When dismantling any 13
component in the fuel system, it is necessary to release fuel system pressure to avoid fuel injection from causing
personal hurt or catching a fire.
4. Before disconnecting any fuel pipeline, you should clean the dust and dirt on or near it.
5. After disconnecting fuel line, it is necessary to seal pipe joint to prevent foreign matters.
6. During the course of maintenance, replace all cracked, scratched or damaged nylon fuel pipe. Do not try to
maintain each segment of fuel pipe.
7. Drainage operation must be conducted before installing fuel system. Detailed steps are shown as follows:
• Use a clean cloth to wrap the fuel rail oil inlet pipe.
• Slowly pull out the fuel rail oil inlet pipe (do not unplug it) to prevent the fuel spilling.
• Turn on the ignition switch to enable the fuel pump to start working.
• Observe the fuel rail oil inlet pipe joint until the oil pipe has oil flowing out smoothly.
• Re-install the fuel inlet pipe of the fuel rail.
8. When mounting new fuel pipes, never use any hammer to directly strike the fuel bundle clamps, or it will
damage the nylon tube and result in oil leakage.
9. When connecting fuel pipe, it is necessary to drip a few cleaning engine oil on oil pipe joint, to ensure correct
connection of fuel pipe and avoid fuel leakage (if operated properly, O-ring in socket will swell. If lubrication
isn't conducted, reinstallation can't be conducted correctly.)
10. Never let any rubber or cortical tool and part exposed to gasoline.
11. Pipe connection in the fuel system shall be reliable.
12. In order to prevent accidental fire or explosion, fuel shall not be placed into a open container.
13. Fuel vapor in evaporation and emission parts has poison, and do not absorb air through evaporation and emission
parts or pipes.
14. It is forbidden to suck gasoline by mouth.
15. Keep a good health habit. After you touch gasoline, wash your hands and face with hot water and soap. Before
washing, do not eat, smoke and drink water.
LIFAN AUTO
13-4
Schematic diagram
Intake manifold
Fuel rail Engine Air filter
Canister solenoid valve
Fuel filter
Canister
Air
Fuel pump
Fuel
Fuel steam
Fuel tank
LIFAN AUTO
13-5
Component diagram (I)
13
1 Engine oil intake pipe assembly 13 Fuel filler pipe assembly
2 Fuel hard pipe components 14 Hexagon bolt and plain washer assy.
3 Hexagon bolt with flange 15 Fuel filler pipe sleeve
4 Fuel filter assembly 16 Fuel filler boot assembly
5 Fuel tank outlet pipe cluster 17 Filler cap assembly
6 Filter outlet pipe cluster 18 Fuel filler hose
7 Electric fuel pump assembly 19 B-type worm drive hoop
Hexagon-headed bolt and taper spring washer

8 Pressing nut 20
component
9 O-ring of pressing nut 21 All-metal hex flange face nuts
10 Fuel tank assembly 22 Hexagon bolt and plain washer assy.
11 Fuel return hose 23 Fuel tank support component
12 C-type worm rod drive type hoop
LIFAN AUTO
13-6
Component diagram ( Ⅱ )
1 A-type worm drive hoop 7 Carbon canister assembly.
Evaporation-hard-pipe-to- control-valve
2 8 B-type worm drive hoop
connecting hose
3 Fuel evaporation hard pipe cluster 9 Canister ventilation pipe
4 Double-pipe clamp 1 10 Canister sleeve
5 Fuel evaporation connection pipe cluster 11 Hexagon bolt with flange
6 Fuel -tank- to- canister connecting hose 12 Hexagon bolt with flange
LIFAN AUTO
13-7
On-Vehicle check
1. Check fuel capacity
(a). Turn the ignition switch to the ON position. At the moment,
the fuel alarm indicator lamp performs self-checking and
illuminates for 3s, and then goes out. If the residual quantity
of fuel is less than 5L, after self-checking, the fuel alarm
indicator lamp stays on. Be sure to refill the tank with fuel
as soon as possible.
13
2. Check whether the fuel system is subject to leakage.

(a). Check whether the fuel tank and fuel pipes are subject to
leakage.
3. Testing the pressure of the fuel system

△ Hint:
To test fuel system pressure, switching on fuel pump function
of active test function in diagnostic scanner can be used. If a
diagnostic scanner is unavailable, the following method can be
used to test:
(a). Release the pressure of the fuel system.
• Open the upper cover of fuse box, and unplug fuel pump
relay.
• Start the engine and let it idle until it misfires
automatically.Let the engine started 2~3 times, and the
fuel system can have its pressure fully released.
• Close ignition switch and install fuel pump relay.
• Install upper cover of fuse box.
LIFAN AUTO
13-8
(b). Check the battery voltage (which should be about 12V).
Attention:
The voltage value can affect the fuel-supply pressure of the fuel
pump directly.
(c). Disconnect the fuel rail oil inlet tube.

△ Hint:
After fuel pressure relief, the oil pipe inside may also have a little
fuel left, so a clean cloth shall be adopted to wrap the oil pipe joint
when disconnecting all oil pipes to prevent the fuel spilling.
Attention:
• If there is any fuel spill, wipe it off to prevent rubber or
leather tools and parts from contacting gasoline.
△ Hint:
• As shown in the figure, pinch the lug boss of the resin tube
connector and pull out it outwards horizontally.
(d). Connect a special pressure gauge to the fuel system.
LIFAN AUTO
13-9
• The special oil pressure gauge should be connected as
shown in the figure (sketch map).
13
(e). Start the engine and let it idle.

△ Hint:
Before starting, it is necessary to accumulate pressure. Turn ignition switch to ON position for 10~15s to store sufficient
fuel in fuel pipe, and then start the engine.
Attention:
Check the connection points for fuel leak.
(f). Read the numerical value indicated by the oil pressure gauge. If inconsistent, replace the fuel pump.
Fuel pressure:0.25~0.35MPa
(g). Turn off the ignition switch.
(h). Release the fuel pressure.
(i). Remove the special fuel pressure gauge and re-install the
fuel system.
△ Hint:
When you hear a ringing click sound, it is an indication that the
resin pipe connector has been installed in place.
Attention:
Pull out the pipe connectors on both ends of the oil pressure
gauge and take it out.
(j). After accumulation of fuel pipe pressure, start the engine.
LIFAN AUTO
13-10
Fuel System - Troubleshooting
Troubleshooting
these parts.
1. Fuel (No fuel in the tank) Fill fuel
Check whether the fuel pump fuse is blown.

2. Electric fuel pump (unable to work)
Check the fuel pump. If necessary, replace it.
3. Fuel tank (water in the fuel tank) Re-fill the tank with clean fuel.
4. System (air in the fuel system) Discharge the air in the fuel system completely.
Engine won't start. 5. System (fuel lines or fuel filter

Clean the fuel pipeline. If necessary, replace the fuel filter.
blocked)
6. Fuel lines (fuel outlet pipe and

Make sure that the fuel pipes are connected correctly.
return pipe reversed)
Make sure that the connectors are connected securely and

7. Connector (connection loosened)
reliably.
8. Fuel injector (damaged) Check the injector working conditions with the special tester.
1. Electric fuel pump ( unable to Check the connection of the fuel pump connector for looseness.
work) If necessary, replace the fuel pump.
2. Fuel lines (fuel lines or fuel filter

Underpowered engine Clean the fuel pipeline. If necessary, replace the fuel filter.
blocked)
3. System (insufficient supply pressure Check the working status of the fuel system pressure, electric
or instable) fuel pump and fuel injector circuits.
Engine shivering 1. Fuel injector (damaged) Check the injector working conditions with the special tester.
1. Fuel (insufficient fuel in the tank) Fill fuel

The engine is stalled during
normal working
2. Circuit (fuel pump fuse blown) Replace the fuel pump fuse.
LIFAN AUTO
13-11
Fuel System - Fuel tank
Fuel tank
Check
1. Washing of fuel tank
(a). Wash the fuel tank with a high-pressure water pistol.
(b). Dry the fuel tank with compressed air.
13

(a). Check the fuel tank for damage or leak. If there is , replace
the fuel tank.
(b). Check the engine oil filler cap of the fuel tank foe crack or
damage. If there is , replace the engine oil filler cap.
(c). Check the gasket of the engine oil filler cap for damage. If
there is , replace the gasket.
LIFAN AUTO
13-12
Replace
1. Removal of fuel tank

(b). Turn off the ignition switch.
Attention:
Turn off the ignition switch before performing operation on the fuel system.
(c). Remove the rear row seat cushion assembly.
(d). Remove the service hole cover of the rear floor.

△ Hint:
Pry up it with a flat-tip screwdriver.
(e). Disconnect the connector of the electric fuel pump.
(f). Disconnect outlet hose and return pipe of electric fuel
pump.
△ Hint:
Attention:
• If there is any fuel spill, wipe it off to prevent rubber or
leather tools and parts from contacting gasoline.
△ Hint:
As shown in the figure, pinch the lug boss of the resin tube
LIFAN AUTO
13-13
(g). Dismantle tail section of exhaust pipe assembly.
(h). Dismantle fixed bolts of heat insulator of fuel tank, and
remove heat insulator of fuel tank.
13
(i). As shown in figure, disconnect No.1 and No.2resin pipe

connection.
(j). Disconnect resin pipe on 2 sides of fuel filter.
(k). As shown in figure, dismantle fixed clamp of No.1 canister

vent pipe and disconnect canister vent pipe connection.
(l). As shown in figure, Disconnect No.2 resin pipe.
(m). As shown in figure, dismantle fixed clamp of vent pipe
of No.3 fuel tank, and disconnect fuel tank vent pipe
connection.
LIFAN AUTO
13-14
(n). Disconnect fixed clamp of oil intake hose of fuel tank, and
(o). Use hydraulic bracket to support fuel tank.

(p). Dismantle fixed bolts of fuel tank bracket, and remove fuel
tank bracket.
(q). Dismantle fixed bolts of fuel tank.
(r). Slowly lower hydraulic bracket, and remove fuel tank.
Attention:
To avoid damage to the tank pipeline, be sure to check it when
lowering the hydraulic bracket.
2. Installation of fuel tank

(a). Use the hydraulic bracket and install the fuel tank in place
slowly.
(b). Install fixed bolts of fuel tank.
(c). Install fuel tank bracket onto mounting position, and tighten
fixed bolts of fuel tank bracket.
LIFAN AUTO
13-15
(d). Lower the hydraulic bracket and hold on it and move it
away.
13
(e). Install the inlet hose of the fuel tank, and tighten its clamp.
(f). As shown in figure, install No.1 canister vent pipe and

tighten clamp.
(g). As shown in figure, install No.2resin pipe.
(h). As shown in figure, install No.3 fuel tank vent pipe and
tighten fixed clamp.
△ Hint:
While installing No.2 resin pipe, if a "tick" sound is produced, it
indicates that resin pipe is installed into proper position.
LIFAN AUTO
13-16
(i). As shown in figure, install No.1 and No.2resin pipe.
Attention:
Don't confuse them.
(j). Install the resin pipes on both sides of the fuel filter.
△ Hint:
(k). Install heat insulator of fuel tank, and tighten fixed bolts of
heat insulator.
Torque: 6~12N•m
(i). Install middle section of exhaust pipe assembly
(m). Connect electric fuel pump connector.

Attention:
Make sure to install the connector securely and reliably.
(n). Install outlet hose and return pipe of electric fuel pump.
Attention:
Don't confuse the outlet pipe and return pipe of the electric
fuel pump.
(o). Install overhaul hole cap of rear floor.
(p). Install rear row seat cushion assembly
(q). Start the engine after accumulating fuel.
LIFAN AUTO
13-17
Fuel System - Fuel pump
Fuel pump
Check
(a). Apply the battery voltage to the Terminal 1 and Terminal 4
of the electric fuel pump, and check whether the fuel pump
is working.
Attention: 13
Attention: The fuel pump can not be working for long without
oil, nor working in the air with fuel, so the detection should not
last too long ( ≤ 10s) to prevent the motor from being burnt.
(b). Use the "Ohm" scale of a digital multimeter to measure the

oil level sensor resistance.
△ Hint:
Have the digital multimeter connected with Terminal 2 and
Terminal 3 of the electric fuel pump, and simultaneously let the oil
float rising slowly from the lowest point to observe the changes of
the resistance value.
Lowest point: infinity
Highest point:40.9Ω
LIFAN AUTO
13-18
Replace
1. Removal of fuel pump

(c). Remove the rear row seat cushion assembly.
(d). Remove the service hole cover of the rear floor.

△ Hint:
Pry up it with a flat-tip screwdriver.
(e). Disconnect the connector of the electric fuel pump.
(f). Disconnect outlet hose and return pipe of electric fuel
pump.
△ Hint:
Attention:
• Never let any rubber or cortical tool and part exposed to
gasoline.
△ Hint:
As shown in the figure, pinch the projection of the connecting pipe
joint and pull it outward horizontally.
LIFAN AUTO
13-19
(g). Use fuel pump pressing nut detector to dismantle fuel pump
pressing nuts.
13
(h). Take out the electric fuel pump slowly and vertically. When
the fuel float occurs at the outlet, tilt and remove the electric
fuel pump.
Attention:
• When you remove the electric fuel pump, don't crash
the fuel float.
• Never let any rubber or cortical tool and part exposed to
gasoline.
(i). Drain the fuel in the electric fuel pump thoroughly.
2. Install the fuel pump.

(a). Install the electric fuel pump into the fuel tank vertically
and slowly.
Attention:
Install the fuel float of the fuel sensor into the tank slowly
before installing the fuel pump. Don't clash the fuel float.
LIFAN AUTO
13-20
(b). Use fuel pump pressing nut to install fuel pump pressing
nut.
(c). Install outlet hose and return pipe of electric fuel pump.
△ Hint:
When you hear a clear "click" sound, it is an indication that the
pipe joint has been installed in place.
Attention:
Don't confuse the outlet pipe and return pipe of the electric
fuel pump.
(d). Install the connector of the electric fuel pump.
Attention:
Make sure that the connectors are connected securely and
reliably.
(e). Install the service hole cover of the rear floor.
(f). Install the rear row seat cushion assembly.
(g). Accumulate the fuel pressure before starting the engine.
LIFAN AUTO
13-21
Fuel System - Fuel filter
Fuel filter
Check
1. Inspection of fuel filter
(a). As shown in figure, use mouth to blow air into inlet pipe
joint to check whether is it smooth. If it is hard to ventilate
or completely doesn't ventilate, replace it.
13
(b). Plug the outlet of the fuel filter, and refill the filter with fuel
through the inlet.
(c). Plug both outlet and inlet of the fuel filter, and shake the
fuel filter left and right.
(d). Discharge the fuel in the fuel filter. If you find impurities in
the fuel or fuel discoloration, replace the fuel filter.
△ Hint:
Generally fuel filter should be replaced after 1 service year or
20,000km.
LIFAN AUTO
13-22
Replace
1. Removal of fuel filter

(c). Disconnect the resin pipes on both sides of the fuel filter.
△ Hint:
△ Hint:
Attention:
(d). Remove the fixed bolts of the fuel filter bracket, and the fuel
filter with bracket assembly.
LIFAN AUTO
13-23
(e). Dismantle tightening bolts of filter.
(f). As shown in figure, push fuel filter towards outside.
13
2. Re-installation of fuel filter

(a). As shown in figure, install fuel filter into the bracket.
(b). Install the fixing bolts of the fuel filter.
Torque: 6~12N•m
(c). Install the fuel filter with the bracket assembly in place and
tighten the fixing bolts.
Torque: 6~12N•m
LIFAN AUTO
13-24
(d). Install resin pipes on 2 sides of fuel filter.
△ Hint:
LIFAN AUTO
13-25
Fuel System - Fuel pipeline
Fuel pipeline
Check
1. Inspection of fuel pipeline
(a). Check the fuel pipe for damage of leakage. If any, replace
it.
13
LIFAN AUTO
13-26
Fuel System - Canister
Canister
Replace
1. Removal of canister

(c). Dismantle fixed bolts of canister sleeve, and remove

canister sleeve.
(d). As shown in figure, dismantle fixed clamp of No.1 canister

vent pipe, and disconnect canister vent pipe connection.
(e). As shown in figure, disconnect No.2resin pipe.
(f). As shown in figure, dismantle fixed clamp of vent pipe
of No.3 fuel tank, and disconnect fuel tank vent pipe
connection.
△ Hint:
Attention:
LIFAN AUTO
13-27
(g). Horizontally and slowly take out canister.
13
2. Re-installation of canister
(a). Install canister horizontally onto the canister bracket.
(b). As shown in figure, install No.1 canister vent pipe and

(c). As shown in figure, install No.2resin pipe.
(d). As shown in figure, install vent pipe of No.3 fuel tank and
△ Hint:
While installing No.2resin pipe, if a crisp "tick" sound is produced,
it indicates that resin pipe joint is installed onto proper position.
LIFAN AUTO
13-28
(e). Install canister sleeve and tightening the fixed bolt.
Torque: 6~12N•m
LIFAN AUTO
Intake and exhaust system
Intake and exhaust system........................................ 14-1
Precautions............................................................. 14-2
Component diagram ( Ⅰ )..................................... 14-3
Component diagram ( Ⅱ )..................................... 14-4
On-Vehicle check................................................... 14-5
Troubleshooting.......................................................... 14-6 14
Table of fault symptom.......................................... 14-6
Air filter....................................................................... 14-7
Check...................................................................... 14-7
Replace................................................................... 14-8
Air filter pipe............................................................ 14-13
Check.................................................................... 14-13
Three-way catalytic converter................................ 14-17
Replace................................................................. 14-17
Muffler...................................................................... 14-21
Replace................................................................. 14-21
LIFAN AUTO
14-1
Intake and Exhaust System - Intake and exhaust system
Intake and exhaust system

Item N•m
Air filter lower cover cluster fixed bolt M6:6~12M8:22~28

Fixed nuts of connecting rod of battery 20~25
Fixed bolts of inlet hose of air filter 6~12 14
Fixed bolts of support rod of three-way catalytic converter 22~28
Fixed nuts of front end of three-way catalytic converter 65~85
Fixed nuts of rear end of three-way catalytic converter 65~85
LIFAN AUTO
14-2
Precautions
1. Be careful to operate because the air filter element is made of paper materials.
2. Always shut off the engine and let the engine and the exhaust system cool down before performing operation on
the exhaust system because the exhaust pipe is hot when the engine running.
Schematic diagram
Air filter
Intake manifold
Fuel rail Engine
Canister solenoid valve

Front muffler three-way catalytic converter
Exhaust Manifold
Air
Fuel
Fuel steam
Exhaust gas
Rear muffler
LIFAN AUTO
14-3
Component diagram ( Ⅰ )
14
1 Inlay expansion snap-fit 9 Air filter element
2 Air filter inlet cluster 10 Clamp
3 Hexagon bolt with flange 11 Air filter upper cover cluster
4 Air filter lower cover subassembly 12 B-type worm drive hoop
5 Sleeve 13 Engine intake hose
6 Bushing 14 C-type worm rod drive type hoop

7 15 Engine vent hose
component
8 Air filter fixed spring plate
LIFAN AUTO
14-4
1 Big gasket 8 Muffler assembly
2 Metallic hexagon-head lock nut with flange 9 Hexagon bolt with flange
3 Rubber suspension block 10 Hexagon bolt with flange
Front pin with rear level purifier assembly

4 11 Heat insulator of fuel tank
(three-way catalytic converter)
5 Hexagon bolt with flange 12 Middle heat insulator
Support rod component of three-way catalytic

6 13 Front heat baffle
converter
7 Small gasket
LIFAN AUTO
14-5
On-Vehicle check
1. Inspection of intake system
(a). As shown in the figure, check the intake system for suction.
If no, check and repair the intake system.
14
2. Inspection of exhaust system

(a). Start the engine, inspect whether exhaust system
components have leakage, crack welding or damage, etc. If
any, repair them. If necessary, replace them.
LIFAN AUTO
14-6
Intake and Exhaust System - Troubleshooting
Troubleshooting
Table of fault symptom
these parts.
Symptom Suspected Area Recommended Action
1. Intake pipe or air filter (air leak or

Clean the intake duct and replace the air filter element.
poor intake)
Unstable engine idling-speed
or weak acceleration
2. Intake air pressure/ temperature Clean intake air pressure and temperature sensor detection hole.
sensor hole clogged If necessary, replace the sensor
It is easy to start the engine

when it is cold but it is Repair the intake duct or the air filter housing. If necessary,
1. Intake pipe or air filter (air leak)
difficult to start it when it is replace it.
hot.
Engine power is not enough 1. Exhaust system (poor exhaust) Check exhaust system and three-way catalyst
Popping or hissing of
1. Exhaust system (leak) Check and repair the exhaust system.
exhaust system
Excessive exhaust noise 1. Muffler (damage) Replace the muffler.
1. Muffler rubber mounting block

Check and repair it or replace it.
Clicking or vibration noise (loosened)
of exhaust system
1. Heat shield(loosened) Tighten the fixing bolts of the heat shield.
LIFAN AUTO
14-7
Intake and Exhaust System - Air filter
Air filter
Check
1. Inspection of air filter cluster
(a). Clean the air filter cluster with high-pressure air.
Attention:
When cleaning the air filter element, make the compressed air
blow into the air filter element from the back until there is no
impurity in it. 14
(b). Check the air filter element visually for damage. If any,
replace it.
LIFAN AUTO
14-8
Replace
1. Dismantle the air filter.
(b). Dismantle fixed nuts of connecting rod of battery, and
remove connecting rod and pull rod of battery.
(c). Remove battery.
(d). Dismantle clamp of engine intake hose, and disconnect

intake hose connection.
LIFAN AUTO
14-9
(e). Dismantle fixed spring plate of air filter, and remove upper
cover components of air filter.
14
(f). Remove air filter element.
(g). Dismantle fixed bolts of lower cover components of air filter.
LIFAN AUTO
14-10
(h). Dismantle inlet hose assembly of air filter, and remove
lower cover components of air filter.
2. Re-installation of air filter

(a). Install the lower cover cluster in place, and tighten its fixed
bolts.
Torque: M6:6~12N•m M8:22~28N•m
Attention:
When installing it, make sure that the intake pipe is connected
to the lower cover cluster securely and reliably.
(b). Install the air filter element.

Attention:
When installing it, pay attention to its font, back and direction.
Don't confuse them.
LIFAN AUTO
14-11
(c). Install upper cover components of air filter onto mounting
position, and install fixed spring plate of air filter.
14
(d). Install engine intake hose and tighten clamp of intake hose.
(e). Install battery onto battery bottom plate.
LIFAN AUTO
14-12
(f). Install connecting rod pull rod of battery and tighten fixed
nuts of connecting rod.
(g). Install positive and negative wire harnesses of battery.
LIFAN AUTO
14-13
Intake and Exhaust System - Air filter pipe
Air filter pipe

Check
1. Inspection of air filter pipe cluster
(a). Clean the air filter pipe cluster with a high-pressure water
gun.
(b). Dry the air filter pipe cluster with high-pressure air.
14
(c). Check the air filter pipe cluster for crack or other damage. If
there is , replace it.
LIFAN AUTO
14-14
1. Removal of engine intake pipe
(a). As shown in figure 1, disconnect engine vent hose
connection.
(b). Remove the clamps on both sides of the engine intake pipe,
and remove the engine intake pipe.
2. Removal of air filter intake pipe

(b). Dismantle fixed nuts of connecting rod of battery, and
remove connecting rod and pull rod of battery.
(c). Remove battery and battery bottom plate.
LIFAN AUTO
14-15
(d). Dismantle fixed snap-fit and fixed bolts of inlet hose of air
filter, and remove inlet hose of air filter.
14
3. Installation of air filter intake pipe

(a). Install inlet hose of air filter to mounting position, and
tighten fixed bolts of inlet hose of air filter and the snap-fit.
Torque:8~10N•m
Attention:
When installing it, make sure that the intake pipe is connected
to the lower cover cluster securely and reliably.
(b). Install battery bottom plate and battery to battery bracket.
LIFAN AUTO
14-16
(c). Install connecting rod and pull rod of battery, and tighten
fixed bolts of inlet hose of air filter.
(d). Install positive and negative wire harnesses of battery.
4. Installation of engine intake pipe

(a). Install the engine intake pipe to the air filter and the throttle
housing, and then tighten the clamps on both sides.
(b). As shown in figure 1, install engine vent hose.
LIFAN AUTO
14-17
Intake and Exhaust System - Three-way catalytic converter
Three-way catalytic converter

Replace
1. Dismantle three-way catalytic converter.
(a). Disconnect rear oxygen sensor connector.
14
(b). Dismantle fixed bolts of support rod of three-way catalytic

converter, and remove support rod of three-way catalytic
converter.
(c). Dismantle fixed nuts of front end of three-way catalytic

converter.
LIFAN AUTO
14-18
(d). Dismantle fixed nuts of rear end of three-way catalytic
converter.
(e). As shown in figure, dismantle three rubber suspension

block, and remove three-way catalytic converter and gasket.
△ Hint:
Don't re-use the removed gasket. Replace it with a new one.
2. Install three-way catalytic converter.

(a). As shown in figure, install three-way catalytic converter
and gasket to mounting position, and install three rubber
suspension blocks.
LIFAN AUTO
14-19
(b). Install fixed nuts of front end of three-way catalytic
converter.
14
(c). Install fixed nuts of rear end of three-way catalytic

converter.
(d). Install support rod of three-way catalytic converter and

LIFAN AUTO
14-20
(e). Install rear oxygen sensor connector.
LIFAN AUTO
14-21
Intake and Exhaust System - Muffler
Muffler
Replace
1. Removal of muffler
(a). Dismantle fixed nuts of muffler (fixed nuts of rear end of
three-way catalytic converter).
14
(b). As shown in figure, dismantle rubber suspension block of

muffler.
(c). Remove muffler and gasket.
△ Hint:
Don't re-use the removed gasket. Replace it with a new one.
2. Re-installation of muffler
(a). As shown in figure, install muffler and gasket to mounting
position, and install rubber suspension block of muffler.
LIFAN AUTO
14-22
Intake and Exhaust System - Muffler
(b). Tightening the fixed nut of muffler.
LIFAN AUTO
Cooling system
Cooling system............................................................ 15-1
Preparation............................................................. 15-1
Precautions............................................................. 15-2
Component diagram (I).......................................... 15-3
Component diagram ( Ⅱ ).............................................
15-4
On-Vehicle check................................................... 15-5
15
15
Troubleshooting.......................................................... 15-6
Problem symptoms table........................................ 15-6
Radiator...................................................................... 15-7
Check...................................................................... 15-7
Replace................................................................... 15-8
Water pump.............................................................. 15-16
Check.................................................................... 15-16
Replace................................................................. 15-17
Thermostat................................................................ 15-19
Check.................................................................... 15-19
Replace................................................................. 15-20
Cooling pipeline........................................................ 15-22
Check.................................................................... 15-22
Replace................................................................. 15-22
LIFAN AUTO
15-1
Cooling System - Cooling system
Cooling system
Preparation
S/N Tools Contour Drawing Description
1 Radiator cap detector Detect radiator pressure

15
Thermostat valve opening temperature 85℃
Thermostat valve lift At 95 ℃ , the lift is at least 8mm or more
Item N•m
Condenser fixed bolt 20~26
Water-pump upper- crossrail-assembly fixed bolt 8~10
Cooling fan shroud fixed bolt 8~10
Fixed bolts of cooling fan 20~26
Fixed bolts of coolant reservoir 8~10
Water pump fixing bolts 11
Fixed bolts of thermostat housing 20~25
Fixed bolts of cooling water pipe weldment 20~26
Intake manifold fixing bolts 30
LIFAN AUTO
15-2
Precautions
1. Make sure the engine are cool before performing operation on the cooling system.
2. Don't let the coolant spill to the drive belt when performing operation.
3. When removing the radiator, be careful not to scratch or damage the radiator cell
4. Be sure to connect each hose securely and firmly and install the hose hoop in place when re-installing the cooling
system.
Schematic diagram
Radiator
Expansion tank
Thermostat
Thermostat housing
Heater exchanger
Water pump
Cylinder block
Thermostat opens up
Thermostat closes
Cylinder head
LIFAN AUTO
15-3
Component diagram (I)
15
1 Expansion tank 8 Lower installation bush of the radiator
2 Coolant reservoir hose 9 Fan assembly
Suite of hexagon bolt, spring washer and flat

3 Elastic clamp 10
washer

4 11 Elastic clamp
washer
5 Upper installation bush of the radiator 12 Radiator outlet hose
6 Radiator cap 13 Radiator inlet hose assembly
7 Radiator
LIFAN AUTO
15-4

1 5 Thermostat
washer

2 Water pump 6
washer

3 7 Cooling water pipe weldment
washer
4 Thermostat cover
LIFAN AUTO
15-5
On-Vehicle check
1. Check the coolant
(a). Check the coolant for leakage.
The methods as follows:
• Fill coolant into radiator assembly.
• Connect the tester of radiator cap and adjust to standard
pressure of the radiator (pressure value: 50~100kPa) ,
and then check if the pressure value decreases.
△ Hint:
• If the pressure decreases, check hose, radiator assembly 15
and water pump leak.
• If the engine has no coolant leakage mark, check
radiator core, cylinder block & head.
(b). Discharge a little coolant into one container.

△ Hint:
For the sake of convenience, you can open the radiator cap.
Attention:
• Never start to work before the engine has cooled down
completely.
• Use cloth to wrap the radiator cap and carefully open
it. Firstly, release the pressure in the radiator, and then
open it fully.
(c). Check whether the discharged coolant has scale, rust,
impurities or discoloration, and if any, replace the coolant.
2. Inspection of radiator cap

(a). Pull out negative pressure valve and open it, check if the
negative pressure valve is completely closed after the
pressure is released. If impossible, replace it.
Attention:
Make sure that there is no dirt or damage on the valve seat of
the negative pressure valve of the radiator cover .
LIFAN AUTO
15-6
Cooling System - Troubleshooting
Troubleshooting
these parts.
1. Water pump (drive belt worn or

Check the drive belt, if necessary, replace it.
loosened)
2. Thermostat (thermostat seized at

Check the thermostat, if necessary, replace it.
its closure position )
Poor or failed cooling
3. Radiator cell (damaged) Replace the cooling element.
4. Radiator (pipe clogged) Clean the radiator.
5. Cooling fan (not working or rotate Check the cooling fan and the fan motor. If necessary, replace
slowly) the fan and its motor.
1. Coolant hose (Clamp loosened or Check the coolant pipeline and replace the damaged
hose cracked) components.
2. Water pump (poorly-sealed) Replace the water pump seal ring.

Coolant leakage
3. Radiator cover (poorly-sealed) Replace radiator cover
4. Radiator water tank (cracked) Check and repair the tank. If necessary, replace it.
5. Coolant reservoir (broken) Replace the expansion tank.
LIFAN AUTO
15-7
Cooling System - Radiator
Radiator
Check
1. Check the radiator
(a). Check whether the radiator is contaminated with mud or impurity, and if any, it can be cleaned as follows.The
steps are as follows:
• Use a soft water hose to wash radiator core along grain direction of radiator core until it is clean.
• Use compressed air to dry the radiator along grain direction of radiator core.
△ Hint:
Because the material of radiator core is very crisp, it is necessary to clean along grain direction of radiator core.
Otherwise, it is easy to damage radiator core. 15
Attention:
• Use the air pressure lower than 490kPa, with the distance kept greater than 30cm.
• Never bend or damage the radiator core.
2. Check the cooling fan.

(a). Check whether the cooling fan has any crack or abnormal
curvature, and if any, replace the fan.
3. Check the fan motor

(a). Check whether the fan motor rotation is out of nimbleness, and if so, repair or replace it if necessary.
LIFAN AUTO
15-8
Replace
1. Remove the radiator assembly
(a). Drain the coolant.
The steps are as follows:
• Place the recoverer below water drain plug of the
radiator.
• Turn on water drain plug and radiator cap, and discharge
the coolant.
• When no coolant flows out, start the engine and run it
idly.
• Observe water drain plug of the radiator. When no
coolant flows out, stop the engine. Now, the coolant has
been discharged completely.
Attention:
It is necessary to discharge the coolant in cold state of the
engine.
(b). Dismantle the elastic clamps of the expansion water tank

hose and disconnect the hose.
(c). Dismantle two fixed bolts of coolant reservoir and remove

coolant reservoir.
LIFAN AUTO
15-9
(d). Remove the fixed clamps of the radiator inlet and outlet
hoses. Disconnect the joints between the inlet and outlet
hoses and the radiator, and remove the inlet and outlet
hoses.
15
(e). Dismantle front bumper assembly. (See Chapter 81 Interiors

and Exteriors – Front Bumper, Front Bumper Replacement)
(f). Disconnect the connectors of the loud-tone horns and the
low-sounding horns.
Attention:
When disconnecting the connectors, don't pull the harnesses.
(g). Remove the condenser fixed bolts.
LIFAN AUTO
15-10
(h). Disconnect the connectors of the cooling fan.
(i). Remove the fixed bolts of the water tank upper crossrail
assembly and the water tank upper crossrail assembly.
(j). Remove the radiator assembly upwards slowly.
Attention:
Don't scratch or damage the radiator cell.
2. Removal of cooling fan

(a). Dismantle the hold-down bolts of the cooling fan housing
and take down the cooling fan assembly.
LIFAN AUTO
15-11
(b). Remove the fixed nuts of the cooling fans and two cooling
fans.
15
3. Dismantle the fan motor

(a). Take fan motor wire harness from fixing clip.
(b). As shown in Fig., push out fan motor wire harness terminal
from inside to outside.
(c). As shown in Fig., dismantle fixed screws of each fan motor,

and take out each motor assembly.
LIFAN AUTO
15-12
4. Mount the fan motor
(a). Install each fan motor to cooling fan cover and tighten
fixing screws of each fan motor.
(b). As shown in Fig., install fan motor wire harness connector

in place.
(c). Install each fan motor wire harness into fixed clips.
5. Mount the cooling fan

(a). Re-install the cooling fan back to the fan shroud, and
tighten the two fan fixed nuts.
LIFAN AUTO
15-13
(b). Mount the cooling fan housing assembly onto the radiator
and fasten the bolts.
Torque: 8 ~ 10N•m
15
6. Mount the radiator assembly

(a). Install the radiator assembly in place.
(b). Install the water tank upper crossrail assembly, and tighten
its fixed bolts.
Torque: 8 ~ 10N•m
(c). Install fixed bolts of the condenser.

LIFAN AUTO
15-14
(d). Connect the connectors of the loud-tone horns and the low-
sounding horns.
(e). Connect the cooling fan connectors.
(f). Install the radiator inlet and outlet hoses, and tighten their
clamps.
Attention:
Make sure that the hoses have been installed securely and
reliably.
LIFAN AUTO
15-15
(g). Install coolant reservoir to mounting position, and tighten
two fixed bolts.
Torque: 8 ~ 10N•m
15
(h). Install coolant reservoir hose to water tank inlet and tighten
elastic clamps.
(i). Install front bumper assembly. (See Chapter 81 Interiors
and Exteriors – Front Bumper, Front Bumper Replacement)
(j). Refill the coolant.
The steps are as follows:
• Open the radiator cap to fill coolant.
△ Hint:
When the coolant reaches to filling port root of the radiator, stop
filling.
• Mount the radiator cap.
• Open coolant reservoir cover, fill the coolant between
the lowest scale and the highest scale of coolant
reservoir.
△ Hint:
Coolant reservoir shall not be full of coolant. Expansion space
shall be reserved.
• Install coolant reservoir cover.
• Start the engine and run it idly. When the coolant
temperature reaches to 85°C (now the thermostat is
opened), stop the engine.
• After the engine cools, open radiator cap, and refill the
coolant.
△ Hint:
When the coolant reaches to filling port root of the radiator, stop
filling. The coolant filling process is over.
• Mount the radiator cap.
LIFAN AUTO
15-16
Cooling System - Water pump
Water pump
Check
1. Inspection of water pump assembly
(a). Rotate the water pump pulley. Check the rotation of the
water-pump bearing for smoothness or noiselessness. If
there is , repair it. If necessary, replace it.
(b). Check the water-pump casing for crack or damage. If there

is , repair it. If necessary, replace it.
LIFAN AUTO
15-17
Replace
1. Dismantle water pump assembly
(a). As shown in Fig., use a box spanner wrench to apply force
on the tensioner clockwise, and remove drive belt.
15
(b). Dismantle fixed bolts of water pump, remove water pump

and seal rings.
Attention:
Water pump seal rings after being removed cannot be reused.
New seal rings shall be used to avoid water pump from leaking
the coolant.
2. Install water pump assembly

(a). Install seal ring and water pump to the engine, and tighten
fixed bolts of water pump.
Torque: 11N•m
LIFAN AUTO
15-18
(b). As shown in Fig., use a box spanner to apply force on the
tensioner clockwise and then install drive belt.
LIFAN AUTO
15-19
Cooling System - Thermostat
Thermostat
Check
1. Inspection of thermostat body
(a). Check the thermostat body for crack or other damage. If
there is , replace it.
15
2. Inspection of thermostat opening temperature

(a). As shown in Fig., place the thermostat into water in a
container; heat the water to check opening temperature of
the thermostat.
Thermostat opening temperature: 85 °C
△ Hint:
If the thermostat opening temperature is inconsistent with
the specified value or the thermostat cannot open, replace the
thermostat.
3. Inspection of thermostat valve lift

(a). Measure the thermostat valve lift.
At 95 °C, the lift is at least 8mm or more
△ Hint:
If the thermostat valve lift is inconsistent with the specified value,
replace the thermostat.
Attention:
When the thermostat is at a low temperature, check if the
thermostat valve is completed closed. If the thermostat valve
cannot be closed completely, replace the thermostat.
LIFAN AUTO
15-20
Replace
1. Removal of thermostat body
(a). Dismantle fixed bolts of thermostat cover, and remove
thermostat housing.
(b). Take out thermostat body and seal rings.

Attention:
Thermostat seal rings after being removed cannot be reused.
New seal rings shall be used to avoid the thermostat from
leaking the coolant.
2. Installation of thermostat body

(a). Re-install the thermostat body and a new seal ring back to
the engine.
LIFAN AUTO
15-21
(b). Install thermostat cover and tighten fixed bolts.
15
LIFAN AUTO
15-22
Cooling System - Cooling pipeline
Cooling pipeline
Check
1. Check cooling pipe
(a). Check if cooling water pipe weldment is cracked or
damaged. if it is, repair it. If necessary, replace it.
Replace.
1. Dismantle the cooling pipeline
(a). As shown in Fig., disconnect vacuum boost pipe connection.
(b). As shown in Fig.2, dismantle PCV valve hose clamp and

(c). As shown in Fig.1, dismantle canister solenoid hose.
LIFAN AUTO
15-23
(d). Remove the intake manifold fixed bolts, and then remove
the intake manifold.
15
(e). Dismantle all fixed bolts of cooling water pipe weldment

and remove the weldment.
2. Mount the cooling pipelines

(a). Install cooling water pipe weldment to mounting position
and tighten all fixed bolts.
LIFAN AUTO
15-24
(b). Install intake manifold to the engine and tighten fixed bolts.
Torque: 30N•m
(c). As shown in figure 2, install PCV valve hose, and tighten

hoseclamp.
(d). As shown in figure 1, install canister solenoid hose.
(e). Install vacuum booster pipe as shown in the picture,
LIFAN AUTO
Lubrication system
Lubrication system.................................................... 16-1
Preparation............................................................. 16-1
Precautions............................................................. 16-3
Components diagram.............................................. 16-4
On-Vehicle check................................................... 16-5
Engine oil.................................................................... 16-8
Replace................................................................... 16-8 16
Engine oil filter......................................................... 16-10
Replace................................................................. 16-10
Oil pan....................................................................... 16-12
Check.................................................................... 16-12
Replace................................................................. 16-13
Engine oil pump....................................................... 16-15
Check.................................................................... 16-15
Replace................................................................. 16-16
Oil dipstick................................................................ 16-29
Replace................................................................. 16-29
LIFAN AUTO
16-1
Lubrication System - Lubrication system
Lubrication system
Preparation
1. Special tool
Used for dismantling and

1 Oil filter disassembler
installing the engine oil filter
16
Used for removing the oil

2 Oil pan remover
pan
Engine oil pressure

1 Detect engine oil pressure
gauge
2 Feeler gauge Check clearance of parts
LIFAN AUTO
16-2
Oil brand 15W-300-SL above
Volume of oil filling 4L
Idle speed 80~300kPa

Oil pressure:
Rated speed 330~430kPa
Top clearance between the oil The minimum clearance 0.023mm

pump drive rotor and driven
rotor The maximum clearance 0.069mm
Clearance between the rotor (drive, driven )and the oil pump hosing
0.025~0.071mm
top
Clearance between the driven rotor and the oil pump housing 0.260~0.325mm
Item N•m
Oil drainage bolt of oil pan 42~46
Engine oil filter 25~30
Oil pan fixed bolts 10
Oil pump fixed bolts 11
Oil pump cap fixing screws 11
Engine oil pump relief valve screw plug 37
Engine oil pressure sender 14~16
Fixed bolts of chain slipper 19
Fixed bolts of timing chain fixing rail 13
Front cover fixed bolts 23
Fixed nut of the tensioner 11
Crankshaft pulley fixed bolts 138
Fixed bolts of engine oil dipstick conduit 10~12
Fixed bolts of engine front mounting support 52
Fixed bolts and nuts of belt tension pulley 69 (bolt) 29(nut)
Generator fixed bolts 25(short bolt) 54 (long bolt)
Cylinder head cover fixed bolts 11
Fixed bolts of water pump assembly 11
Fixed bolts of Ignition Coil 11
LIFAN AUTO
16-3
Precautions
1. Make sure the engine is cool before performing operation on the lubricating system.
2. Be sure to prevent oil from spilling over the drive belt when performing operation.
3. Collect the used oil of the engine in a uniform manner. Always keep the repair field clean.
4. For the use of sealant, pay attention to the following points:
• Remove the residual sealant on the mounting surfaces of the oil pan and the cylinder block(including the
grooves, fixed bolts and bolt mounting holes of the application of sealant) thoroughly with the scraper.
• When using sealants, it is necessary to clean the applied surface of the sealants, remove water or other foreign
objects on the surface.
• If there is any foreign object in the sealant, immediately remove it completely.
16
Schematic diagram
Main gallery
Main gallery
of cylinder head
VVT Screen
First air intake camshaft bearing hole
Filter Main bearing
Oil control valve
Intake camshaft oil passage
Left side cylinder head Right side cylinder head

Pressure limiting Crankshaft main oil passage oil passage
valve
Timing chain oil passage
Automatic tensioner
journal
Intake camshaft First camshaft-bearing
cap oil passage
First camshaft-bearing First camshaft-bearing
Oil pump
cap oil passage cap oil passage
Crankshaft connecting Exhaust camshaft

rod journal Intake camshaft Exhaust camshaft
oil passage oil passage
Intake 2, 3, 4, 5 Exhaust 2, 3, 4,
camshaft 5 camshaft
bearing hole bearing hole
Strainer Connecting rod VVT (valve timing regulator)
bearing
Intake camshaft Exhaust camshaft

Remarks
and mechanical and mechanical
1. Lubrication for cam and tappet is in splash type
tappet tappet
2. VVT oil return is passing from the valve core
inside OCV.
Oil pan
LIFAN AUTO
16-4
Components diagram
1 Bolt 5 Engine oil filter
2 Engine oil pump 6 Oil pan
3 Engine oil dipstick conduit 7 Bolt
4 Oil dipstick
LIFAN AUTO
16-5
On-Vehicle check
1. Check engine oil
(a). Check engine oil level.

The methods as follows:
• Warm up the engine, stop it and then wait for 5 min.
• Check whether the oil level is between the upper and
lower marks of the dipstick.
△ Hint:
Make sure the vehicle is parked on level ground. And then
pull out the dipstick and wipe it with a cloth. Insert it all the
way in its tube. Pull it out again and look at the oil level at
the end of the dipstick. 16
(b). Check engine oil is deteriorated, discolored or mixed with

water (A: engine oil, B: water) , If necessary, replace it.
△ Hint:
The normal oil is transparent and relatively thick. If the oil
becomes dark and thin, replace the oil.
LIFAN AUTO
16-6
2. Check the oil pressure
(a). Disconnect engine oil pressure sensor connector.
(b). Dismantle engine oil pressure sensor and install engine oil
pressure gauge.
(c). Warm up the engine and observe engine oil pressure gauge.
Engine oil pressure at idle speed: 80~300kPa
Engine oil pressure at rated speed: 330~430kPa
△ Hint:
If the pressure is not within specified range, check engine oil
pump.
(d). Take down pressure gauge, install engine oil pressure sensor
and connect sensor connector.
Engine oil pressure sensor torque: 14 ~ 16 N•m
△ Hint:
When installing the engine oil pressure sender, coat the sensor
thread with sealant.
Attention:
Don't start the engine just after installing the engine oil
pressure sender . Be sure to wait for a period of time before
starting the engine.
LIFAN AUTO
16-7
Lubrication System - Troubleshooting
Troubleshooting
these parts.
1. E n g i n e o i l p r e s s u r e s e n d e r
Replace the engine oil pressure sensor.
(damaged)
2. Low oil level Add oil.
Check the causes resulting in low oil viscosity and repair it.
Hint:
The reasons that cause engine oil viscosity is too low: 16
• Engine oil brand is not applicable locally
3. Low oil viscosity
• High engine temperature
• Cylinder head gasket is damaged, so the coolant goes into
engine oil.
• Cylinder head gasket or cylinder block is cracked, so the
Abnormal oil pressure coolant goes into engine oil
4. Oil filter (clogged) Replace oil filter.
5. Main bearing shell and connecting

Replace the main bearing bush and the connecting-rod bearing
rod bearing shell (excessive
bush.
clearance)
Check fault cause of engine oil pump and make troubleshooting

Hint:
Common faults of engine oil pump:
6. Engine oil pump (failure) • Drive rotor and driven rotor of engine oil pump are worn
heavily
• Engine oil pump filler opening blockage
• Engine oil pump pressure regulating valve fault
LIFAN AUTO
16-8
Lubrication System - Engine oil
Engine oil
Replace
1. Discharge the engine oil
(a). Dismantle oil pan drain plug to drain engine oil to the
recoverer.
Attention:
completely.
• In time of operation, prepare a piece of cloth to clean up
spilled or splashed engine oil.
• Never spill the engine oil onto the transmission belt.
• Clean up the engine oil spilled onto the engine or motor.
(b). Install oil pan drain plug.

Torque: 42 - 46 N•m
2. Fill the engine coolant.

(a). Dismantle engine oil filling cap of cylinder head cover.
LIFAN AUTO
16-9
Lubrication System - Engine oil
(b). Refill the engine with the recommended oil
Attention:
• Select engine oil of 15W/30 SF above.
• Use the oil dipstick to check whether the oil is
appropriately filled.
16
(c). Reinstall the engine oil fill cap of washer fluid reservoir.
LIFAN AUTO
16-10
Lubrication System - Engine oil filter
Engine oil filter

Replace
1. Removal of oil filer
(a). Drain the engine oil into an appropriate container.
(b). Remove the oil filter with the oil filter remover.
Attention:
completely.
• In time of operation, prepare a piece of cloth to clean up
spilled or splashed engine oil.
• Never spill the engine oil onto the transmission belt.
• Clean up the engine oil spilled onto the engine or motor.
2. Installation of oil filter

(b). Clean up the foreign materials attached to the mounting
surface of the oil filter.
(b). Apply a layer of clean engine oil on oil seal of new engine
oil filter.
Attention:
Use original engine oil filter.
LIFAN AUTO
16-11
Lubrication System - Engine oil filter
(c). Use dismantling tool for engine oil filter to install engine oil
filter.
Attention:
While mounting the oil filter, first mount the oil filter by hand
onto the filter base, until the "O"-shaped sealing ring has
completely located on the filter base. Then use dismantling tool
for engine oil filter to tighten engine oil filter.
16
(d). Refill the engine with the recommended oil.
LIFAN AUTO
16-12
Lubrication System - Oil pan
Oil pan
Check
1. Inspection of oil pan
(a). Clean the oil pan thoroughly.
(b). Dry the oil pan with high-pressure air.
(c). Check the oil pan for crack or damage. If there is , repair it.
If necessary, replace it.
LIFAN AUTO
16-13
Replace
1. Removal of oil pan
(a). Drain the engine oil into an appropriate container.
16
(b). Remove the oil pan fixed bolts.
(c). As shown in the figure, install oil pan dismantling tool on

the contact surface between oil pan and cylinder block.
(d). Strike the side of dismantling tool for oil pan slightly, and
move this tool along sealing surface between oil pan and
cylinder block, then remove oil pan.
LIFAN AUTO
16-14
2. Installation of oil pan
(a). As shown in Fig., apply sealants on the installation surface
of oil pan uniformly.
Attention:
When coating new sealant, be sure to clean the residual sealant
completely on the cylinder block and the oil pan in advance.
(b). Reinstall the oil pan to the cylinder block, and tighten all oil
pan fixed bolts.
Torque: 10 N•m
△ Hint:
When installing the fixed bolts, be sure to coat clean oil onto the
bolt threads.
Attention:
When tightening the bolts, be sure to start tightening the bolts in
the middle and then work to both sides.
(c). Fill the engine oil.
LIFAN AUTO
16-15
Lubrication System - Engine oil pump
Engine oil pump

Check
1. Inspection of oil pump components
(a). As shown in Fig., measure top clearance between drive
rotor and driven rotor of engine oil pump with a feeler
gauge. If it exceeds the maximum, replace engine oil pump.
The minimum clearance: 0.023mm
The maximum clearance: 0.069mm
16
(b). As shown in Fig., measure top clearance between two

rotors and engine oil pump housing with a feeler gauge. If it
exceeds the maximum, replace engine oil pump.
Standard clearance: 0.025~0.071mm
(c). As shown in Fig., measure the clearance between driven

rotor and engine oil pump housing with a feeler gauge. If it
exceeds the maximum, replace engine oil pump.
Standard clearance: 0.260~0.325mm
LIFAN AUTO
16-16
(d). Apply a layer of clean engine oil on relief valve of engine
oil pump, check and confirm engine oil valve slides into
valve hole with its weight. If impossible, replace engine oil
pump.
Replace
1. Removing oil pump

(b). Dismantle fixed bolts of ignition coil, and remove all

ignition coils.
Attention:
LIFAN AUTO
16-17
16

(f). Remove the fixed bolts of the generator assembly, and then
LIFAN AUTO
16-18
(g). Dismantle fixed bolts and nuts of belt tension pulley
assembly, and then remove timing belt tensioner.
(h). Dismantle engine front mounting and support assembly.
(i). Dismantle fixed bolts of water pump and remove water

pump assembly.
LIFAN AUTO
16-19
(j). Dismantle fixed bolts of crankshaft pulley.
△ Hint:
When dismantling fixed bolts of crankshaft pulley, first fix the
flywheel in order to prevent crankshaft from rotating.
(k). Use a puller to remove crankshaft pulley remove.
Attention:
When using a puller, do not damage crankshaft pulley.
16
(l). Dismantle fixed nuts of the tensioner and remove the

tensioner.
(m). Dismantle fixed bolts of front cover, and remove front

cover.
△ Hint:
When removing front cover, it may be not easy to remove the
cover due to sealants. Use a rubber hammer to knock front cover.
Attention:
Don't tap it with an iron hammer or a hard tool.
LIFAN AUTO
16-20
(n). Dismantle fixed bolts of chain slipper, and fixing rail
assembly, then remove chain slipper assembly.
Attention:
In order to prevent damaging valve tappet due to cam shaft
or crankshaft rotation after dismantling timing chain, it is
necessary to rotate crankshaft before dismantling to make No.1
cylinder on TDC and confirm timing gear mark is aligned. (o).
Remove timing chain.
(p). Remove crankshaft timing sprocket wheel retainer ring.

(q). Remove crankshaft timing sprocket wheel and location pin.
Attention:
Store location pins together to prevent them from losing.
(r). Remove the oil pump fixed bolts and the oil pump and its
washer.
Attention:
Once the washer has been removed, don't reuse it any longer.
Be sure to use a new one to replace it.
LIFAN AUTO
16-21
2. Decompose the oil pump.
(a). Dismantle fixed screws of engine oil pump and remove
engine oil pump cover.
16
(b). Remove drive rotor and driven rotor of engine oil pump.
(c). As shown in Fig., dismantle engine oil pump relief valve

screw plug and take out relief valve spring and relief valve.
LIFAN AUTO
16-22
3. Reassembling oil pump
(a). Install relief valve and spring of engine oil pump into valve
opening.
(b). Install relief valve screw plug of engine oil pump.
Torque: 37N•m
(c). As shown in Fig., install drive rotor and driven rotor of

engine oil pump.
Attention:
When installing, align with installation identification as shown
in the Fig.
(d). Install the oil pump cover and tighten its fixed screws.
Torque: 11N•m
LIFAN AUTO
16-23
4. Installation of oil pump
(a). Install engine oil pump and engine oil pump gasket to
mounting position, and tighten fixed bolts of engine oil
pump.
Torque: 11N•m
16
(b). Install crankshaft timing sprocket wheel and location pin.

(c). Install crankshaft timing sprocket wheel retainer ring.
(d). Install timing chain.

Attention:
As shown in the figure, align the timing marks when installing
the timing chain.
LIFAN AUTO
16-24
(e). Install chain slipper (as shown in Fig. 1) , fixing rail
assembly (as shown in Fig. 2) , and tighten fixed bolts.
Fixed bolts of moving rail
Torque: 19N•m
Fixed bolts of fixing rail
Torque: 13N•m
(f). As shown in Fig., apply sealant on matching surface of

front housing uniformly.
Attention:
Before applying new sealant, it is necessary to remove old
sealant.
(g). Install front housing to the engine and tighten all fixed bolts.
Torque: 23N•m
LIFAN AUTO
16-25
(h). Install the tensioner to mounting position and tighten two
fixed nuts.
Torque: 11N•m
△ Hint:
When installing the tensioner, it is necessary to lock the tensioner
plunger through locking piece. After fixed bolts of the tensioner
is installed, rotate crankshaft counter clockwise to release locking
piece.
16
(i). Rotate crankshaft clockwise to check if the tensioner is

installed correctly.
(j). Install crankshaft pulley and tighten bolts.

Torque: 138N•m
△ Hint:
When installing fixed bolts of crankshaft pulley, first fasten the
flywheel to prevent crankshaft from rotating.
LIFAN AUTO
16-26
(k). Install water pump assembly and tighten bolts.
Torque: 11N•m
(l). Install engine front mounting and support assembly and

tighten bolts.
Torque: 52N•m
(m). Install timing belt tensioner assembly and tighten bolts and
nuts.
Bolt torque: 69N• m
Nut torque: 29N• m
LIFAN AUTO
16-27
(n). Install generator assembly and tighten bolts.
16
(o). Install cylinder head cover assembly and tighten all fixed
bolts.
Torque: 11N•m
(p). As shown in figure 1, install PCV valve hose and tighten

(q). As shown in Fig.2, install vent hose.
LIFAN AUTO
16-28
(r). Install each ignition coil in turn and tighten bolts.
Torque: 11N•m
Attention:
(s). As shown in Fig., use a box spanner to apply force on the

LIFAN AUTO
16-29
Lubrication System - Oil dipstick
Oil dipstick
Replace
△ Hint:
In order to dismantle engine oil dipstick conduit easily, first dismantle the generator.
1. Removal of dipstick and its tube
(a). Remove the dipstick.
16

tensioner clockwise and then remove drive belt.
(c). Remove the fixed bolts of the generator assembly, and then
LIFAN AUTO
16-30
(d). Dismantle fixed bolts of engine oil dipstick conduit and
then remove engine oil dipstick conduit.
2. Dismantle engine oil dipstick conduit and engine oil

dipstick
(a). Install the dipstick tube in place, and tighten the dipstick
tube fixed bolt.
Torque: 10 ~ 12N·m
(b). Install generator assembly and tighten bolts.

LIFAN AUTO
16-31
(c). As shown in Fig., use a box spanner to apply force on the
16
(d). Install the dipstick.
LIFAN AUTO
• Memo •
LIFAN AUTO
Ignition system
Ignition system........................................................... 17-1
Preparation............................................................. 17-1
Precautions............................................................. 17-2
On-Vehicle check................................................... 17-4
Troubleshooting . ...................................................... 17-5
Spark plug.................................................................. 17-6
Check...................................................................... 17-6
Replace................................................................... 17-7
17
LIFAN AUTO
17-1
Ignition System - Ignition system
Ignition system
Preparation
1 Spark plug socket Dismantle spark plug.
17
2 Extension bar Dismantle spark plug.

3 Feeler gauge
spark plug gap.
LIFAN AUTO
17-2
Standard spark plug electrode clearance About 0.85~0.95mm
Item N•m
Fixing Bolts of Ignition Coil 11
Spark Plug 40
Precautions
1. Don't cause damage to spark plug thread when removing spark plugs.
2. Don't crash spark plug electrodes.
3. Don't exceed 2s when performing the ignition test of the spark plug ground.
LIFAN AUTO
17-3
Components diagram
17
1 Spark plug 2 Ignition coil
LIFAN AUTO
17-4
On-Vehicle check
1. Check whether spark plugs can work normally
(a). Disconnect each ignition coil and fuel injector connector.
(b). Remove the ignition coil and spark plug of each cylinder.
(c). Install the spark plug of No.1 cylinder to the ignition coil,
and connect the connector of the ignition coil.
(d). Ground the spark plug.
(e). Check whether the spark plug can spark in the process of
the engine starting.
Attention:
Make sure that the engine starting process will not exceed 2s.
(f). Check the spark plugs of other cylinders in the same
manner.
(g). Install the spark plug and the ignition coil of each cylinder.
(h). Install each cylinder ignition coil and fuel injector
connector.
LIFAN AUTO
17-5
Ignition System - Troubleshooting
Troubleshooting
these parts.
1. Ignition coil or ignition switch Check the ignition coil or ignition switch. If necessary, replace
It is impossible or difficult to (damaged) it.
start the engine.
2. Spark plug is damaged Replace.
1. I g n i t i o n c o i l o r s p a r k p l u g
Idle speed is not stable Check the ignition coil or spark plug. If necessary, replace it.
(damaged)
1. Ignition Coil Damaged Check the ignition coil. If necessary, replace it.
Engine bucking or
accelerating poorly
2. Spark plug is damaged Replace.
17
Poor fuel economy 1. Spark plug is damaged Replace.
LIFAN AUTO
17-6
Ignition System - Spark plug
Spark plug
Check
1. Cleaning spark plugs
(a). Clean the spark plugs with a brush or equivalent.
Attention:
Never apply force between electrodes. Otherwise, central
electrodes may be damaged.
(b). Check spark plug electrode clearance. If it does not conform

to the requirement, repair it. If necessary, replace it.
Standard spark plug electrode clearance: about
0.85~0.95mm
(c). Check the spark plug thread for damage. If so, replace the
spark plug.
LIFAN AUTO
17-7
Replace
1. Removal of spark plug
(a). Turn off the ignition switch.
(b). Disconnect the connector of the ignition coil of each
cylinder in turn.
17
(c). Remove the fixed bolts of the ignition coil of each cylinder
in turn.
(d). Pull out the ignition coil of No.1 cylinder slowly.
△ Hint:
Don't cause damage to the rubber component of the spark plug.
(e). Use a sleeve and extension bar to dismantle spark plug of

No.1 cylinder.
△ Hint:
After removing the spark plug, you can use the ignition coil to take
out the spark plug.
Attention:
To avoid damage to the spark plug thread or electrode, don't
crash the spark plug when removing it.
(f). Remove the spark plugs of No. 2, 3 and 4 cylinders in the
same manner.
△ Hint:
For the convenience of subsequent installation, put the removed
ignition coils in sequence.
LIFAN AUTO
17-8
2. Installation of spark plug
(a). Install the spark plug of No.1 cylinder with the socket and
extension bar.
Torque: 40N.m
△ Hint:
Set the spark plug in its mounting position with the ignition coil,
and then tighten it with the socket and extension bar.
Attention:
Don't crash the spark plug, especially, the spark plug
electrodes, when installing the spark plug.
(b). Install No.1 cylinder ignition coil and tighten fixed bolts.
Torque: 11N.m
(c). In the same way, install spark plugs and ignition coils for
No.2, No.3, No.4 cylinder in turn.
(d). Install the ignition coil connector of each cylinder in turn.
LIFAN AUTO
Starting and charging systems
Starting and charging systems.................................. 18-1
Preparation............................................................. 18-1
Precautions............................................................. 18-2
Electrical wiring diagram (Starting system)........... 18-3
Electrical wiring diagram (Charging system)........ 18-4
On-Vehicle check................................................... 18-5
Troubleshooting . ....................................................... 18-6
Starter......................................................................... 18-7
Check...................................................................... 18-8
Replace................................................................. 18-12
Generator.................................................................. 18-18 18
Check.................................................................... 18-19
Replace................................................................. 18-21
LIFAN AUTO
18-1
Starting and Charging Systems - Starting and charging systems
Starting and charging systems

Preparation
Used for measuring

1 Multimeter current, voltage or
resistance
18
Used for measuring

2 Dial caliper component length or
diameter
Commutator ring gear runout Maximum value 0.05mm
Standard diameter 30mm

Commutator diameter
Minimum diameter 29mm
Standard value 15.5mm

Starter brush length
Minimum value 10mm
Standard exposed length 10.5mm

Starter brush exposed length
Minimum exposed length 1.5mm

Generator rotor slip-ring diameter
Generator rotor slip-ring resistance Standard value (cold) 2.1~2.5Ω
LIFAN AUTO
18-2
Item N•m
Starter assembly fixed bolt 80~86
Starter magnet switch fixed screw 9~11
Commutator end cap fixed bolts 20~25
Commutator end cap fixed screw 9~11
Generator assembly fixed bolts 45~49
Generator rear end cap fixed bolt 9~11
Generator rear end cap fixed screw 5~6
Generator brush fixed screw 3~4
Generator pulley fixing nuts 110.5
Generator coil fixed bolt 3~4
Precautions
1. When the engine running, don't disconnect the battery connection.

2. When checking the starting and charging system, be sure to check all connectors and harness connections for
fastness or reliability at first.
3. When performing the operation of dismantling the starter or generator, don't cause damage to the insulation
sealant on the external surfaces of the coils.
LIFAN AUTO
18
18-3
Starting system
Engine compartment
central control box
LIFAN AUTO
ST relay control
Wiring diagram (Starting system)
Ignition switch ST
5-loop fuse box
Starter
Battery
Ignition switch
Charging system
Driver compartment
central control box
Engine compartment
central control box
LIFAN AUTO
Wiring diagram (Charging system)
Instrument cluster
Battery
Generator
18-4
18-5
On-Vehicle check
1. Check the battery.
(a). As shown in the figure, check whether the battery voltage
can meet the requirement for the engine starting. If not,
charge the battery or replace it.
Minimum battery voltage:8V
18
2. Inspection of starter and generator
(a). Check the connection of starter (as shown in Figure 2) and
generator (as shown in Figure 1). If there is there is any
looseness, tighten it.
(b). Power on starting circuit (start the engine) to check if the
starter runs. If it does not run, repair or replace it
(c). Use DC voltage position of a multimeter to connect the positive electrode to the generator “armature” terminal,
and the negative electrode to the generator housing.
(d). When the engine runs faster than medium speed, test the battery voltage. It shall be about 14V. If testing result is
the battery voltage (12V), it means the generator does not generate electricity, it is necessary to repair or replace
the generator.
LIFAN AUTO
18-6
Starting and Charging Systems - Troubleshooting
Troubleshooting
these parts.
1. Battery (voltage < 8V) The battery is charging or replaced
2. Battery (connection corruption or Clean and tighten the battery wiring. Apply a thin layer of
Starter won't start
looseness) petroleum jelly on wiring end
3. Starter motor (damaged) Check and repair it or replace it.
The battery voltage is low 1. Generator (not generate electricity) Check and repair it or replace it.
LIFAN AUTO
18-7
Starting and Charging Systems - Starter
Starter
Components diagram
18
1 Commutator end cap fixed bolts 8 Magnetic switch fixed screw
2 Commutator end cap fixed screw 9 Washer
3 Commutator end cap 10 Starter pinion drive rod
4 Brush holder 11 Magnetic switch
5 Armature 12 Gear
6 Starter magnetic yoke 13 Intermediate bearing clutch sub-assembly
7 Starter drive end cap
LIFAN AUTO
18-8
Check
1. Inspection of starter assembly
△ Hint:
In order to prevent the starter from running, disconnect magnet
exciting coil wire harness of terminal A.
Attention:
Complete the following test within 3~5s.
(a). As shown in Fig., connect the battery to both terminals
A and B of the starter to check if clutch pinion moves
outwards.If the clutch pinion cannot rotate or move outward,
replace the electromagnetic starter switch assembly.
(b). As shown in the figure, disconnect the lead of the terminal

A. check whether the clutch pinion can stay at its original
position (without inward movement).
(c). As shown in Fig., disconnect terminal A wire harness and

housing grounding wire, check if clutch pinion can return
(moving inwards).
LIFAN AUTO
18-9
(d). As shown in the figure, perform the no-load test on the
starter, and observe and record the current value (by
switching the digital multimeter to the current function).
△ Hint:
Fix the starter between the aluminum sheets or cloth with the vise.
Attention:
When the battery voltage is 11. 5V, the current value should
be <90A . Otherwise, replace the starter.
2. Inspection of starter magnetic switch

(a). As shown in the figure, push into the iron core and check 18
whether the iron core can return to its original position
quickly. If not, replace the magnetic switch assembly.
(b). As shown in Fig., measure the resistance between terminals

A and B with the resistance position of a multimeter. If it
does not conform to the requirement, replace the magnetic
switch.
Resistance value :<1Ω
LIFAN AUTO
18-10
(c). As shown in Fig., measure the resistance between
terminal B and the housing with the resistance position of
a multimeter. If it does not conform to the requirement,
replace the magnetic switch.
Resistance: <2Ω
3. Inspection of armature coil

(a). As shown in the figure, check the continuity between any
two commutator laminas by switching the digital multimeter
to the resistance function. If no continuity, replace the
armature windings.
(b). As shown in Fig., check if the commutator (as shown in

Fig. A) and armature coil core (as shown in Fig. B) have
continuity with the resistance position of a multimeter. If
they have, replace armature winding.
LIFAN AUTO
18-11
4. Inspection of commutator
(a). Check the surface of commutator for dirt or burning. If
there is , repair it with sand paper.
(b). Put the commutator on the V-shaped block. Measure the
run-out of the commutator ring gear with a dial gauge. If the
run-out is greater than the maximum value, be sure to repair
the commutator ring gear. If necessary, replace it.
Maximum run-out of commutator ring gear: 0.05mm
(c). Measure the diameter of the commutator with a venire

caliper. If the diameter is less than the minimum, replace the
18
armature.
Standard diameter: 30mm
Minimum diameter: 29mm
5. Inspection of starter brush

(a). Check the length of the starter brush with a venire caliper.
If the length less than the minimum, replace the brush. If
necessary, replace the brush holder and the starter magnetic
yoke assembly.
Standard value: 15.5mm
Minimum value: 10mm
LIFAN AUTO
18-12
Replace
1. Dismantle the starter assembly
(a). Turn off the ignition switch.
(b). As shown in the figure, remove the power leads of the
starter and disconnect its connector.
(c). Remove the two fixing screws of the starter, and then
remove the starter assembly.
2. Dismantling of starter assembly

(a). As shown in Fig., dismantle fixed bolts of A terminal wire
harness to disconnect A terminal wire harness.
(b). Remove the two fixing screws of the starter magnetic

switch, and then remove the magnetic switch.
△ Hint:
When removing the magnetic switch, be sure to raise the front of
the magnetic switch firstly to make it disengage the hook, and then,
remove the magnetic switch.
LIFAN AUTO
18-13
(c). Remove the fixed bolts and screws of the starter commutator
end cap, and then remove the commutator end cap.
(d). Remove the starter brush holder assembly.
18
(e). Remove the starter magnetic yoke assembly (as shown in

Figure A) and the armature assembly (as shown in Figure B).
LIFAN AUTO
18-14
(f). As shown in Fig., remove rubber seals (as shown in Fig. A
and B) and gaskets (as shown in Fig. C).
(g). Remove the intermediate bearing clutch sub-assembly (as

shown in Figure A) and the starter pinion drive rod (as
shown in Figure B).
3. Reassembly of starter assembly

(a). Re-install the drive rod of the starter pinion (as shown in
Figure B) and the subassembly of the intermediate bearing
clutch (as shown in Figure A) back to the starter drive-end
cover.
LIFAN AUTO
18-15
(b). As shown in Fig., install gaskets (as shown in Fig. C) and
rubber seals (as shown in A and B).
(c). Install the starter armature into the starter magnetic yoke.
(d). As shown in the figure, install the starter magnetic yoke (as 18
shown in Figure A) and the armature assembly (as shown in
Figure B) in place.
(e). Install the starter brush holder assembly to the starter

armature.
Attention:
Be sure to let the harness rubber component of the brush
holder seat in the snap-ring groove of the starter magnetic yoke
when installing.
LIFAN AUTO
18-16
(f). Install the starter commutator end cover and tighten its fixed
bolts and screws.
Bolt torque: 20 ~ 25N•m
Screw torque: 9 ~ 6N•m
Attention:
Be sure to let the harness rubber component of the brush
holder seat in the snap-ring groove of the commutator end cap.
(g). Install the starter magnetic switch, and tighten its two fixing
screws.
Torque: 9 ~ 11N•m
Attention:
Be sure to make the iron core of the starter magnetic switch
engage the drive rod when installing.
(h). As shown in the figure, install the harness of Terminal A

and tighten its fixed bolts.
LIFAN AUTO
18-17
4. Installation of starter assembly
(a). Install starter assembly to mounting position and fasten two
fixed boltsBolt
(b). As shown in the figure, install the power lead and connector
of the starter.
18
LIFAN AUTO
18-18
Starting and Charging Systems - Generator
Generator
Components diagram
1 Generator assembly
LIFAN AUTO
18-19
Check
1. Inspection of generator brush
(a). Measure the exposed length of the generator brush with a
dial caliper. If the length is less than the minimum, replace
the brush. If necessary, replace the brush holder.
Standard exposed length: 10.5mm
Minimum exposed length: 1.5mm
18
2. Inspection of generator rotor assembly
(a). Visually inspect the slip-ring surface for crack or other
damage, if any, replace the rotor assembly.
(b). Measure the slip-ring diameter with a dial caliper. If

the diameter is less than the minimum, replace the rotor
assembly.
LIFAN AUTO
18-20
(c). As shown in the figure, measure the resistance between
the slip rings by switching the digital multimeter to the
resistance function. If the resistance is inconsistent with the
specified value, replace the rotor assembly.
Standard value (cold): 2.1~2.5Ω
(d). As shown in the figure, check the continuity between the

slip ring and the rotor by switching the digital multimeter
to the resistance function. If continuity, replace the rotor
assembly.
LIFAN AUTO
18-21
Replace
1. Removal of generator assembly
18
(b). Remove the fixed bolts of the generator assembly, and then
2. Dismantling of generator assembly

(a). Remove the fixing nuts and screws of the generator rear end
cap, and then remove the rear end cap.
LIFAN AUTO
18-22
(b). Remove the fixing screws of the generator brush holder, and
then remove the generator brush holder (with brush).
(c). Remove the fixed bolts of the generator coil assembly, and
then remove the generator coil assembly.
(d). Remove the fixing nuts of the generator pulley, and then
remove the generator pulley.
Attention:
In order to prevent the pulley from rotating, fix the generator
rotor shaft beforehand when removing.
LIFAN AUTO
18-23
(e). Remove the generator rotor gasket, rotor rear bearing cap
and rotor rear bearing in turn.
(f). Remove the generator rotor assembly.
3. Reassembly of generator assembly

(a). Install the generator rotor assembly to the drive end holder 18
(stator).
(b). Install the generator rotor rear bearing, rear bearing cap and
gasket to the generator rotor in turn.
(c). Install the generator pulley and tighten the pulley fixing
nuts.
Torque: 110.5N•m
Attention:
In order to prevent the pulley from rotating, fix the generator
rotor shaft beforehand when installing.
LIFAN AUTO
18-24
(d). Install the generator coil assembly to the rectifier end holder
and tighten the fixed bolts.
Torque: 3 ~ 4N•m
(e). Install the generator brush holder to the rectifier end holder
and tighten the fixing screws.
Torque: 3 ~ 4N•m
(f). Install the generator rear end cap and tighten its fixing nuts
and screws.
Nut torque:9 ~ 11N•m
Screw torque: 5 ~ 6N•m
LIFAN AUTO
18-25
4. Install the generator assembly.
(a). Install the generator assembly in place, and tighten the fixed
bolts.

tensioner clockwise and then remove drive belt. 18
LIFAN AUTO
• Memo •
LIFAN AUTO
Manual transmission
Manual transmission................................................. 21-1
Preparation............................................................. 21-1
Precautions............................................................. 21-5
Transmission control mechanism............................. 21-8
Replace................................................................... 21-9
Transmission assembly............................................ 21-15
Replace................................................................. 21-15
Disassemble.......................................................... 21-24
Check it completely.............................................. 21-28
Assembly.............................................................. 21-29
Input shaft assembly................................................ 21-34
Components diagram............................................ 21-34 21
Dismantling.......................................................... 21-35
Check.................................................................... 21-42
Assembly.............................................................. 21-46
Output shaft assembly............................................. 21-53
Dismantling.......................................................... 21-54
Check.................................................................... 21-59
Assembly.............................................................. 21-62
Differential assembly............................................... 21-68
Dismantling.......................................................... 21-69
Check.................................................................... 21-71
Assembly.............................................................. 21-72
Reverse idler gear assembly.................................... 21-76
Check.................................................................... 21-77
Replace................................................................. 21-78
Fork shaft assembly................................................. 21-79
Dismantling.......................................................... 21-80
Assembly.............................................................. 21-83
Gear shift mechanism assembly.............................. 21-86
Dismantling.......................................................... 21-87
Assembly.............................................................. 21-90
Housing assembly..................................................... 21-94
Check.................................................................... 21-95
Replace................................................................. 21-96
LIFAN AUTO
21-1
Manual Transmision - Manual transmission
Manual transmission
Preparation
1. Special tool
Used for installation

Axle-shaft oil seal
1 of axle-shaft oil seal
installer
of differential
Fork-shaft pin Used for removal of 21

2
punch fork-shaft pins
Differential bearing Used for installation

3
press-fitting tool of bearings
Reverse shaft Used for removal of

4
bushing remover reverse shaft bushing
Pressing tool of
Install oil seal of
5 oil seal of gear
gear shifting shaft
shifting shaft
LIFAN AUTO
21-2
Manual Transmission - Manual transmission
Shift-shaft bushing Used for installation of shift-

6
installer shaft bushings
Housing positioning-pin Used for installation of

7
installer housing positioning-pins
Installs the clutch pressure

Clutch pressure plate
8 plate make it be concentric
positioning tool
with the driven plate.
Output-shaft
Install output shaft
9 synchronizer gear-hub
synchronizer hub
installing tool
Output-shaft bearing Used for installation of

10
press-fitting tool output-shaft ball-bearings
Used for installation of

Input-shaft front ball-
11 input-shaft front ball-
bearing press-fitting tool
bearings
LIFAN AUTO
21-3
Installing tool of oil seal Install oil seal of gear

12
of gear selector shaft selector shaft
Used for installation of gear-

Gear selector cover
13 selector-cover positioning
positioning-pin installer
pins
21
Gear selector shaft Dismantle and install gear

14
bushing remover selector shaft sleeve
Installing tool of oil seal

15 Install oil seal of input shaft
of input shaft
LIFAN AUTO
21-4
Manual Transmission - Manual transmission
Type 5 forward gear, and 1 reversing gear
MT type Five-speed manual transmission, mechanical flexible shaft operation
Final drive ratio 4.308
1st gear ratio 3.182
2nd gear ratio 1.895
3rd gear ratio 1.25
4th gear ratio 0.969
5th gear ratio 0.784
Reversing gear ratio 3.133
Refilling volume of gear oil 2L
Side clearance of 3rd gear shaft 0.1~0.35mm
5th gear axial clearance 0.1~0.5mm
Clearance between 4th gear and 5th gear 0.058mm
1st gear axial clearance 0.1~0.35mm
2nd gear axial clearance 0.1~0.35mm
1st gear and 2nd gear radial runout 0.056mm
Speed 1 0.522~2.208mm
Speed 2 0.522~2.208mm
Clearance between
synchronizer ring and each Speed 3 0.73~1.53mm
gear
Speed 4 0.77~1.57mm
5th speed 0.73~1.53mm
Input-shaft radial runout Maximum value 0.03mm
Clearance between gear sleeve

Maximum value 0.35mm
and shift fork
Clearance between
synchronizer ring back and Minimum value 0.8mm
gear end
Input-shaft front ball-bearing

Minimum value 0.01~0.21mm
radial runout
Input-shaft rear ball-bearing

Minimum value 0.01~0.21mm
radial runout
Output-shaft radial runout Maximum value 0.03mm
Teeth of differential gear and

Standard value 0.025~0.15mm
axle shaft gear
Inner diameter of gear sleeve Wear limit 0.2mm
LIFAN AUTO
21-5
Item N•m
Shifting support fixed bolts 23
Fixed bolts of connecting bracket of left suspension 60
Connecting bolts of left mounting 60
Connecting bolts of right mounting 60
Fixed bolts of connecting bracket of rear mounting 60
Rear suspension connecting bolts 60
Drain bolt 45
Oil filler bolt 45
Housing connecting bolts 23
Fixed bolts of gear selector mechanism assembly 23
Differential ring gear bolt 130~150
21
Precautions
1. Don't reuse the drained oil of manual transmission.

2. Park the vehicle on level ground before checking or replacing the manual transmission oil.
3. Keep free of any dust or impurity inside when removing and installing the transmission.
4. Check and determine a proper installation position before removal or dismantling. If you need to make the
installation marks, make sure that the marks will not affect the function of marked parts.
5. When tightening bolts and nuts, take several steps to conduct it and follow diagonal sequence. First tighten
middle one and then tighten bolts and nuts of external position. Unless otherwise specified.
6. Be careful not to cause damage to the sliding surfaces and mating surfaces.
7. When shifting gear, step the clutch pedal completely. After transmission separates from engine torque, rapidly
control gear rod to change speed.
8. When up sloping and down sloping or turning, it is necessary to use slow speed. It is not allowed to slide
traveling by separating clutch.
9. When it is difficult to operate gear lever, stop the vehicle to find out cause. Do not use hard push force.
LIFAN AUTO
21-6
Manual Transmission - Troubleshooting
Troubleshooting
Use the table below to help you find the cause of the problem. Check each part in order. If ecessary, repair or replace
these parts.
1. Crankshaft and transmission input shaft

Reinstall them.
centerline (non-concentric)
2. Output shaft front bearing (wear, dirt, fluff) Replace the bearings.
3. Transmission constant mesh gears (wear,

Repair the gears pairwise.
excessive backlash, teeth broken)
Noisy neutral position
4. C o n s t a n t m e s h g e a r s ( u n p a i r e d
replacement, poor mesh)
5. Bearings (loosened, damaged, excessive

Replace the bearings.
gear axial clearance)
6. Fork and engaged sleeve (excessive

Replace the fork.
clearance)
1. Shaft ( bent, deformed, loose matching

Replace the shaft.
between spline and sliding gear-hub)
2. Gear mesh (improper) Repair the gears pairwise.
3. Bearings (loosened) Replace the bearings.

A sound is produced after
shifting gear.
4. All joints of control mechanism (loosened) Tighten
5. Shift fork (deformed) Replace the fork.
6. Tolerance clearance (excessive) of drive

and driven bevel gear
1. Shift-fork-shaft groove and positioning ball

Replace.
(worn)
2. Self-locking device (failed) Replace.

Transmission gear jumps out
3. Transmission shaft, bearings (worn,
Replace.
loosened)
4. Bearing axial clearance (excessively large) Replace the bearings.
1. Shift fork shaft(bended, deformed) Replace the fork shaft.
2. Self-locking or interlocking steel ring

Replace.
(broken, seized up due to roughness)
Transmission is difficult to 3. Shift coupling rod adjustment (improper or

Replace.
gear on. damaged)
4. Synchronizer (worn or defective) Replace the synchronizer assembly.
5. Transmission shaft (bended, deformed, or

Replace.
spline damaged)
LIFAN AUTO
21-7
Manual Transmision - Troubleshooting
1. Gear shift lever and stirring end of the gear

Replace.
shift lever (loose or damaged)
2. Internal hole of gear shift and stirring end

Replace.
(excessively worn)
Wrong gear shift of
transmission
3. Compression amount of gear shift return
Replace.
spring (out of standard requirement)
4. gear shift sliding rod interlock pin hole and

Replace.
interlock pin (excessively worn)
1. Bearings (assembled too tightly) Reinstall them.
Transmission heats up 2. Gear meshing clearance (too small) Replace them in pair.
3. Gear oil (insufficient or too low viscosity) Replace gear oil
1. Seal gaskets in all parts of transmission

Replace.
(badly air-tight)
2. Oil seal (damaged) Replace.
3. Fastening bolts (loose) Tighten

Gear oil leaks
4. Transmission housing (broken) Replace. 21
5. Gear oil (too much) Drain gear oil
6. Transmission oil drain plug or vent (cloggy) Replace.
LIFAN AUTO
21-8
Manual Transmission - Transmission control mechanism
Transmission control mechanism

Components diagram
1 Gear shift ball joint 5 Hexagonal bolt with washer
2 Gear shift bracket assembly 6 Hexagon lock nut with flange
3 Split pin 7 E-shaped card
Flexible gear selecting and shifting shaft

4 8 fixed clamp of gear shifting cable joint
assembly
LIFAN AUTO
21-9
Manual Transmision - Transmission control mechanism
Replace
1. Remove the gear shift ball joint
(a). Pry the shift lever sheath pressure plate.
(b). Pull off the gear shift ball joint and remove the sheath.
△ Hint:
Push the upper fixed sleeve of gear lever sleeve down, and unplug
rod ball.
2. Dismantle console assembly.
3. Remove the gear shift bracket assembly 21

(a). Dismantle the fixed snap ring of flexible selecting and
shifting shafts on gear lever. Separate selecting and shifting
rod from flexible selecting and shifting shafts.
(b). Remove the gear shift bracket bolts.
LIFAN AUTO
21-10
(c). Pull upward the gear shift bracket out from the selector
cable and the gear shift cable.
4. Dismantle cable of flexible selecting and shifting shafts

on transmission end
(a). Remove the battery with bracket assembly.
(b). Remove the air filter with bracket assembly.
(c). Remove the gear shift cable fixing clip and E-type clip.
(d). Remove the gear shift cables from the selector and gear
shift cable bracket
△ Hint:
When removing, move flexible shifting shaft backward a little and
take it from bracket opening.
LIFAN AUTO
21-11
(e). Remove the gear selector cable fixing clip and E-type clip.
(f). Remove the gear shift cables from the selector and gear
shift cable bracket
△ Hint: 21
When removing, move flexible selecting shaft backward a little
and take it from bracket opening.
5. Remove the fixed bolts of the gear selector cable and the
gear shift cable on the chassis.
(a). Lift vehicle.
(b). Remove the exhaust pipe and the heat insulation plates.
(c). Remove the set nuts of the gear selector cable and the gear
shift cable on the vehicle body and the bracket fixed bolts.
6. Take off the gear selector cable and the gear shift cable
LIFAN AUTO
21-12
7. Mount the gear selector cable and the gear shift cable
(a). Mount the front end of the gear selector cable and the gear
shift cable from the mounting holes of the vehicle body and
then fasten the set nuts.
(b). Mount the bracket fixed bolts of the gear selector cable and
the gear shift cable in the front suspension.
(c). Mount the exhaust pipe and the heat insulation plates.
8. Install cable of flexible selecting and shafting shafts on

transmission end.
(a). Mount the gear selector cable from the bracket opening of
the gear selector cable and the gear shift cable.
(b). Push the gear selector cable forward and expose the slot,
and then mount the E-type clip of the fixing cable.
(c). Mount the gear selector cable connector onto the transverse
arm of the selector shaft, and then fasten it by the fixing
clips of the gear shift cable connector.
LIFAN AUTO
21-13
(d). Mount the gear shift cable from the bracket opening of the
gear selector cable and the gear shift cable.
(e). Push the gear shift cable forward and expose the slot, and
then mount the E-type clip of the fixing cable.
(f). Mount the gear shift cable connector onto the transverse 21
arm of the gear shift shaft, and then fasten it by the fixing
clips of the gear shift cable connector.
(g). Mount the battery with bracket assembly.
(h). Mount the air filter with bracket assembly.
9. Mount the gear shift bracket assembly

(a). Mount and fasten gear shift bracket bolt by bolts.
Torque: 23N•m
LIFAN AUTO
21-14
(b). Install flexible selecting and shifting shafts onto the groove
of gear shifting bracket.
(c). Install flexible selecting and shifting shafts onto selecting

and shifting rod.
10. Install console.

11. Install handle ball joint and gear lever sleeve
△ Hint:
Install handle ball joint to the lower position, and pull upper fixed
sleeve of gear lever sleeve upward.
LIFAN AUTO
21-15
Manual Transmision - Transmission assembly
Transmission assembly
Replace
1. Lift vehicle.
2. Drainage of transmission oil
(a). Dismantle drain bolt of transmission to drain oil.
Attention:
Transmission gear oil should be recycled.
△ Hint:
After draining oil, install bolt into drain hole, and tighten it to the
specified torque to avoid missing or forgetting tightening and cause
oil leakage.
3. Dismantle wheel drive shaft (See Chapter 41 Drive Shaft
- Propeller Shaft, Replacement)
21
4. Dismantle battery and air filter bracket assembly.

5. Remove the gear selector cable and the gear shift cable
on the transmission end.
6. Remove the clutch oil pipes from the transmission.
(a). Remove the locking plates of oil pipe on the bracket and
push out the oil pipe connector to expose the bracket fixed
bolt.
(b). Remove fixed bolts of the clutch oil pipe bracket.
LIFAN AUTO
21-16
Manual Transmission - Transmission assembly
(c). Remove fixed bolts of clutch slave cylinder and then detach
the clutch slave cylinder from the transmission.
△ Hint:
Do not disconnect the clutch oil pipe when removing it. Otherwise
hydraulic oil may leak.
7. Disconnect the wiring harnesses of switches and sensors

connecting with the transmission.
(a). Press snap ring and unplug speed sensor wire harness
connector.
(b). Disconnect engine crankshaft position sensor connector.
(c). Disconnect the reverse lamp switch wiring harness
connector.
(d). Remove the ground cable fixed bolts connecting with the
transmission.
LIFAN AUTO
21-17
8. Dismantle connecting rod of lower mounting of
transmission and Front left support beam.
(a). Dismantle connecting rod of lower mounting of
transmission, and remove connecting rod.
(b). Dismantle fixed bolts of Front left support beam of

transmission, and remove Front left support beam.
21
9. Disconnect connection between transmission and engine.

(a). Remove the connecting bolts from the engine compartment
above the transmission and the engine.
(b). Remove the starter fixed bolts, and mount the starter
securely onto the engine to prevent starter from falling
down.
(c). Lift up the vehicle and remove the fixed bolts on the
inspection hole pressure plate and remove the pressure
plate.
(d). Use a bracket to prop up the bottom of the engine; remove
the connecting bolts from the engine compartment below
the transmission and the engine.
Warning:
Engine and front and rear overhangs are located on
transmission. While dismantling transmission, to avoid engine
falling off, it is necessary to lay a support under the engine.
After connecting bolts of transmission are dismantled, use
support to fix engine.
LIFAN AUTO
21-18
10. Dismantle mounting of transmission and remove
transmission assy.
Warning:
While dismantling mounting of transmission, lay a support
under the transmission to avoid transmission falling off and
injuring repair technician.
(a). Support transmission, and dismantle fixed bolts of left
mounting fixed on transmission.
(b). Dismantle connecting bolts of left suspension, and
remove connecting bracket between left suspension and
transmission.
(c). Dismantle connecting bolt of left mounting of transmission,

and disconnect connection with vehicle body.
(d). Dismantle fixed bolts of rear overhang fixed on

transmission.
(e). Dismantle connecting bolts of rear mounting fixed on
transmission, and remove connecting bracket between rear
overhang and transmission.
LIFAN AUTO
21-19
(f). Tow transmission backward, to unplug transmission input
shaft from clutch.
(g). Slowly lower support, and remove transmission assy.
11 Mount the transmission assembly

(a). Place the transmission assembly onto the bracket and fasten
it; slowly lift up the bracket to align the transmission input 21
shaft with the clutch driven disk spline hole, and then mount
it.
Warning:
While installing mounting, an assistant should be employed to
assist installation, to avoid transmission falling off and cause
unnecessary loss or injury.
(b). Install connecting bolts which is easy to install under
transmission and engine, and install starter assembly.
12. Install transmission mounting.

(a). Install connecting bracket of left mounting of transmission,
and install fixed bolts and tighten them.
Torque: 60N•m
(b). Adjust support height, and install connecting bolts of left
mounting and tighten them.
Torque: 60N•m
LIFAN AUTO
21-20
(c). Install connecting bolts of right mounting of transmission
and tighten them.
Torque: 60N•m
(d). Install connecting bracket of rear mounting of transmission,

Torque: 60N•m
(e). Install connecting bolts of rear mounting and tighten them.
Torque: 60N•m
△ Hint:
After installing all mountings, remove bracket and lower vehicle.
(f). Install front left support beam under transmission, and

install fixed bolts and tighten them.
LIFAN AUTO
21-21
(g). Install connecting rod of suspension under transmission,
(h). Install connecting bolts above transmission and engine.

(i). Install observation hole cover plate and fixed bolts.
21
13. Install sensor and switch wire harness

(a). Install speed sensor wire harness connector.
(b). Install engine crankshaft position sensor connector.
(c). Install reversing switch wire harness connector.
LIFAN AUTO
21-22
(d). Install transmission grounding wire and fixed bolts.
14. Install clutch slave cylinder assembly

(a). Mount the clutch slave cylinder onto the transmission;
ensure that the clutch push rod is mounted in the slot of the
clutch fork push rod, and then mount and tighten the fixed
bolts.
Torque: 60N•m
(b). Install fixed bracket of oil pipe of clutch slave cylinder onto
the transmission housing, and install fixed bolts and tighten
them.
LIFAN AUTO
21-23
(c). Use lock plate to fix oil pipe joint onto the bracket.
15. Install flywheel drive shaft (See Chapter 41 Drive Shaft -
propeller shaft, Replacement)
16. Install flexible selecting and shifting shaft on transmission
side.
17. Install battery and air filter bracket assembly.
18. Add gear oil

(a). Inspect whether drain bolt of transmission is tightened.
21
Torque: 45N•m
(b). Dismantle filler bolt of transmission.
(c). Use oiling machine to fill gear oil into transmission until
gear oil level flushes with filler bolt.
Filling volume: 2L
(d). Install filler bolt and tighten it.
Torque: 45N•m
LIFAN AUTO
21-24
Disassemble
1. Dismantle clutch fork and clutch release bearing (See
Chapter 22 Clutch - Clutch, Dismantling)
2. Dismantle reversing switch and sensor on transmission.

(a). Remove the transmission reverse lamp switch assembly.
(b). Remove fixed bolts of the engine crankshaft position sensor
fixed bolt, and take off the sensor assembly.
3. Dismantle transmission gear selecting and shifting

mechanism assembly.
(a). Remove the transmission gear shift locating bolts.
(b). Dismantle fixed bolts of gear selector and shift mechanism
assembly.
LIFAN AUTO
21-25
(c). Remove selecting and shifting assembly, and remove return
spring.
(d). Remove damping bolts of 3rd and 4th fork gears.

(e). Remove damping bolts of 1st and 2nd fork gears.
21
(f). Remove damping bolts of 5th fork gears.
4. Remove the transmission housing assembly

(a). Remove connecting bolts (in the clutch housing) connecting
with the transmission housing.
LIFAN AUTO
21-26
(b). Lay clutch housing of transmission downward, and
dismantle fixed bolts of reverse idler gear shaft on housing.
(c). Remove the connecting bolt connecting the transmission
housing with the clutch housing.
(d). Take off the transmission housing assembly.

△ Hint:
While installing, a layer of sealant is applied between transmission
housing and clutch housing, so it is uneasy to remove transmission
housing. While dismantling transmission housing, use rubber
hammer to strike proper position of housing to make is loose and
facilitate removing.
(e). Remove the shims from the input shaft bearing.
5. Remove the reverse idler gear assembly.

(a). Pull upward the reverse idler gear shaft out.
(b). Remove the reverse idler gear and the shims.
LIFAN AUTO
21-27
(c). Remove fixed bolts of reverse gear transverse arm bracket
assembly.
(d). Remove the reverse gear transverse arm assembly and the
reverse gear swing arm bracket pad.
6. Remove the transmission shift shaft assembly, the input

shaft assembly and the output shaft assembly
(a). Respectively move each assembly to facilitate removal of 21
three shift shaft.
(b). Take out the transmission shift shaft, the input shaft and the
output shaft together at the same time.
△ Hint:
The complete transmission should be taken out to facilitate
dismantling and installation. While dismantling, 2 persons can
operated together. Lift differential and take out shift shaft assembly,
input shaft assembly and output shaft assembly.
(c). Take off the transmission shift shaft assembly and detach
the input shaft from the output shaft.
7. Remove the differential assembly
LIFAN AUTO
21-28
Check it completely
1. Check the input shaft assembly
(a). Use feeler gauge to check the clearance of 3rd gear shaft.
(b). Check axial clearance of 5th gear shaft.

(c). Check the clearance of 4th and 5th gear.
Standard value is less than: 0.058mm
2. Check the output shaft assembly

(a). Measure axial clearance of 1st gear and 2nd gear shaft of
the output shaft by a feeler.
1st gear: 0.1 ~ 0.35mm
2nd gear: 0.1 ~ 0.35mm
LIFAN AUTO
21-29
(b). Measure radial run-out of gear in 1st gear and 2nd gear.
Assembly
1. Mount the differential assembly 21
(a). Mount the differential assembly into the clutch housing.
2. Mount the transmission shift shaft assembly, the input

shaft assembly and the output shaft assembly
(a). Assemble the input shaft and output shaft, and install
transmission shift shaft assembly.
(b). Mount the transmission shift shaft, the input shaft and
the output shaft together at the same time onto the clutch
housing.
LIFAN AUTO
21-30
3. Mount the reverse idler gear assembly.
(a). Mount the reverse gear swing arm bracket assembly and the
reverse gear transverse arm bracket pad.
(b). Mount and tighten fixed bolts of reverse gear transverse
arm bracket assembly.
(c). Mount the reverse idler gear and the shims.

(d). Insert reversing middle gear shaft.
4. Mount the transmission housing assembly

(a). Mount the input shaft bearing gasket.
LIFAN AUTO
21-31
(b). Mount the transmission housing assembly.
△ Hint:
Smear sealant on the contacting surface between the transmission
housing and the clutch housing.
(c). Mount the fixed bolts of the reverse idler gear shaft in the
housing.
(d). Install connecting bolts between transmission housing and 21
clutch housing.
Torque: 23N•m
(e). Install connecting bolts of clutch housing and transmission

housing.
LIFAN AUTO
21-32
5. Mount the gear selection and shifting mechanism
assembly of the transmission
(a). Install bolts of 3rd and 4th fork gear.
(b). Install bolts of 1st and 2nd shift gear.
(c). Mount damping bolts of 5th fork gears.
(d). Mount the gear selection and shifting mechanism assembly

and the return springs.
(e). Dismantle fixed bolts of selecting and shifting mechanism

assembly.
Torque: 23N•m
(f). Dismantle positioning bolts of transmission gear shift.
LIFAN AUTO
21-33
6. Mount the transmission reverse switch and sensors
(a). Mount the transmission reverse switch assembly.
(b). Mount the engine crankshaft position sensor assembly and
fixed bolts.
7. Mount the clutch fork and the clutch release bearing (see
Chapter 22 Clutch - Clutch , Removal)
21
LIFAN AUTO
21-34
Manual Transmission - Input shaft assembly
Input shaft assembly

Components diagram
1 Input shaft front ball-bearing 13 Bearing race
2 Input shaft 14 Needle bearing of 4th speed drive gear
3 Opening thrust spacer pin 15 4th speed drive gear
4 Needle bearing of 3rd speed drive gear 16 Snap plate of 4th gear
5 3rd speed drive gear 17 Retainer ring of 4th gear
6 3rd speed synchronizer ring 18 5th speed ball bearing of drive gear
7 Snap ring 19 5th speed drive gear
8 3rd and 4th speed gear hub 20 Gear synchronizer lock ring
9 Synchronizer slider 21 5th Gear synchronizer gear hub
10 3rd and 4th Speed sliding sleeve of synchronizer 22 5th Gear synchronizer gear sleeve
11 Elastic retainer ring of 3rd and 4th synchronizer 23 Input shaft rear radial ball bearing
12 4th Speed synchronizer ring
LIFAN AUTO
21-35
Manual Transmision - Input shaft assembly
Dismantling
1. Put the input shaft assembly upright and tighten it
(a). Put the front end of input shaft down and use fixed bracket
to vertically fix it onto the working table.
Attention:
Before removal of the input shaft, always check the
synchronizer snap ring clearance; measure clearance between
the synchronizer ring and each transmission gear by a feeler
gauge. Correct clearance is as follows:
1st gear: 0.522 ~ 2.208mm
2nd gear: 0.522 ~ 2.208mm
3rd gear: 0.73 ~ 1.53mm
4th gear: 0.77~1.57mm
5th gear: 0.73~1.53mm
If the clearance of some synchronizer ring doesn't in this
parameter, it is necessary to inspect whether it has abrasion, 21
and replace it.
2. Remove the input shaft rear bearing
(a). Install bearing puller and dismantle rear ball-bearing of
input shaft.
3. Remove the 5th-speed synchronizer assembly

△ Hint:
Make an upward mark While dismantling synchronizer to facilitate
installation.
(a). Pull out the 5th-speed synchronizer completely and then
remove it.
Attention:
To avoid missing of synchronizer sliding block While installing
synchronizer, the synchronizer assembly can be removed in a
complete unit.
LIFAN AUTO
21-36
(b). Take off the sliding sleeve of 5th-speed synchronizer.
(c). Remove the 5th-speed synchronizer sliding block and the

circlips in the both sides of the synchronizer gear hub.
4. Remove the 5th-speed drive gear assembly.

(a). Remove the 5th-speed gear synchronizer ring.
LIFAN AUTO
21-37
(b). Remove 5th speed drive gear assembly.
(c). Remove 5th speed gear needle bearing.
21
5. Remove the 4th-speed drive gear assembly.

(a). Dismantle retainer ring of opening thrust pad of 4th speed
drive gear.
LIFAN AUTO
21-38
(b). Remove opening thrust pad of 4th speed drive gear.
(c). Pull out the opening thrust spacer pin.
(d). Remove the 4th-speed drive gear.
LIFAN AUTO
21-39
(e). Remove needle bearing of 4th speed drive gear.
(f). Take off the bearing races.
21
(g). Remove the 4th-speed gear synchronizer ring.
LIFAN AUTO
21-40
6. Remove the 3rd/4th speed synchronizer assembly
△ Hint:
Make an upward mark While dismantling synchronizer to facilitate
installation.
(a). Remove 3rd/4th speed synchronizer elastic circlip.
(b). Remove the 3rd/4th speed synchronizer assembly.
(c). Remove the 3rd/4th speed synchronizer sliding sleeve.
LIFAN AUTO
21-41
(d). Remove the 3rd/4th-speed synchronizer sliding block and
the elastic lock ring in the both sides of the synchronizer
gear hub.
(e). Remove the 3rd-speed gear synchronizer ring.
21
7. Remove the 3rd-speed drive gear assembly.

(a). Remove the 3rd-speed drive gear.
LIFAN AUTO
21-42
(b). Remove the 3rd-speed drive gear needle bearing.
8. Rotate input shaft to 180° and re-fix it. Use puller to

dismantle front ball-bearing of input shaft.
9. Clean all parts.
Attention:
Use engine oil to clean gear, bearing, shaft, synchronizer, thrust
pad, and use compressed air to dry all parts except for
bearing. Leave the bearing become dry slowly or dry it by a
cloth wiping.
Check
1. Check the input shaft
(a). Inspect whether input shaft has abrasion, whether bearing
seat has damage, teeth of gear falls off. If necessary, replace
them.
(b). Check the input shaft spline for severe wear and damage. If
necessary, replace the input shaft.
LIFAN AUTO
21-43
(c). Check input shaft radial runout; if beyond this range,
replace the input shaft.
(d). Use micrometer to check the abrasion condition of input

shaft: minimum diameter of surface A is: 33.985mm;
minimum diameter of surface B is 30.985mm. If the value 21
exceeds this range, replace input shaft.
2. Check the synchronizer

(a). Use feeler gauge to check the clearance between gear sleeve
and shift fork. If necessary, replace gear sleeve or shift
shaft.
LIFAN AUTO
21-44
(b). Check the sliding block for wear; replace it when necessary.
(c). Assemble synchronizer gear sleeve and gear hub, and

inspect whether they are sliding smoothly without
stagnation.
(d). Check the front and rear ends of internal surface of the gear
sleeve for damage.
Attention:
If the synchronizer gear sleeve or the gear hub is required to be
changed, both of them should be replaced together.
3. Check gears in all speeds

(a). Use feeler gauge to check whether the clearance between
the back side of synchronizer ring and end surface of gear is
in specified range. If no, replace synchronizer.
Minimum value: 0.8mm
LIFAN AUTO
21-45
(b). Tooth surface of the synchronizer gear ring should be free
of damage and breakage. Internal surface of a cone should
be free of damage, wear; or the thread teeth should not be
broken.
(c). Check if the needle bearings of gears in all speeds are worn
or broken; Check if the needle bearing bracket is broken;
replace it when necessary. 21
(d). When the input shaft, the sliding sleeve and the gears are
rotating together, the rotation should be smooth without
abnormal noise.
4. Check the front and rear bearings of the input shaft

(a). Check the radial runout of front bearing of input shaft.
Limit value: 0.01~0.21mm
(b). Check the radial runout of rear bearing of input shaft.
Limit value: 0.01~0.21mm
LIFAN AUTO
21-46
Assembly
1. Mount the input shaft front bearing.
(a). Mount the input shaft front bearing to the correct position
by a special bearing punch sleeve.
2. Rotate input shaft to 180°, and use fixed bracket to fix on

the working table.
3. Mount the 3rd-speed drive gear assembly.
(a). Mount the 3rd-speed drive gear needle bearing.
(b). Mount the 3rd-speed drive gear.
LIFAN AUTO
21-47
(c). Mount the 3rd-speed synchronizer ring.
4. Mount the 3rd/4th speed synchronizer assembly

(a). Make the 3rd/4th speed synchronizer gear hub onto the
synchronizer sliding sleeve; mount the sliding blocks in 3 21
notches of the synchronizer gear hub; fix the both sides by
elastic circlips.
Attention:
Pay attention to direction (upward) of sliding sleeve in
installation.
(b). According to "Upward" mark made during removal, mount

the synchronizer gear hub onto the input shaft and then
press it tightly.
LIFAN AUTO
21-48
(c). Mount 3rd/4th speed synchronizer elastic circlip.
Attention:
Select elastic retainer ring with proper specification, and the
clearance between elastic retainer ring and ring groove can't
exceed 0.07mm.
(d). Mount the 4th-speed synchronizer ring.
5. Mount the 3rd-speed drive gear assembly.

(a). Mount the 4th-speed drive gear needle bearing races and the
needle bearing
LIFAN AUTO
21-49
(b). Mount the 4th-speed drive gear.
(c). Mount the 4th-speed drive gear stop pin onto the input
shaft.
21
(d). Install thrust plate of 4th speed drive gear.

Attention:
Align two notches of thrust plate with thrust pin.
LIFAN AUTO
21-50
(e). Install retainer ring of thrust plate of 4th speed drive gear
onto two thrust plates.
6. Mount the 5th-speed drive gear assembly.

(a). Install 5th speed needle bearing.
(b). Mount the 5th-speed drive gear assembly.
LIFAN AUTO
21-51
(c). Mount the 5th-speed synchronizer ring.
7. Mount the 5th-speed synchronizer assembly

(a). Make the 5-th speed gear hub onto the synchronizer
sliding sleeve; mount the sliding blocks in 3 notches of the 21
synchronizer gear hub; fix the both sides by elastic circlips.
Attention:
Pay attention to direction (upward) of sliding sleeve in
installation.

the synchronizer gear hub onto the input shaft and then
press it tightly.
LIFAN AUTO
21-52
8. Mount the input shaft rear bearing.
(a). Mount the input shaft rear bearing to the correct position by
a special bearing punch sleeve.
9. Check installation of the input shaft; mount it again if
out of standard requirements
(a). Check clearance between gears.
(b). Inspect synchronizer sliding condition. The sliding
condition should be normal without stagnation.
(c). Move the gears in all speeds; it is ok if no abnormal sound
is heard.
LIFAN AUTO
21-53
Manual Transmision - Output shaft assembly
Output shaft assembly

Components diagram
21
1 Output shaft front bearing 11 2nd-speed gear synchronizer ring assembly
2 Output shaft 12 2nd-speed gear needle bearing
3 1st-speed gear needle bearing 13 2nd-speed gear
4 1st-speed gear 14 3rd-speed driven gear
5 1st-speed gear synchronizer ring assembly 15 Spacer bush
6 1st/2nd speed synchronizer gear hub 16 4th-speed driven gear
7 Steel ball 17 5th-speed driven gear
8 Spring 18 Snap ring
9 Engagement sleeve 19 Output shaft rear bearing
10 Retaining ring
LIFAN AUTO
21-54
Manual Transmission - Output shaft assembly
Dismantling
1. Place the output shaft assembly upright and securely
(a). Make the output shaft front end downward and then
keep the mounting bracket upright and then fix it on the
workbench.
Attention:
Before removal of the input shaft, always check the
synchronizer snap ring clearance; measure clearance between
the synchronizer ring and each transmission gear by a feeler
gauge.
Correct clearance is as follows:
1st gear: 0.522 ~ 2.208mm
2nd gear: 0.522 ~ 2.208mm
3rd gear: 0.73 ~ 1.53mm
4th gear: 0.77~1.57mm
5th gear: 0.73~1.53mm
If some thrust ring clearance isn't in this range, inspect
whether it has abrasion, and replace it if necessary.
2. Dismantle the output shaft rear bearing

(a). Mount the output shaft rear bearing by a bearing puller.
Attention:
For tapered roller bearing of rear bearing, bearing puller
should be installed on the roller of rear bearing.
3. Remove the 5th-speed driven gear and the 4th-speed

driven gear.
(a). Use circlamp caliper to dismantle elastic retainer ring of 5th
speed drive gear.
LIFAN AUTO
21-55
(b). Mount the puller, and then pull out the 5th-speed driven
gear and the 4th-speed driven gear together at the same
time.
(c). Take out the spacer.
21
4. Remove the 3rd-speed driven gear and the 2nd-speed

driven gear assembly.
(a). Install puller and unplug 3rd speed drive gear and 2nd speed
driven gear assembly.
△ Hint:
When mounting the puller, you may stir the 1st/2nd speed
synchronizer gear sleeve to the 1st speed position for easy
installation.
(b). Remove the 3rd-speed driven gear and the 2nd-speed driven
gear assembly.
LIFAN AUTO
21-56
(c). Remove the 2nd-speed driven gear needle bearing.
(d). Take out 2nd-speed gear synchronizer ring assembly.
5. Remove the 1st/2nd speed synchronizer assembly

(a). Remove the 1st/2nd speed synchronizer retainer ring by
circlip pliers.
LIFAN AUTO
21-57
(b). Make a mark "Upward" on the synchronizer assembly; take
the 1st/2nd speed synchronizer assembly together.
(c). Put the synchronizer onto the clean cloth and wrap it. Press
the internal gear hub; carefully open the cloth and remove
the spring, the steel balls, the gear hub and the engagement 21
sleeve.
Attention:
Do not put retainer ring into engine oil to clean, because this
may cause friction material polluted. Put synchronizer parts
onto proper bracket, and then clean them with engine oil, and
then dry it.
6. Remove the 1st-speed driven gear assembly.

(a). Remove the 1st-speed synchronizer ring assembly.
LIFAN AUTO
21-58
(b). Remove the 1st-speed driven gear assembly.
(c). Remove the 1st-speed driven gear needle bearing.
7. Remove the output shaft front bearing

(a). Rotate output shaft to 180°, and install bearing puller to
dismantle front ball-bearing of output shaft.
Attention:
For tapered roller bearing of front bearing, bearing puller
should be installed on the roller of front bearing.
8. Clean all parts.
Attention:
Use engine oil to clean gear, bearing, shaft, synchronizer, and
use compressed air to dry all parts except for bearing. Leave
the bearing become dry slowly or dry it by a cloth wiping.
LIFAN AUTO
21-59
Check
1. Check the output shaft
(a). Inspect whether output shaft has abrasion, whether bearing
seat has damage, teeth of gear falls off. If necessary, replace
them.
(b). Check the output shaft spline for severe wear and damage.
If necessary, replace the output shaft.
(c). Inspect radial runout of output shaft. If the value exceeds 21

this range, replace output shaft.
(d). Use micrometer to check the abrasion condition of out

shaft: minimum diameter of surface is: 30.985mm. If the
value exceeds this range, replace output shaft.
LIFAN AUTO
21-60
2. Check the synchronizer
(a). Use feeler gauge to inspect whether the clearance between
gear sleeve and shift shaft is qualified. If no, replace gear
sleeve or shift shaft.
(b). Check the spring and the sliding block.

(c). Assemble synchronizer gear sleeve and gear hub, and
inspect whether they are sliding smoothly without
stagnation.
(d). Check the front and rear ends of internal surface of the gear
sleeve for damage.
Attention:
If the synchronizer gear sleeve or the gear hub is required to be
changed, both of them should be replaced together.
3. Check gears in all speeds

(a). Use feeler gauge to check the back side of synchronizer
ring and end surface of gear is qualified. If no, replace
synchronizer ring.
Minimum value: 0.8mm
LIFAN AUTO
21-61
(b). Tooth surface of the synchronizer gear ring should be free
of damage and breakage. Internal surface of a cone should
be free of damage, wear; or the thread teeth should not be
broken.
(c). Check if the needle bearings of gears in all speeds are worn
or broken; Check if the needle bearing bracket is broken;
replace it when necessary. 21
(d). When the output shaft, the sliding sleeve and the gears are
rotating together, the rotation should be smooth without
abnormal noise.
4. Check the front and rear bearings of the input shaft

(a). Check the tapered roller bearing's roller for wear and
breakage. Replace it on time when necessary.
(b). Check the tapered roller bearing's bracket for deformation;
replace it on time when necessary.
Attention:
The bearing outer sleeve should be replaced when changing the
tapered roller bearing.
LIFAN AUTO
21-62
Assembly
1. Mount the output shaft front bearing
(a). Mount the output shaft front shaft to the correct position by
2. Mount the 1st-speed driven gear assembly.

(a). Mount the 1st-speed driven gear needle bearing.
(b). Mount the 1st-speed driven gear assembly.
LIFAN AUTO
21-63
(c). Mount the 1st-speed synchronizer ring assembly.
3. Mount the 1st/2nd speed synchronizer assembly

(a). Assembly the 1st/2nd speed synchronizer.
21

the 1st/2nd speed synchronizer onto the output shaft and
then press it tightly.
LIFAN AUTO
21-64
(c). Use circlamp pliers to install retainer ring of 1st and 2nd
speed synchronizer.
(d). Mount 2nd-speed gear synchronizer ring assembly.
4. Mount the 2nd-speed driven gear assembly.

(a). Mount the 2nd-speed driven gear needle bearing.
LIFAN AUTO
21-65
(b). Mount the 2nd-speed driven gear.
5. Mount the 3rd-speed driven gear.

(a). Mount the 3rd-speed driven gear, and then press and mount
it to the mounting position. 21
6. Mount the 4th-speed driven gear.

(a). Mount the intermediate sleeve of the 3rd-speed driven gear
and the 4th-speed driven gear.
LIFAN AUTO
21-66
(b). Mount the 4th-speed driven gear, and then press and mount
it to the mounting position.
7. Mount the 5th-speed driven gear assembly.

(a). Mount the 5th-speed driven gear, and then press and mount
it to the mounting position.
(b). Use circlamp pliers to install elastic retainer ring of 5th

speed driven gear.
LIFAN AUTO
21-67
8. Mount the output shaft rear bearing.
(a). Mount the output shaft rear bearing to the correct position
by a special bearing punch sleeve.
9. Check installation of the output shaft; mount it again if
out of standard requirements
(a). Check clearance between gears.
(b). Inspect synchronizer sliding condition. The sliding
condition should be normal without stagnation. (c).
Move the gears in all speeds; it is ok if no abnormal sound
is heard.
21
LIFAN AUTO
21-68
Manual Transmission - Differential assembly
Differential assembly
Components diagram
1 Differential front bearing sleeve 9 Pinion
2 Differential front bearing 10 Pinion shaft
3 Speedometer gear ring 11 Planetary gear shaft elastic cylindrical pin
4 Housing fasteners 12 Differential housing
5 Snap plate of gear shaft 13 Differential ring gear
6 Axle shaft gear washer 14 Differential rear bearing
7 Axle shaft gear 15 Differential rear bearing sleeve
8 Washer, differential gear
LIFAN AUTO
21-69
Manual Transmision - Differential assembly
Dismantling
1. Removing the differential front and rear bearings
(a). Fit the puller and the remove the differential front bearing.
Attention:
Puller should be installed on roller of front bearing.
(b). Remove speed sensor gear ring. 21
(c). Remove the rear bearing by a bearing puller.
LIFAN AUTO
21-70
2. Remove the differential gear ring.
(a). Remove the differential gear ring bolts
(b). Remove snap plate of differential gear shaft.
(c). Take out the differential gear ring.
3. Remove the differential planetary gear and the half-shaft

gear
(a). Remove the differential planetary gear shaft cylindrical pin
by a punch and then take out the planetary gear shaft.
LIFAN AUTO
21-71
(b). Rotate gears and take out the planetary gear, the planetary
gear shims, the half shaft gears and the half shaft gear
shims.
Check
1. Check the main reducer gear ring.
21
(a). Inspect whether main reducer gear ring has broken, pit,
serious abrasion and cement. If any of above conditions
occurs, replace main reducer gear ring.
2. Check the planetary gear and the half-shaft gear

(c). Check the pinion and the axle shaft gear as well as the
spline teeth for serious wear or damage. If so, replace it.
LIFAN AUTO
21-72
3. Check the differential front and rear bearings
(a). Check the tapered roller bearing external ring and the rollers
for wear; if badly worn, replace the bearing.
Attention:
At the same time, external rings of the differential front and
rear tapered roller bearings should be replaced.
(b). Feel by hands whether the bearing may rotate smoothly
without seizure. If it can not rotate smoothly or seizure
exists, replace the bearing.
Assembly
1. Mount the differential planetary gear and the half-shaft
gear
(a). Install washer onto the back side of axle shaft gear, and then
install inside differential housing.
(b). Install washer onto the back side of differential gear to make
differential gear mesh with axle shaft gear. Rotate gear rack
and install differential gear shaft onto the specified position.
LIFAN AUTO
21-73
(c). Measure clearance between the planetary gear and the half-
shaft gear; if beyond standard value, select proper spacers
and then measure clearance.
Attention:
Gear backlash on both side shall be equability by adjustment.
(d). Mount Planetary gear shaft elastic cylindrical pin.
21
2. Mount the differential gear ring.

(a). Mount the differential ring gear onto the differential housing
and align bolt holes.
LIFAN AUTO
21-74
(b). Mount the differential ring gear bolts, and then mount all
retaining plates on bolts in the both sides of the planetary
gear shaft.
Attention:
Before installing bolts, all thread of bolts should be applied
with anaerobic sealant.
3. Mount the differential front and rear bearings

(a). Mount the differential rear shaft to the correct position by a
special bearing punch sleeve.
(b). Turn over the differential and install the speedometer gear
ring.
LIFAN AUTO
21-75
(c). Mount the differential front shaft to the correct position by
21
LIFAN AUTO
21-76
Manual Transmission - Reverse idler gear assembly
Reverse idler gear assembly

Components diagram
1 Shaft, reverse idler gear 4 Reverse idler gear assembly
2 Washer 5 Reverse idler gear bolts
3 Gear sleeve
LIFAN AUTO
21-77
Manual Transmision - Reverse idler gear assembly
Check
1. Check the reverse idler gear.
(a). Use dial caliper to check whether inner diameter of gear

lining has abrasion. If the abrasion exceeds limit value,
replace gear lining.
Wear limit: 0.2mm
(b). Check whether the reverse gear shaft is worn, and if 21

seriously worn, please replace it.
(c). Inspect whether gear has abrasion, fatigue falling off, pit
and breaking conditions. If any, replace reverse idler gear.
LIFAN AUTO
21-78
Manual Transmission - Reverse idler gear assembly
Replace
1. Replace the reverse idler gear sleeve
(a). Push out the reverse idler gear sleeve by a sleeve punch.
(b). Use punching pin of lining to install reverse idler gear

lining onto the mounting position.
LIFAN AUTO
21-79
Manual Transmision - Fork shaft assembly
Fork shaft assembly

Components diagram
21
1 1st-2nd speed shift fork 9 5th-speed and reverse shift fork
2 Gear shift fork stopper bolt 10 3rd/4th speed fork shaft
3 1st/2nd speed fork shaft 11 5th speed-reverse shift guide block
4 1st-2nd speed shift guide block 12 Fork return spring
5 Elastic cylindrical pin 13 3rd-4th speed shift fork
6 Fork shaft spacer 14 Interlock pin B
7 Reverse shifting block 15 5th speed gear shift fork
8 Interlock pin A
LIFAN AUTO
21-80
Manual Transmission - Fork shaft assembly
Dismantling
1. Decompose the 1st/2nd speed fork shaft
(a). Remove the retaining bolts of the 1st/2nd speed shift fork
and take off the 1st/2nd speed shift fork.
(b). Fix the 1st/2nd speed fork shaft and then push out the gear
shift guide block elastic cylindrical pin. Take off the 1st/2nd
speed gear shift guide block.
(c). Dismantle retainer ring of 1st and 2nd speed gear shift fork
shaft.
LIFAN AUTO
21-81
2. Decompose the 3rd-4th speed fork shaft and the 5th-
speed and reverse fork shaft.
(a). Take out the interlock pin out from the 5th gear shift fork
interlock pin hole.
(b). Dismantle retainer ring under 5th speed and reversing gear
shift fork shaft. Remove 5th speed and reversing gear shift
fork shaft from reversing block. And take out interlock pin 21
of reversing block.
(c). Punch off the snap ring above 5th speed and reversing gear
shift fork shaft. Remove 5th speed gear shift fork and fork
return spring.
LIFAN AUTO
21-82
(d). Fix 5th speed and reversing fork shaft and punch elastic
cylindrical pin of reversing and shifting block, and remove
5th speed and reversing and shifting block.
(e). Fix the 3rd-4th speed fork shaft and push out the upper
and lower fork shaft spacers, and then take off the reverse
shifting block.
(f). Remove the retaining bolts of the 3rd/4th speed shift fork
and take off the 3rd/4th speed shift fork.
LIFAN AUTO
21-83
Assembly
1. Assemble 1st/2nd speed fork shaft.
(a). Mount the 1st/2nd speed fork shaft guide block and mount
the elastic cylindrical pin for fixing.
(b). Install 1st and 2nd speed gear shifting fork and align bolt 21
hole to install stopper bolt of gear shifting fork.
(c). Install snap ring of 1st and 2nd speed gear shift fork shaft.
LIFAN AUTO
21-84
2. Assemble the 3rd/4th speed fork shaft and the 5th-speed
and reverse fork shaft.
(a). Install 3rd and 4th speed gear shift fork and align bolt hole
to install stopper bolt of gear shifting fork.
(b). Mount the reverse shifting block onto the 3rd/4th speed fork
shaft.
(c). Mount the upper and lower fork shaft spacers onto the
3rd/4th speed fork shaft .
(d). Install 5th and reversing gear shift block onto 5th and
reversing gear shift fork shaft,
LIFAN AUTO
21-85
(e). Install fork return spring and 5th speed gear shift fork onto
5th speed and reversing gear shift fork shaft, and install
retainer ring of fork shaft.
(f). Mount the interlock spin on the reverse shifting block

interlock pin holes; and then mount the 5th-speed and
reverse fork shaft into the reverse shifting block shaft hole. 21
(g). Mount the fork spacers below the 5th-speed and reverse
fork shaft.
LIFAN AUTO
21-86
Manual Transmission - Gear shift mechanism assembly.
Gear shift mechanism assembly.

Components diagram
1 Shift guide shaft component 13 5th speed-reverse interlock cam pin
2 Gear shift guide shaft nylon washer 14 Shift cover
3 Retainer ring of gear shift guide shaft. 15 5th speed-reverse interlock cam
4 Shift guide shaft shield sleeve 16 5th speed-reverse interlock cam spring
5 Shift cover bolt 17 Spring
6 Vent valve assembly 18 Shift guide shaft oil seal
7 Shift cover oil seal 19 Shift rocker lever interlock bracket
8 Seal, selector arm 20 Retainer ring of gear shift guide shaft.
9 Gear shift transverse arm 21 Shift rocker lever
10 Gear shift transverse arm bolt 22 Return spring
11 Gear shift swing link 23 Return spring seat
12 5th speed-reverse interlock cam seal ball
LIFAN AUTO
21-87
Manual Transmision - Gear shift mechanism assembly.
Dismantling
1. Remove the gear shift swing link
(a). Push the gear shift swing link out of the elastic cylindrical
pin by a punch.
(b). Dismantle snap ring of gear shift guide shaft. 21
(c). Remove the gear shift swing link, the gear shift swing link
interlocking bracket, the return spring and the return spring
from the gear shift guide shaft.
Attention:
When removing the gear shift swing link, make a mark on the
gear shift swing link and the guide shaft for easy installation.
LIFAN AUTO
21-88
2. Remove the gear shift swing link.
(a). Remove the gear shift swing link bolts and take out the gear
shift transverse arm, and then take off the gear shift swing
link.
3. Dismantle gear shift guide shaft.

(a). Punch off retainer ring of gear shift guide shaft.
(b). Dismantle gear shift guide shaft and sleeve from gear shift
cover.
(c). Use screwdriver to pry nylon washer of gear shift guide

shaft from gear shift guide shaft.
LIFAN AUTO
21-89
4. Dismantle gear shift cover.
(a). Use screwdriver to pry oil seal of gear shift cover.
Attention:
After removed, the seal must be replaced, but never used again.
(b). Pry 5th speed and reversing gear interlock camshaft sealing
ball. Use magnetic bar to take out 5th and reversing gear
interlock cam pin.
21
(c). Remove 5th speed and reversing gear interlock cam and
spring.
(d). Remove the vent plug bolt, and take out the vent plug.
LIFAN AUTO
21-90
Assembly
1. Assembly gear shift cover.
(a). Mount the vent plug and fasten the vent plug bolt.
(b). Install 5th speed and reversing gear shift interlock cam
and spring into gear shift cover hole. Make it press 5th
and reversing gear interlock cam opening and align with
pin hole, and then install them into 5th and reversing gear
interlock cam pin.
(c). Seal the pin opening by sealing balls with sealant.
(d). Mount the shift cover oil seals by oil seal mounting tool.
LIFAN AUTO
21-91
2. Install gear shift guide shaft.
(a). Install gear shift guide shaft sleeve and install it into gear
shift cover.
Attention:
When install gear shift guide shaft, do not damage oil seal of
gear shift cover.
(b). Install retainer ring of gear shift guide shaft into retainer
ring groove of gear shift guide shaft.
21
(c). Mount the shift guide shaft nylon washers into the shift
guide shaft.
LIFAN AUTO
21-92
3. Mount the gear shift swing link.
(a). Install gear shift swing rod into gear shift cover groove and
insert it into gear shift swing arm.
(b). Rotate the gear shift transverse arm to align bolts with the
gear shift swing link bolt holes; mount and tighten the gear
shift swing link bolts.
Attention:
While installing gear shift swing arm, do not damage oil seal of
gear shift cover.
4. Mount the gear shift swing link.

(a). Mount successively the return spring seat, the return spring,
the gear shift swing link and the interlocking bracket of the
gear shift swing link onto the shift guide shaft.
Attention:
Align the pin hole with the shift guide shaft pin hole when
mounting the gear shift swing link; mount and remove it
according to marks.
(b). Push the gear shift swing link elastic cylindrical pin into the
gear shift swing link pin hole.
LIFAN AUTO
21-93
(c). Install snap ring on gear shift guide shaft.
21
LIFAN AUTO
21-94
Manual Transmission - Housing assembly
Housing assembly
Components diagram
1 Clutch fork 11 Magnet
2 Oil seal 12 Oil guide groove
3 Release fork strut 13 Input shaft gasket
4 Connecting bolt 14 External sleeve of output shaft rear bearing
5 Reverse switch sensor 15 Transmission housing
6 Crankshaft position sensor 16 Odometer sensor
7 External sleeve of output shaft front bearing 17 Drain bolt
8 Input shaft oil seal 18 Damper bolt
9 External sleeve of differential bearing 19 Shift guide shaft sleeve
10 Clutch housing 20 Oil seal
LIFAN AUTO
21-95
Manual Transmision - Housing assembly
Check
1. Check the housing assembly
(a). Use flat tape and feeler gauge to check the flatness of
contact surface between clutch housing and transmission
housing, flatness of contact surface of gear shift cover. If the
value doesn't meet requirement, repair or replace it timely,
to avoid oil leakage from transmission.
△ Hint:
Move the steel ruler and the feeler gauge in different directions
during inspection; after measuring many times, you may obtain
rather correct values.
(b). Check if the housing assembly is cracked or damaged; 21

replace it when necessary.
2. Check the housing oil seals

(a). Check oil seals in both sides of differential and the input
shaft oil seals for damage and obvious oil leakage; replace
oil seals when necessary.
LIFAN AUTO
21-96
3. Check the tapered roller bearing external sleeve.
(a). Check if the differential and the upper/lower tapered roller
bearing external sleeves of the output shaft are worn.
Replace the whole tapered roller bearing when necessary.
4. Inspect gear shift guide shaft lining.
(a). Inspect whether inner diameter of gear shift guide shaft

lining has abrasion. If any, replace gear lining.
Replace
1. Remove the clutch housing square magnet.
(a). Take out the square magnet from the clutch housing, and
use a clean cloth to wipe off scrap iron on the square
magnet.
LIFAN AUTO
21-97
(b). Apply a layer of aerotolerance sealant on the contact surface
between square magnet and housing to adhere it to clutch
housing.
2. Replace the oil guide groove

(a). Remove the transmission oil guide groove from the
transmission housing. 21
(b). Mount the oil guide groove on the transmission housing.
LIFAN AUTO
21-98
3. Replace the housing oil seal.
(a). Remove the differential half-shaft oil seal by a screwdriver.
(b). Mount the differential half-shaft oil seal by an oil seal

mounting device.
Attention:
Pay attention to the mounting direction of oil seal in
installation.
(c). Use a screwdriver to remove the input shaft oil seal.
LIFAN AUTO
21-99
(d). Use the oil seal installer to install input shaft oil seal.
4. Replace the output shaft,differential bearing cover

(a). Use the bearing cover puller to remove the upper and lower
bearing of output shaft, upper and lower bearing cover of 21
differential.
Attention:
Tapered roller bearing and outer ring should be replaced in
pairs.
(c). Use the bearing cover installation punch to mount the

bearing cover of output shaft and differantial to the
assembly position.
LIFAN AUTO
21-100
5. Replace gear shift guide shaft lining.
(a). Use a punching pin to punch gear shift guide shaft lining of
housing.
(b). Mount the housing onto the fitting position using punch.
LIFAN AUTO
Clutch
Clutch.......................................................................... 22-1
Preparation............................................................. 22-1
Precautions............................................................. 22-2
Component diagram (Operated clutch arrangement)
. .............................................................................. 22-3
System description................................................. 22-4
On-Vehicle check................................................... 22-5
Clutch pedal................................................................ 22-8
Adjustment............................................................. 22-8
Replace................................................................... 22-9
Clutch master pump................................................ 22-11
Replace................................................................. 22-11
Clutch slave pump................................................... 22-14
Replace................................................................. 22-14 22
Exhaust................................................................. 22-16
Clutch assembly....................................................... 22-17
Check.................................................................... 22-17
Replace................................................................. 22-18
LIFAN AUTO
22-1
Clutch - Clutch
Clutch
Preparation
1. Special tool
Used for installing and

Clutch pressure
positioning the clutch
1 plate positioning
pressure plate and
tool
driven plate
Used for preventing the

flywheel from rotating
2 Flywheel stopper
when removing the
clutch pressure plate 22
For measuring the clutch

1 Dial caliper
wear
Remove the oil pipe bolt and

2 Pipe wrench
the clutch bleed plug
LIFAN AUTO
22-2
Clutch - Clutch
Height from the clutch to the floor 160±15mm
Clutch Pedal Free Travel ≤10mm
Clutch pressure plate diaphragm spring wear limit 0.8mm
Clutch driven disk wear limit 1.5mm
Item N•m
Locknut of check bolt 12~18
Push rod lock nut 20~26
Connecting bolt between the clutch pedal and the bracket 12~18
Clutch control oil pipe nut 14~18
Clutch master cylinder(master pump) retaining nut 20~26
Clutch slave-cylinder fixed bolt 20~26
Clutch pressure plate fixed bolt 30~34
Precautions
1. It is recommended to use clutch hydraulic oil - brake fluid "DOT4", and do not use mineral oil such as gasoline
or kerosene. Otherwise it will corrode the rubber parts in the hydraulic system.
2. Do not re-use the drained clutch hydraulic oil.
3. Do not splash clutch hydraulic oil over the vehicle body paint surface.
4. Never use gasoline to clean the clutch pressure plate.
5. Don't clean the release bearing with oil or liquid substances because the release bearing is filled with grease.
6. While mounting the clutch, the temperature and pressure resistant grease shall be used to properly lubricate
the driven disc spline and the transmission first shaft spline to ensure the driven disc could move freely on the
transmission first shaft spline. Excessive lubrication will result in slippage of the friction plates.
7. When the friction plate is worn down to the prescribed limit, the driven disc assembly should be Hintly replaced,
in order to avoid scratches on the pressure plate and flywheel surfaces due to slippage of the clutch.
Warning:
Please use a vacuum cleaner but never compressed air to clean the clutch friction plates!
LIFAN AUTO
22-3
Clutch - Clutch
Component diagram (Operated clutch arrangement)
22
1 Hexagon bolt with flange 6 Clutch control oil pipe component Ⅰ
2 Clutch pedal assembly 7 Hexagon bolt with flange
3 Lock pin 8 Clutch control oil pipe component Ⅱ
4 Axle pin 9 Steel belt type elastic hoop
5 Clutch master pump 10 Inlet hose of clutch master cylinder
LIFAN AUTO
22-4
Clutch - Clutch
System description
1. Clutch control schematic diagram
1 Clutch pedal 5 Clutch release fork
2 Clutch master cylinder 6 Pressure plate
3 Clutch hydraulic line 7 Driven disk
4 Clutch release cylinder 8 Flywheel
LIFAN AUTO
22-5
Clutch - Clutch
2. Descriptions of principles
Clutch control can control the engagement and release of clutch through remote hydraulic control method,
to achieve power transmission and cut off between engine and transmission. Detailed processing is shown as
follows:
(a). While releasing: driver steps clutch pedal and by using push rod on pedal and clutch main cylinder, to push
clutch-used special hydraulic oil in existing main cylinder into separation cylinder through pipeline consisting
clutch hard pipe and hose. And then push release bearing shaft move forwards through shift fork. So as to push
the release of clutch pressing disc diaphragm spring, and enlarge the distance between pressing disc and flywheel
and clearance of chamber formed by driven disc and flywheel. Driven disc gradually can't transmit power to
input shaft of transmission due to gradual reduction. Power transmission is cut off.
(b). When engaging: driver slowly release clutch pedal. Release of diaphragm spring of pressing disc refers to gradual
return due to reduction of pressure. Lever effect makes sub-cylinder liquid chamber reduce, while liquid chamber
of main cylinder slowly increase and push clutch pedal gradually rise up. Meanwhile the clearance between
pressing disc and flywheel gradually reduces, so the clearance between driven disc, flywheel and pressing disc
reduces and driven disc gradually can transmit power to input shaft of transmission due to the gradual increase of
friction and power is transmitted.
On-Vehicle check
1. Inspection of clutch 22
(a). When engine is at idle speed, only stepping clutch pedal almost completely can clutch be cut off. Or when
stepping clutch, you feel that it is difficult to gear on or transmission gear produces sharp crash sound. Or vehicle
begins to travel even when clutch pedal isn't released after gear on. All these indicate the incomplete separation
of clutch.
(b). Causes of clutch skidding: clutch pedal has small free stroke and release bearing often presses on diaphragm
spring, and pressing disc is always in semi-release condition; pressing disc spring of clutch is soft or broken.
Screw connecting clutch and flywheel is loose.
(c). If the clutch has any abnormal sound during operation, it is not normal. The causes of fault: release bearing has
serious abrasion, and return spring of bearing is too soft or broken and diaphragm spring bracket has fault, etc.
2. Inspection of clutch pedal

(a). Inspect whether the height of clutch pedal is correct. If not,
adjust it.
Height from pedal to floor: 160±15mm
(b). Press the pedal until you feel a resistance, and check
whether the clutch pedal free travel is correct or not. If not,
adjust it.
Pedal free travel: 10mm
LIFAN AUTO
22-6
Clutch - Troubleshooting
Troubleshooting
these parts.
1. Engine or transmission fixed bracket

Tighten the fixing bolts.
(loose)
2. Clutch driven disc (big swing action) Replace the driven plate.
3. Clutch driven disc (oil stained) Clean the driven plate.

Clutch seizure/judder
4. Clutch driven disc (polish) Replace the driven plate.
5. Clutch driven disc (hardened) Replace the driven plate.
6. Driven disc spring (elasticity is weak or

Replace the driven plate.
spring is broken)
1. Clutch oil pipe (air intake) Exhaust air in clutch system
Clutch pedal soft 2. Rubber cup of master cylinder (damaged) Replace the master cylinder
3. Rubber cup of slave cylinder (damaged) Replace the cup
1. Clutch release bearing (worn, damaged) Replace the release bearing.
2. Clearance between external spline of input

Abnormal clutch noise shaft of transmission and spline groove Replace the driven plate.
inside driven disc (big)

spring is broken)
1. Clutch pedal (free stroke is out of tune) Adjust the free travel.
2. Clutch oil pipe (air intake) Exhaust air in clutch system
3. Rubber cup of master cylinder (damaged) Replace the cup
4. Rubber cup of slave cylinder (damaged) Replace the cup
5. Clutch driven disc (deformed) Replace the driven plate.

Clutch won't be disengaged.
6. Clutch driven disc (big swing action) Replace the driven plate.
7. Clutch driven disc (damaged during friction) Replace the driven plate.
8. Clutch driven disc (stained or burned) Replace the driven plate.
10. Clutch driven disc (lack of lubricating oil

Coat the lubricating oil.
on the spline)
LIFAN AUTO
22-7
Clutch - Troubleshooting
1. Clutch pedal (free stroke is out of tune) Adjust the free travel.
3. Clutch driven disc (polish) Replace the driven plate.

Clutch slipping
spring is broken)
5. Clutch pressing disc (deformed) Replace the clutch pressure plate.
6. Flywheel (deformed) Replace.
22
LIFAN AUTO
22-8
Clutch - Clutch pedal
Clutch pedal
Adjustment
1. Adjust the height of clutch pedal.
(a). Dismantle left lower panel assembly of dashboard (See
Chapter 85 Dashboard and Console - Left Lower Panel
Assembly of Dashboard, Replacement)
(b). Unscrew locknut of check bolt of clutch pedal, and adjust
pedal to proper height through the adjustment of height of
check bolt.
(c). Tighten locknut of check bolt.
2. Adjust free stroke of clutch pedal.

(a). Unscrew locknut of pull rod, and rotate pull rod to adjust
the length of pull rod until free stroke of pedal is in proper
range.
(b). Tighten locknut.
LIFAN AUTO
22-9
Replace
1. Remove brake pedal
(a). Dismantle lower panel of dashboard. (See Chapter 85

Dashboard and Console - Left Lower Panel of Dashboard,
Replacement)
(b). Dismantle return spring of clutch pedal.
(c). Dismantle lock of axis pin of clutch pedal and clutch master
cylinder, and remove axis pin.
22
(d). Dismantle connecting bolt of clutch pedal and bracket, and

remove clutch pedal.
LIFAN AUTO
22-10
2. Install brake pedal
(a). Mount the brake pedal to the pedal bracket; mount the
connecting bolts and nuts and then tighten them.
(b). Mount the clutch pedal and the clutch master pump pin
shaft, and then mount the lock pin of the pin shaft.
(c). Install return spring of clutch pedal.

(d). Adjust height and free stroke of clutch pedal.
(e). Install lower pedal of dashboard. (Chapter 85 Dashboard
- Console - Left Lower Trim Panel of Dashboard,
Replacement)
LIFAN AUTO
22-11
Clutch - Clutch master pump
Clutch master pump

Replace
1. Dismantle air filter with bracket assembly (See Chapter
14 Intake and Exhaust System - Air Filter, Replacement)
2. Drain hydraulic oil in the brake oil can and the clutch
line.
3. Remove the brake master pump and the vacuum booster
assembly (see Chapter 51 Service Brake - Vacuum
Booster, Replacement)
22
4. Dismantle inlet hose of clutch master cylinder and clutch
control oil pipe.
(a). Dismantle inlet hose with elastic snap ring of clutch master
cylinder, and unplug inlet hose of clutch master cylinder.
(b). Dismantle nut of clutch control oil pipe, and disconnect
clutch control oil pipe.
(c). Dismantle left lower panel assembly of dashboard. (See

Chapter 85 Dashboard and Console - Left Lower Panel of
Dashboard, Replacement)
(d). Dismantle lock of axis pin of pull rod of clutch master
cylinder, and unplug axis pin.
(e). Dismantle fixed nuts of clutch master cylinder.
LIFAN AUTO
22-12
(f). Take clutch master cylinder out of engine compartment.
5. Mount the clutch master pump

(a). Mount the clutch master pump onto the chassis mounting
holes from the engine compartment; mount the retaining
nuts from the engine compartment.
(b). Mount the clutch master pump push rod shaft lock pin, and
then mount the pin shaft.
△ Hint:
After installation, adjust pedal height and tree stroke of pedal.
6. Install inlet hose of clutch master cylinder and clutch

control oil pipe.
(a). Mount the clutch master pump inlet oil pipe onto the clutch
master pump and then tighten it by the steel strip elastic
hoop.
(b). Install clutch control oil pipe, and tighten nut of clutch
control oil pipe joint.
LIFAN AUTO
22-13
7. Mount the brake master pump and the vacuum booster
assembly (see Chapter 51 Service Brake - Vacuum
Booster, Replacement)
14 Intake and exhaust system - air filter, replacement)
9. Fill brake fluid, and exhaust air from brake system and
clutch system.
10. Confirm whether clutch function is normal.
22
LIFAN AUTO
22-14
Clutch slave pump

Replace
1. Dismantle of clutch slave cylinder.
(a). Open the engine hood.
(b). Disconnect the clutch slave pump oil pipe.
(c). Remove fixed bolts of clutch slave pump and then take off
the clutch slave pump.
2. Detachment of clutch slave cylinder.

(a). Dismantle dustproof sleeve and pull rod from clutch slave
cylinder.
LIFAN AUTO
22-15
(b). Remove the piston and the springs from the cylinder body.
Attention:
Do not damage internal surface of the cylinder body.
(c). Remove the piston cup.
3. Assembly of clutch slave cylinder.

(a). Install rubber cup onto the piston.
(b). Smear grease on the piston and mount the piston and the
springs onto the cylinder body. 22
Attention:
Do not damage internal surface of the cylinder body.
(c). Install dustproof sleeve and pull rod of clutch slave cylinder.
4. Installation of clutch slave cylinder

(a). Make the clutch slave pump push rod against the clutch fork
and then mount the fixed bolt; fix it on the transmission.
LIFAN AUTO
22-16
(b). Install oil hose of clutch slave cylinder
(c). Exhaust air from clutch slave cylinder.
Exhaust
Attention:
After dismantling clutch pipeline, clutch main cylinder, clutch slave cylinder, hydraulic release bearing or when
clutch pedal is soft, exhaust air from system.
1. When transparent rubber pipe and collecting tank are
connected onto outlet port of clutch slave cylinder, use
wrench to release exhaust bolt of clutch slave cylinder.
△ Hint:
When bleeding, two persons are required to work together - one
sitting in cab and depressing the pedal; and another operating the
exhaust bolt.
2. A driver continuously depresses the clutch pedal 2 or 3
times and then depresses the pedal to the bottom and
holds it; loosen the exhaust bolt and bleed air in the
clutch slave pump and the oil pipe.
3. Tighten the exhaust bolt, and lift up the clutch pedal
4. Repeat operation until the hydraulic oil drained from
system is clean and without air bubbles, and tighten
exhaust bolt.
Attention:
Fill the clutch hydraulic system with more hydraulic oil;
always keep the level height in the oil reservoir.
5. Confirm that the clutch works normally

(a). Start the engine, depress the clutch pedal, and wait about 2s before shifting carefully to the reverse gear. If large
noise is heard in selecting a gear, depress the clutch pedal completely 5 times to bleed the system.
(b). Wait about 30s, and then check the clutch operating conditions. If there is still big noise, repeat exhaust system.
LIFAN AUTO
22-17
Clutch assembly
Check
1. Inspection of clutch pressure plate
(a). Check the diaphragm spring end for wear or height
difference. If there is significant wear or there is a height
difference exceeding the limited value, replace the clutch
pressure plate.
Limit: 0.8mm
(b). Check the clutch pressure plate spring for softness or crack,
if necessary, replace it.
22
(c). Check the pressure plate surface for wear, crack or
discoloration.
(d). Check the pressure plate rivets for looseness. If any, replace
the clutch pressure plate.
(e). Check whether the surface is contaminated with engine oil,
and if any, clean it up.
2. Inspection of driven plate

Attention:
Don’t clean the clutch driven plate with gasoline!
(a). Check the surface for rivet looseness, single-face contacting,
burning resulting in deterioration, attached grease or any. If
you find any one of the above problems, replace the clutch
driven plate.
(b). Measure the depth of rivet embedded in the driven plate.
If such depth exceeds the limited value, replace the clutch
driven plate.
Limit: 1.5mm
(c). Check whether the torsional spring is loose or broken, and if
there is any fault, the clutch driven disc should be replaced.
(d). Check whether the spline in the spline shaft sleeve is worn,
and if worn, replace it.
(e). Fit the clutch driven disc onto the input shaft, and check its
sliding state and whether there is any looseness in the direction
of rotation. If it moves poorly, clean it. And re-install it before
rechecking it. If there is obvious looseness, replace the clutch
driven plate or input shaft, or replace both at the same time.
LIFAN AUTO
22-18
3. Inspection of clutch release bearing
(a). Apply a force in the axial direction and rotate the release
bearing. If necessary, replace the release bearing.
Replace
1. Removal of clutch pressure plate and driven plate
(a). Remove the transmission assembly. (See Chapter 21
Manual Transmission - Transmission Assy., Replacement)
(b). Use paint or needle to make a mark of pressing plate on
flywheel to facilitate assembly.
(c). Dismantle the hold-down bolts between the clutch pressure
plate and the flywheel.
△ Hint:
Install the flywheel stopper to prevent the flywheel from rotating
with the clutch pressure plate when removing the bolts.
(d). Remove the clutch pressure plate and driven plate.
2. Removal of clutch release bearing and yoke

(a). Draw out the clutch release fork from the transmission
outward a little to allow it to disengage the release bearing.
(b). Remove the release bearing from the transmission input
shaft.
(c). Pull out the release fork from the sheath towards the inside
of the housing. Remove the release fork sheath.
LIFAN AUTO
22-19
3. Mount the clutch pressure plate and the driven disc
(a). Align the clutch pressure plate and driven plate to the
flywheel center with the clutch concentric positioning tool.
(b). Install the fixing bolts of the clutch pressure plate by
aligning to the marks which have been made when
removing.
(c). Tighten the pressure plate bolts evenly and tighten the fixing
bolts in a crossover manner.
(d). Remove the clutch concentric positioning tool.
(e). Install the transmission assembly. (See Chapter 21 Manual
Transmission - Transmission Assy., Replacement)
4. Installation of clutch release bearing and yoke

(a). Check the clutch release fork.
△ Hint:
Coat grease onto the contacting faces between the release fork and 22
the release bearing and between the release fork and the push rod,
as well as onto the release fork pivot.
(b). Put clutch release fork into transmission fork, and install
release bearing onto input shaft.
(c). Install the release fork to the retaining groove of the release
bearing and clip the fork circlip to the release fork shore.
(d). Install the release fork sheath.
Attention:
After installation, move the release fork forward and backward
to check whether the release bearing can slide smoothly.
(e). Install the transmission assembly. (See Chapter 21 Manual
Transmission - Transmission Assy., Replacement)
(f). Mount the propeller shaft and the front wheels.
LIFAN AUTO
• Memo •
LIFAN AUTO
Front overhang
Front overhang........................................................... 31-1
Preparation............................................................. 31-1
Precautions............................................................. 31-3
Components diagram (front overhang).................. 31-4
Part diagram (front shock absorber assembly)....... 31-5
Components diagram (steering knuckle)................ 31-6
On-Vehicle check................................................... 31-7
Front shock absorber assembly................................ 31-9
Replace................................................................... 31-9
Steering knuckle....................................................... 31-17
Replace................................................................. 31-17
Transverse arm assembly........................................ 31-25
Replace................................................................. 31-25
Subframe assembly.................................................. 31-27
31
Replace................................................................. 31-27
LIFAN AUTO
31-1
Front Overhang - Front overhang
Front overhang
Preparation
1. Special tool
Compress the shock absorber

1 Spring compressor
spring when removing it
Remove the transverse arm

2 ball joint remover and the steering knuckle
connecting all head
31
3 Wheel bolt remover Remove the wheel bolts
1 Bracket Lift up the front subframe
LIFAN AUTO
31-2
Front wheel toe-in value 2±2mm
Front wheel camber 0° 05′ ±45′
Item N•m
Locknut of front shock absorber 60~80
The shock absorber connects the vehicle body 65~85
Shock absorber and steering knuckle connection 200~220
Transverse stabilizer bar connecting rod ball retaining nut 80~110
Brake clamp assembly fixed bolt 65~68
Transverse arm ball pin assembly fixed bolt 170~190
propeller shaft locking nut 180~240
Fixed bolts of wheel speed sensor wire harness connector 20~25
Connection between transverse arm and subframe 200~220
Fixed bolts of left/ right mounting cover plate of horizontal stabilizer

80~110
rod
Fixed bolts of mounting bracket of the support. 200~220；170~190；80~110
Fixed bolts of connecting rod of overhang 80~110
Fixed bolts of front support beam components 80~110
Steering gear retaining bolt 80~110
Engine rear overhang fixed bolt 80~110
Connection between front sub frame and vehicle body 170~190
Torque of connecting bolts of steering knuckle and front shock

200~220
absorber.
Fixed bolt between the brake line and the wheel speed sensor wire
20~26
harness bracket
Connect ball joint of connecting rod of horizontal stabilizer rod and

80~110
left/Front right horizontal stabilizer rod
LIFAN AUTO
31-3
Precautions
1. Don't remove the knuckle or other non-overhaul parts.

2. Be careful to perform operation on the parts to avoid dirt to the parts and to prevent the entrance of any foreign
object.
3. Clean the dismantled parts (excluding rubber parts) with kerosene and dry them with air or wipe off them with
paper or cloth.
4. Be sure to check the wheel alignment after maintaining the overhang components.
5. The engine oil contamination will shorten the service life of the rubber bush. The spilled engine oil shall be
cleaned up.
6. Don't reuse the non-reusable parts.
7. Check the components thoroughly before repairing or replacing them.
8. After installation, be sure to check the fasteners for their specified torques.
9. When removing the oil pipes, block up the brake pipes with rubber caps to avoid the brake fluid leak.
10. When installing the overhang or rubber bushes, be sure to tighten them finally with the tires on level ground and
under the no-load condition.
System description 31
1. Front overhang is MacPherson independent overhang. It consists of spiral spring, whole type asymmetrical
double-action barrel type hydraulic shock absorber, horizontal stabilizer rod and lower swing arm.
2. Its main axis pinline and center line of piston rod of shock absorber are misaligned, and leaning angle of
main pin is more than that of piston rod of shock absorber. Its features are shown as follows:
(a). To avoid horizontal movement of steering handwheel during deformation of independent overhang, it can reduce
the abrasion of steering handwheel.
(b). When overhang has elastic deformation, although positioning parameter of main pin of wheel has changed,
positioning parameters of steel handwheel have compensation function, so it can improve driving stability of
vehicle.
(c). It has compact structure and its shock absorber, spring and vertical rod are a complete unit with small volume
and occupying space, which facilitates arrangement of front drive of front engine.
(d). During use, front wheel positioning has small change and needn't to adjust leaning angle and rear leaning angle
of main pin.
(e). No-spring load mass is small, which can reduce impact load borne by small overhang and improve traveling
smoothness of vehicle.
LIFAN AUTO
31-4
Components diagram (front overhang)
1 Front horizontal beam components 14 Hexagonal flange bolt and plain washer assemblies.
2 Front left support beam components 15 Hexagon bolt with flange
3 Connecting rod of overhang 16 Mounting plate of front shock absorption, right
4 Front right overhang beam components 17 Subframe assembly
5 Hexagon bolt with flange 18 Left support mounting bracket
6 Hexagon bolt with flange 19 Right support mounting bracket
7 Hexagon bolt with flange 20 Hexagon bolt with flange
Left mounting cover plate of horizontal

8 Left/ right swing arm assembly 21
stabilizer rod
9 Ball joint components 22 Right mounting cover plate of horizontal stabilizer rod
10 Hex flange slotted nut 23 Front stabilizer bar
11 Split pin 24 Left buffer sleeve of horizontal stabilizer rod
12 Hexagon bolt with flange 25 Right buffer sleeve of horizontal stabilizer rod
13 Mounting plate of front shock absorption, left 26 Connecting rod assembly of horizontal stabilizer rod
LIFAN AUTO
31-5
27 Hexagon nut with flange 29 Hexagon nut with flange
28 Hexagon bolt with flange 30 Hexagon nut with flange
Part diagram (front shock absorber assembly)
31
1 Front shock absorber assembly 6 Boot
2 Rubber cushion of spring 7 Upper spring of spring
3 Stopper block 8 Upper support assembly
4 Spiral spring 9 Non-metal hex locknut
5 Upper rubber cushion of spring 10 Boot cover
LIFAN AUTO
31-6
Components diagram (steering knuckle)
1 Front brake disc 6 Hexagon bolt with flange
2 Front wheel hub assembly 7 Front brake caliper assembly
3 Front brake bottom plate assembly 8 External brake friction lining
4 Steering knuckle 9 Internal brake friction lining
5 Hexagon bolt with flange
LIFAN AUTO
31-7
On-Vehicle check
1. Measure vehicle height
Vehicle height (front): as height of a new vehicle
△ Hint:
In the measurement point of the front overhang, measure distance
from the ground to the front lower overhang arm mounting bolt
center.
Attention:
If the vehicle height doesn't meet requirement, it is necessary
to adjust it by pressing downwards or rising up.
2. Check front wheel toe-in value A-B; if toe-in does not

meet standard, check and replace relevant overhang
parts.
Toe-in value: 2±2mm 31
Attention:
Adjust vehicle body height to specified value during inspection.
3. Check front wheel camber (See Chapter 33 Wheels
and Tires - Four-Wheel Alignment, Inspection and
Adjustment)
(a). Mount measurement instrument for camber, kingpin caster
angle and kingpin inclination, and then place the vehicle on
the wheel alignment tester.
(b). Inspect camber angle of front wheel. If the check value doesn't
meet standard, inspect whether overhang parts are damaged
or performance decreases. If necessary, replace them.
Camber angle: 0°05′±45′
4. Check the front overhang coil spring

(a). Check spring for fracture.
(b). Inspect whether upper and lower mounting rubber cushions of spring have abrasion or cracks. If any, replace
them.
5. Check the front shock absorber assembly
(a). Drive the car in rather poor road for 10km and then stop it.
(b). Inspect whether there is oil leakage and use hands to feel front shock absorber housing. If it is not hot enough, it
indicates that there is no resistance inside front shock absorber, so it doesn't work.
LIFAN AUTO
31-8
Front Overhang - Troubleshooting
Troubleshooting
these parts.
1. Tires (worn or improperly inflated) Check wheel tires
2. Wheel alignment (Wrong) Repositioning
3. Steering connector (loose or wear) Tighten or replace it

Runout
4. Wheel hub bearing (wear) Replace wheel hub
5. S t e e r i n g g e a r ( m i s a l i g n e d o r
Replace.
damaged)
6. Overhang parts (wear) Replace worn-out parts
1. Vehicle (overload) Unload
Body sinking 2. Spring (too weak) Replace.
3. Shock absorber (wear) Replace.
Swing/inclination 2. Stabilizer bar (Bent or torn) Replace.
2. Wheel (Wrong alignment) Check wheel balance

Front wheel swing and shock
5. Tie-rod end (wear) Replace.
6. Wheel hub bearing (wear) Replace wheel hub
7. Steering connector (loose or wear) Tighten or replace it
8. Steering gear (misaligned or

Replace.
damaged)

Abnormal tire wear
4. Overhang parts (wear) Replace.
LIFAN AUTO
31-9
Front Overhang - Front shock absorber assembly
Front shock absorber assembly

Replace
1. Lift up the vehicle, and remove front wheels
2. Remove fixed bolts between the brake line and the wheel
speed sensor wire harness bracket
△ Hint:
All needs to do is to remove the brake hose and the wheel speed
sensor wiring harness from the front overhang bracket; do not
disconnect them.
3. Remove the transverse stabilizer bar tie rod assembly.

(a). Dismantle fixed nuts of connecting rod ball joint of 31
horizontal stabilizer rod, and release connecting rod of
horizontal stabilizer rod.
4. Remove the fixed bolt and nut between the shock

absorber and the steering knuckle
(a). Make marks on the front shock absorber.
△ Hint:
Before removal of bolt, make marks; if you conduct installation
according to marks, there is no need to carry out the four-wheel
alignment. If without marks, you must carry out the four-wheel
alignment after installation.
(b). Remove the fixed bolt and nut between the front shock
absorber and the steering knuckle
△ Hint:
While dismantling, use wrench to fix bolts on one end, and use
socket wrench to dismantle nut on the other end. After removing
nuts, it is necessary to rise up brake with steering knuckle assembly
and gradually unplug fixed bolts one by one.
LIFAN AUTO
31-10
5. Remove the front shock absorber assembly
(a). Remove the engine compartment front ventilation cover.
(b). Dismantle fixed nuts of front shock absorber assembly
and vehicle body, and take mounting plate of front shock
absorber.
(c). Remove front shock absorber assembly.
6. Decompose the front shock absorber assembly

(a). Fix front shock absorber assembly onto the table vice.
(b). Install spring compressor, release spring compressor, and
make the compressor claw locates between the top and
bottom of spring.
(c). Compress the coil spring until the spring is detached from
the upper and lower spring seat.
Warning:
• Make sure the compressor is installed properly, and then
begin to compress spiral spring.
• Do not use a pneumatic tool when tightening the spring
compressor bolt.
(d). `Dismantle boot of front shock absorber assembly.
LIFAN AUTO
31-11
(e). Dismantle locknut of front shock absorber.
△ Hint:
Use shock absorber nut to dismantle socket and gradually
dismantle its fixed nuts.
(f). Dismantle upper support assembly.

(g). Remove upper seat of spring, boot and upper rubber sleeve
of spring.
31
(h). Remove spiral spring of front shock absorber.
LIFAN AUTO
31-12
(i). Dismantle stopper block of front shock absorber.
(j). Dismantle lower rubber cushion of spring.
7. Check the front shock absorber assembly

(a). Compress and extend pull rod of shock absorber, inspect
whether there is any abnormal resistance or sound during
operation. If any, replace shock absorber.
(b). Check the shock absorbers for oil leak. If any, replace it.
(c). Inspect whether stopper block is damaged; inspect whether
stopper block of overhang spring has abrasion, crack or
deformation, and replace defect parts.
LIFAN AUTO
31-13
△ Hint:
Scrap treatment of front shock absorber:
• Stretch shock absorber rod as much as possible.
• Drill a hole to drain hydraulic oil from shock absorber
cylinder, and use bit to drill a hole on the cylinder as shown
in figure, and drain the hydraulic oil out.
Warning:
The drained liquid is harmless, but pay attention to the iron
scraps when drilling a hole.
8. Assemble the front shock absorber assembly

(a). Mount the spring lower rubber pad onto the shock absorber.
31
(b). Install stopper block of front shock absorber.
LIFAN AUTO
31-14
(c). Use spring compressor to press spiral spring.
(d). Install spiral spring into shock absorber.
△ Hint:
Install spiral spring onto lower support, to make the spring align
with positioning groove.
(e). Install upper rubber sleeve of spring and boot.

(f). Install upper seat of spring and upper support assembly.
(g). Install locknut of front shock absorber and tighten it.

△ Hint:
Use shock absorber nut to dismantle socket and tighten its fixed
nuts to the specified torque.
LIFAN AUTO
31-15
(h). Remove the spring compressor.
(i). Install boot of front shock absorber assembly.
31
9. Mount the front shock absorber assembly

(a). Install front shock absorber assembly from the bottom of
vehicle body. Before installation, install mounting plate and
fixed bolts and tighten them.
(b). Install front cowl top grille of engine compartment.
LIFAN AUTO
31-16
10. Install fixed bolts and nuts of shock absorber and
steering knuckle.
(a). Align previously made mark, and install fixed bolts and nuts
of front shock absorber and steering knuckle and tighten
them.
11. Mount the transverse stabilizer bar tie rod assembly.

(a). Mount the transverse stabilizer bar connecting rod ball onto
the front shock absorber and tighten the ball joint retaining
nut.
12. Install fixed bolts of brake oil pipe and wheel speed
sensor wire harness bracket, and fix brake oil pipe
and wheel speed sensor wire harness onto the front
overhang.
LIFAN AUTO
31-17
Front Overhang - Steering knuckle
Steering knuckle
Replace
3. Remove the wheel speed sensor

(a). Remove the wheel speed sensor wiring harness fixed bolt. 31
(b). Pull out the wheel speed sensor.
4. Remove the front brake line

(a). Drain brake fluid in the brake system.
(b). Remove the front brake line hollow bolt and take off the
seal ring; and then move away the brake hose.
LIFAN AUTO
31-18
5. Remove the steering knuckle assembly
(a). Remove the slotted thin nut cotter pin of the steering gear
pull rod connecting ball joint.
(b). Remove the slotted thin nut of the steering gear pull rod
connecting ball joint.
(c). Remove the steering gear push rod ball joint by a ball joint
remover.
(d). Remove cotter pin between the front overhang steering

knuckle and the propeller shaft slotted nut.
(e). Dismantle slotted nuts and take out plain washer.
△ Hint:
When removing this slotted nut, you should shift to the reverse
gear and depress the brake pedal for easy removal and in order to
prevent nut and driving shaft from rotating with the wrench.
LIFAN AUTO
31-19
(f). Remove the connecting bolt between the front shock
absorber and the steering knuckle.
(g). Turn the front brake with the steering knuckle assembly to a
proper angle; and then remove the propeller shaft from the
steering knuckle.
(h). Dismantle fixed bolts of lower swing arm ball joint and
knurled bolt and nut of step
(i). Take out the front steering knuckle assembly.
31
6. Remove the lower transverse arm ball pin assembly

(a). Remove the slotted thin nut cotter pin of the lower
transverse arm ball pin assembly.
(b). Remove the slotted thin nut of the lower transverse arm ball
pin assembly.
△ Hint:
During removal, tighten the lower transverse arm ball pin
subassembly and then loosen the lock nut to avoid rotation.
(c). Remove the lower transverse arm ball pin subassembly
using a ball pin remover.
LIFAN AUTO
31-20
7. Remove the brake assembly
(a). Dismantle fixed bolts of brake caliper.
(b). Take out the brake assembly and the brake disc.
8. Remove the front wheel hub assembly

(a). Dismantle fixed bolts of front wheel hub.
(b). Remove front wheel hub assembly and brake bottom plate.
9. Dismantle wheel bolts of front wheel hub.

(a). Press out the wheel bolts by a wheel bolt remover.
LIFAN AUTO
31-21
10. Install wheel bolt.
(a). Mount the wheel bolts into the wheel bolt mounting holes.
(b). Add gaskets with a certain thickness; tighten them by nuts
to tension the wheel bolts completely.
(c). Removes nuts and take off all gaskets.
Attention:
Do not damage splines between the bolts and the hole when
mounting.
11. Mount the front wheel hub assembly

(a). Install front brake bottom plate assembly.
(b). Align bolt hole mounting position to install front wheel hub
assembly. 31
(c). Install fixed bolts and tighten them.
12. Install lower swing arm ball joint components.

(a). Mount the lower transverse arm ball pin subassembly to the
steering knuckle.
(b). Mount the slotted thin nut of the lower transverse arm ball
pin assembly.
(c). Cotter pin of slotted thin nut of swing arm ball joint
components.
LIFAN AUTO
31-22
13. Install brake assembly.
(a). Mount the brake disc onto the steering knuckle.
(b). Install brake caliper assembly and fixed bolts, and tighten
them.
14. Mount the steering knuckle assembly

(a). Mount the steering knuckle assembly and the lower
transverse arm ball joint onto the lower transverse arm;
mount the fixed bolt and the stepped knurl bolt and nuts and
then tighten them.
(b). Turn the front steering knuckle and then mount the propeller
shaft steering knuckle laterally onto the steering knuckle
wheel hub.
(c). Rise up front steering knuckle, and install connecting bolts
of steering knuckle and front shock absorber assembly, and
bolts and nuts and tighten them.
LIFAN AUTO
31-23
(d). Install plain washer and slotted nuts of drive shaft and
tighten them, and make it expose mounting hole of cotter
pin.
△ Hint:
When tightening this slotted nut, you should shift to the 1st-gear
and depress the brake pedal for easy tightening and in order to
prevent nut and driving shaft from rotating with the wrench.
Attention:
If pin holes are misaligned, further tighten slotted nuts to align
it with the shaft lock pin hole.
(e). Mount cotter pin of slotted nut.
(f). Mount the steering gear pull rod connecting ball joint onto
the steering knuckle.
(g). Mount the slotted thin nut of the steering gear pull rod
connecting ball joint.
(h). Mount the slotted thin nut cotter pin of the steering gear
pull rod connecting ball joint.
31
15. Mount the front brake line.

(a). Mount the front brake line hollow bolts and the seal ring,
and fasten the brake hoses on the brake.
LIFAN AUTO
31-24
16. Mount the wheel speed sensor
(a). Mount the wheel speed sensor wiring harness connector,
and then mount and tighten the fixed bolt.
17. Install fixed bolts of brake oil pipe and wheel speed
sensor wire harness bracket.
18. Mount front wheels and conduct four-wheel alignment
(See Chapter 33 Wheels and Tires - Four-Wheel
Alignment, Inspection and Adjustment)
LIFAN AUTO
31-25
Front Overhang - Transverse arm assembly
Transverse arm assembly

Replace
1. Remove the transverse arm assembly
(a). Remove the slotted thin nut cotter pin of the transverse arm
ball pin assembly.
(b). Remove the slotted thin nut of the lower transverse arm ball
pin assembly.
△ Hint:
During removal, tighten the lower transverse arm ball pin
subassembly and then loosen the lock nut to avoid rotation.
(c). Remove the lower transverse arm ball joint subassembly

using a ball pin remover.
31
(d). Dismantle connecting bolts of swing arm assembly on sub

frame, and remove swing arm assembly.
LIFAN AUTO
31-26
Front Overhang - Transverse arm assembly
(e). Remove the transverse arm ball pin subassembly fixed bolt
and the stepped knurl bolt and nuts; take off the bolts and
the transverse arm ball pin subassembly.
2. Mount the transverse arm assembly
(a). Install fixed bolts of swing arm ball joint components and
swing arm ball joint component and knurled bolt and nut of
step, and tighten fixed bolts and nuts.
(b). Mount the transverse arm assembly to the sub-frame

assembly, mount and tighten connecting bolts.
(c). Install swing arm assembly ball joint components onto

steering knuckle.
(d). Mount the slotted thin nut of the lower transverse arm ball
pin assembly.
(e). Mount the slotted thin nut cotter pin of the lower transverse
arm ball pin assembly.
LIFAN AUTO
31-27
Front Overhang - Subframe assembly
Subframe assembly
Replace
1. Remove the front subframe assembly

(a). Dismantle fixed bolts of rear overhang on front sub frame.
(b). Dismantle fixed bolts of steering gear on front sub frame.
31
(c). Dismantle fixed bolts of left/ Front right support beam

components on front sub frame, and disconnect connection
with sub frame.
LIFAN AUTO
31-28
(d). Dismantle fixed bolts of connecting rod of overhang on
front sub frame, and disconnect connection with sub frame.
(e). Dismantle locknut of connecting ball joints of front

horizontal stabilizer rod and connecting rod of left/ Front
right horizontal stabilizer rod.
(f). Dismantle left/ right swing arm assembly.

(g). Dismantle fixed bolts of mounting bracket of front sub
frame, and remove mounting bracket of left/ right support.
LIFAN AUTO
31-29
(h). Lay a support under front sub frame, and dismantle fixed
bolts of front sub frame assembly on vehicle body.
(i). Lower support, and remove sub frame assembly.
Warning:
Two or more persons are required to remove it in order to
avoid falling of the front subframe.
(j). Dismantle fixed bolts of left/ right mounting cover plate of

horizontal stabilizer rod, and remove left/ right mounting
cover plate of horizontal stabilizer rod.
(k). Remove horizontal stabilizer rod of front sub frame.
(i). Dismantle left/ right buffer sleeve of horizontal stabilizer
rod.
31
2. Mount the front subframe assembly

(a). Install left/ right buffer sleeve of horizontal stabilizer rod.
(b). Install horizontal stabilizer rod onto front sub frame.
(c). Install left/ right mounting cover plate and fixed bolts of
horizontal stabilizer rod, and tighten fixed bolts.
LIFAN AUTO
31-30
(d). Use a support to rise up front sub frame, install front sub
frame assembly onto vehicle body, and install left/ right
Warning:
While installing, it requires 2 or more persons to co-work, to
avoid front sub frame from falling off.
(e). Install left/ right swing arm assembly.

(f). Install left/ right support mounting bracket under the
support of from sub frame, and install fixed bolts of bracket
and tighten them.
Tightening torque: No. ① Bolt 200 ~ 220 N•m
No. ② bolt 170 ~ 190 N•m
No. ③ bolt 80 ~ 110 N•m
(g). Install connecting ball joint of connecting rod of front

horizontal stabilizer rod and left/ Front right horizontal
stabilizer rod, and install locknut and tighten it.
LIFAN AUTO
31-31
(h). Install connecting rod of overhang and fixed bolts onto front
sub frame, and tighten fixed bolts.
(i). Install left/ Front right support beam components and fixed
nuts onto front sub frame, and tighten fixed bolts.
31
(j). Install fixed bolts of steering gear on front sub frame, and
tighten them.
LIFAN AUTO
31-32
(k). Install fixed bolts of rear overhang of engine on front
auxiliary frame, and tighten them.
LIFAN AUTO
Rear overhang
Rear overhang............................................................ 32-1
Preparation............................................................. 32-1
Precautions............................................................. 32-2
Components diagram (rear overhang).................... 32-3
Components diagram (rear shock absorber assembly)
. .............................................................................. 32-4
On-Vehicle check................................................... 32-5
Rear axle assembly..................................................... 32-7
Replace................................................................... 32-7
Rear shock absorber assembly................................ 32-11
Replace................................................................. 32-11
Rear wheel hub......................................................... 32-13
Check.................................................................... 32-13
Replace................................................................. 32-13
32
LIFAN AUTO
32-1
Rear Overhang - Rear overhang
Rear overhang
Preparation
1. Special tool
For removing the nuts of

1 Pipe wrench
pipe joints
2 Wheel bolt remover Remove the wheel bolts
32
Prop up the rear axle

1 Bracket
assembly
Support up the vehicle body

2 Jack
after removing the wheels
LIFAN AUTO
32-2
Rear Ovehang - Rear overhang
Rear wheel toe-in value 1±3mm
Rear wheel camber － 1° 20′ ±30′
Item N•m
Connecting bolt between rear axle and vehicle body chassis 170~190
Connecting bolt between rear axle assembly and rear shock absorber 80~110
Rear wheel hub fixed bolt 80~110
Oil pipe bracket fixed bolt 20~26
Fixed bolts of ABS bracket 20~26
Precautions
1. Final tightening should be conducted with the tires on ground and without load when mounting the overhang.
2. Conduct necessary alignment inspection after installation of system.
4. Check the components thoroughly before repairing or replacing them.
5. After installation, be sure to check the fasteners for their specified torques.
6. When removing the oil pipes, block up the brake pipes with rubber caps to avoid the brake fluid leak.
LIFAN AUTO
32-3
Components diagram (rear overhang)
32
1 Hexagon bolt with flange 6 Spring
2 Hexagon bolt with flange 7 Rear axle assembly
3 Hexagon bolt with flange 8 Upper mounting rubber cushion of spring
4 Square nut 9 Rear shock absorber assembly
5 Lower mounting rubber cushion of spring
LIFAN AUTO
32-4
Rear Ovehang - Rear overhang
Components diagram (rear shock absorber assembly)
1 2-type hex nut 4 Centering washer
2 Stopper seat 5 Damper
3 Upper damper 6 Rear shock absorber assembly
LIFAN AUTO
32-5
On-Vehicle check
1. Measure vehicle height
△ Hint:
In the measurement point of the rear overhang, measure distance
from the ground to the rear overhang mounting bolt center.
2. Check rear wheel toe-in A-B; if toe-in does not meet the
standard, check and replace relevant overhang parts
Toe-in value: 1±3mm
Attention:
Adjust vehicle body height to specified value during inspection. 32
3. Inspect camber angle of rear wheel.
(a). Install measuring instrument of camber angle of rear wheel,
caster angle and leaning angle, and put the vehicle on wheel
locater.
(b). Inspect whether the check value of camber angle of rear
wheel meets standard, and inspect whether overhang part
has damaged or performance reduction. If necessary, replace
it.
Camber angle: -1°20′±30′
4. Check the rear overhang damping spring

(a). Check spring for fracture.
(b). Inspect whether upper and lower mounting rubber cushions of spring have abrasion or cracks. If any, replace
them.
5. Check the rear shock absorber assembly
(a). Drive the car in rather poor road for 10km and then stop it.
(b). Inspect whether there is oil leakage and use hands to feel rear shock absorber housing. If it is not hot enough, it
indicates that there is no resistance inside rear shock absorber and doesn't work, it is necessary to replace it.
LIFAN AUTO
32-6
Rear Ovehang - Troubleshooting
Troubleshooting
Use the table below to help you find the cause of the problem. Check each part in order. If ecessary, repair or replace
these parts.
1. Rear hub bearing (worn) Replace rear wheel hub

Runout
2. Rear overhang part (worn) Replace the bearing and wear parts
1. Vehicle (overload) Check after releasing load
Body sinking 2. Spring (over soft) Replace the spring
3. Rear strut assy.(invalid) Replace the rear shock absorber assembly
1. Tire (worn or abnormal air inflation) Check wheel tires

Swing/inclination
2. Wheel (imbalance) Check wheel tires

Rear wheel swing and shock
4. Wheel (not correctly positioned) Wheel Alignment
2. Wheel (not correctly positioned) Wheel Alignment

Abnormal tire wear
4. Rear overhang part (worn) Replace worn-out parts
LIFAN AUTO
32-7
Rear Overhang - Rear axle assembly
Rear axle assembly

Replace
1. Rise vehicle and dismantle rear wheel assy.
2. Dismantle parking brake cable and parking brake
return spring (See Chapter 52 Parking Brake - Parking
Brake Control Device, Replacement)
3. Dismantle wheel speed sensor wire harness and brake oil
pipe on rear axle.
(a). Disconnect wheel speed sensor wire harness connector.
(b). Remove E-clamp of rear brake pipe, disconnect rear brake

oil pipe, and use rubber cap to plug rear brake oil pipe.
Attention:
32
Use the plastic cap to block the brake line to avoid leakage.
(c). Remove bolts of mounting bracket between the rear axle

brake line and the wheel speed sensor wiring harness; move
away the brake line and the wheel speed sensor wiring
harness.
LIFAN AUTO
32-8
Rear Ovehang - Rear axle assembly
4. Remove the rear overhang spring
(a). Use a bracket to prop up the intermediate position of the
rear axle assembly and prop up the rear axle assembly.
(b). Remove connecting bolts between the rear axle assembly
and rear left shock absorber assembly
(c). Lower the bracket slowly and remove the lower spring from
the rear axle assembly and the spring upper/lower rubber
pads.
5. Remove the rear axle assembly

(a). Remove connecting bolts between the rear axle assembly
and the chassis vehicle body.
(b). Move the rear axle assembly backward and take off it from
the bracket.
△ Hint:
Prop up the assembly a little by the bracket when removing so that
the rear axle assembly can be removed.
Warning:
Two or more persons are required to remove it in order to
avoid falling of the rear axle.
(c). Lower the bracket slowly and lift the rear axle assembly
away.
LIFAN AUTO
32-9
Rear Overhang - Rear axle assembly
6. Mount the rear axle assembly
(a). Prop up the rear axle assembly by a bracket.
(b). Mount the rear axle assembly onto the chassis vehicle body
and insert the left and right connecting bolts from outside
and then tighten them.
(c). Install upper and lower mounting rubber pad on 2 sides of

spring.
(d). Mount the springs onto the rear axle assembly.
Attention:
Pay attention to correct alignment between the coil spring
opening and the mounting position.
(e). Prop up the rear axle assembly and mount and tighten the 32
connecting bolt between the rear axle assembly and the rear
shock absorber.
7. Connect the brake lines and the wheel speed sensor

wiring harness connectors.
(a). Mount the E-type clip of the rear brake line and fix the
brake hose onto the bracket.
(b). Connect the brake line and tighten the oil pipe connector
nuts by an oil pipe wrench.
LIFAN AUTO
32-10
Rear Ovehang - Rear axle assembly
(c). Mount and tighten bolts of mounting bracket between the
rear brake line and the wheel speed sensor wiring harness.
Attention:
After brake pipeline is dismantled and installed, exhaust air
from brake system.
(d). Install wheel speed sensor wire harness connector.

8. Install parking brake cable and parking brake return
spring (See Chapter 52Parking Brake - Parking Brake
Control Device, Replacement)
9. Mount the wheel assembly
LIFAN AUTO
32-11
Rear Overhang - Rear shock absorber assembly
Rear shock absorber assembly

Replace
1. Open the rear truck lid
2. Dismantle rear trunk trimming plate and plastic snap-
fits and floor carpet.
3. Remove the rear wheel assembly
4. Removal of rear shock-absorber assembly
(a). Prop up the rear axle assembly by a jack.
(b). Dismantle 2-type hex nuts of rear strut assy.
(c). Take out the shock absorber upper buffer pad and the
cushioning pad.
32
(d). Use jack to support rear axle, and dismantle connecting

bolts of rear axle assembly and column assembly.
(e). Take out the rear shock absorber assembly.
△ Hint:
Remove the rear shock absorber assembly in another side in the
same method.
LIFAN AUTO
32-12
Rear Ovehang - Rear shock absorber assembly
5. Inspect column assembly.
(a). Compress and elongate the shock absorber push rod; at the
same time Check if resistance or abnormal sound is found
during operation; if any abnormality is found, replace the
shock absorber.
6. Installation of rear shock-absorber assembly
(a). Mount the shock absorber assembly below the vehicle body.
(b). Prop up the rear axle assembly by a jack and mount and
tighten the connecting bolts.
(c). Mount the shock absorber upper buffer pad and the
cushioning pad.
(d). Install 2-type hex nut of rear shock absorber and tighten it.
7. Mount the rear wheel assembly
8. Install rear trunk trimming plate and plastic snap-fits
and floor carpet.
LIFAN AUTO
32-13
Rear Overhang - Rear wheel hub
Rear wheel hub

Check
1. Confirm whether tightening condition (clearance) of each part and wear degree is normal or not
(a). Push the wheel hub and the bearing assembly along the axis to Check if the wheel bearing is loose. If it is loose,
it is recommended to change into bearing or re-install it.
(b). Rotate the wheel hub to confirm whether abnormal sound exists or other abnormalities occur. If any abnormality
is found, it is recommended to replace bearing.
2. Inspect whether wheel bolt thread of rear wheel hub has abrasion or damage. If any, replace it.
Replace
1. Remove the wheel assembly
2. Dismantle wheel speed sensor wire harness connector.
3. Remove the rear brake assembly (see Chapter 51 Service
Brake - Rear Brake, Replacement)
4. Take out the rear brake disc.
△ Hint:
If brake disc and wheel hub have a tight contact, while dismantling,
install a proper bolt into bolt hole of brake disc to push it out.
32
5. Remove the rear wheel hub assembly

(a). Remove the rear wheel hub assembly fixed bolt.
△ Hint:
When removing the rear wheel hub assembly set bots, you may use
the socket to remove the wheel hub flange disc.
LIFAN AUTO
32-14
Rear Ovehang - Rear wheel hub
(b). Remove rear wheel hub assembly and mudguard of rear
brake.
(b). Dismantle ABS probe.

(a). Pry ABS probe of rear wheel hub.
△ Hint:
While dismantling, make a position mark to facilitate installation.
7. Dismantle wheel bolt of rear wheel hub.

(a). Press out the wheel bolts by a wheel bolt remover.
LIFAN AUTO
32-15
Rear Overhang - Rear wheel hub
8. Install wheel bolt.
(a). Mount the wheel bolts into the wheel bolt mounting holes.
(b). Add gaskets with a certain thickness; tighten them by nuts
to tension the wheel bolts completely.
(c). Removes nuts and take off all gaskets.
Attention:
Do not damage splines between the bolts and the hole when
mounting.
9. Install ABS probe of rear wheel hub.

Attention:
While installing, align with mounting position of ABS probe.
32
10. Install rear wheel hub assembly.

(a). Install mudguard of rear brake.
(b). Install rear wheel hub assembly and fixed bolts.
LIFAN AUTO
32-16
Rear Ovehang - Rear wheel hub
(c). Mount the rear wheel hub assembly fixed bolt, and tighten
bolts from the rear wheel hub flange hole.
11. Install brake disc.

12. Install rear brake assembly (See Chapter 51 Service
Brake - Rear Brake, Replacement)
13. Install wheel speed sensor wire harness connector.
14. Mount the wheel assembly
LIFAN AUTO
Tires and wheels
Tires and wheels......................................................... 33-1
Preparation............................................................. 33-1
Precautions............................................................. 33-3
On-Vehicle check................................................... 33-5
Wheel assembly.......................................................... 33-9
Tire rotation............................................................ 33-9
Replace................................................................... 33-9
Spare wheel............................................................... 33-11
Use........................................................................ 33-11
Wheel balance........................................................... 33-12
Inspection and adjustment.................................... 33-12
Four-wheel alignment.............................................. 33-15
Inspection and adjustment.................................... 33-15
33
LIFAN AUTO
33-1
Tires and Wheels - Tires and wheels
Tires and wheels

Preparation
Check wheel axial and

1 Dial gauge
radial runouts.
Check the tire

2 Tire pressure gauge
pressure.
33
3 Wheel wrench Remove the wheel nuts
Lift and Jack up the

4 Jack
Vehicle.
Wheel balancing Test and adjust wheel

5
machine balance.
LIFAN AUTO
33-2
Four-wheel position
6 Inspect wheel alignment.
indicator
1. Technical Specifications
Axial circular run-

0~0.07mm
out value
Axial
Minimum value 2mm
Wheel runout.
Radial circular
0~0.07mm
run-out value
Radial
Minimum value 1.5mm
Tire pressure (no-load) 220kPa
Tire specification 205/55 R16 (standard configuration)
Tire type Radial tire
Front wheel camber value 0° 05′ ±45′
Front wheel toe-in value 2±2mm
Toe-in of kingpin value 11° 45′ ±30′

Wheel alignment
Kingpin inclination value 5° 30′ ±30′
Rear wheel camber － 1° 20′ ±30′
Rear wheel toe-in value 1±3mm
Maximum angle of front wheel Internal wheel: 38° 50' External wheel: 31° 40'
Item N•m
Wheel nut 120
LIFAN AUTO
33-3
Precautions
1. All wheels must have the consistent type, without mixed use of radial tire, bias tire or diagonal-ply tire.
Otherwise typical operation risk may occur to cause the car to lose control.
2. Attention should be paid to regularly rearrange the tires to reduce the camber wear of tire and ensure the driving
performance of the vehicle and span the service life of the tire.
3. Lifan special tires should be used. Tires with different specifications and patterns should be used in the same car.
4. The mud and sand stone on the tires shall be timely flushed away to avoid vehicle vibration and tire damages
during high-speed running.
5. Don't apply oil or lubricating oil to the bolts or nuts.
6. Follow the instructions for jacking up.
7. Do not put any of your body under vehicle section which is supported by lifting jack, because this will cause
personal injury.
8. When the vehicle is jacked up, never start to move or start the engine.
9. Park your vehicle on a flat and solid ground, pull up the parking brake tightly and set the transmission at its
neutral position. If necessary, place a stopper under the tire in the diagonal direction of the replaced tire.To block
the wheel, put the stopper in front of the front wheel or behind the rear wheel.
11. You should confirm that the jack is placed on a flat and solid ground and that it is set at the correct jack-up point.
If the jack is placed in wrong position to prop up the car, the car might be damaged or falling of the car from the
jack might cause personal injury.
12. It is forbidden to jack up the vehicle if someone is in the vehicle.
33
LIFAN AUTO
33-4
Components diagram
1 Spare tire fixture rod 5 Tire valve assembly
2 Tire assembly 6 Wheel nut
3 Wheel rim 7 Center nameplate
4 Counterbalance weight
System description
Tires are the final executors of the most control commands of the vehicle. The tires not only bear the body weight,
transfer the vehicle driving force and braking force to ground and maintain the direction of the vehicle driving, but also
absorb ground vibration and improve riding comfort. High-quality tires can also reduce the rolling resistance so as to
improve fuel economy. Spare tire is an emergent tire used when wheel has a fault. After the fault is eliminated, it is
necessary to replace it with normal tire.
LIFAN AUTO
33-5
On-Vehicle check
1. Inspection of air pressure
(a). Check tire inflation pressure by a pressure gauge. If not in
the standard value, please adjust it.
Standard value: 220kPa
Attention:
• Use a good tire pressure gauge to check tire pressure.
• Ensure that wheels are worn, improperly inflated,
cracked or have other damages.
• When ambient temperature changes abruptly, you
should frequently check tire pressure.
(b). Insufficient air pressure may cause rapid wear of tire

shoulder, tire flexing and increase of rolling resistance.
33
(c). Too much pressure may cause rapid wear of tire tread center
and reduce buffering capacity of the tire.
LIFAN AUTO
33-6
2. Inspection of alignment
(a). Tire has feather type abrasion and front wheel toe-in and
rear wheel toe-in are too big (or small).
△ Hint:
Adjust front wheel toe-in and rear wheel toe-in, or replace or pairly
change tire according to abrasion condition.
(b). Single side abrasion (camber angle problem)

△ Hint:
Adjust camber angle; replace or exchange tires according to wear
condition.
3. Inspection of tire surface

(a). Inspect the depth of tire wheel tread and indication mark to
check when it is necessary to replace tire.
Tire specification: 205/55 R16 (standard configuration)
Attention:
When thread wear is almost the same as tread wear indication
mark, replace the tire. The thinner the tread is, The greater
risk of slipping or tire burst is.
(b). Check if any foreign matter exists in the tire tread. Clean it
when any exists.
LIFAN AUTO
33-7
4. Check radial and horizontal circular run-out of wheels
(a). Lift up the vehicle and make the wheels off from the
ground.
(b). Check tires for obvious deformation.
(c). Install a dial indicator and slowly rotate wheel, and check
axial runout of rear wheel. If the check value exceeds limit
value, please replace wheel.
Axial runout: 0~0.07mm
Limit: 2mm
(d). Measure radial circular run-out of front and rear wheels; if

beyond limit value, replace the wheel .
Radial runout: 0~0.07mm
Limit: 1. 5mm
Attention:
Clean wheels when checking them.
33
LIFAN AUTO
33-8
Tires and Wheels - Troubleshooting
Troubleshooting
these parts.
1. Vehicle (travels fast under bad road condition) —
2. Vehicle (too excessive acceleration or braking) —

Too rapid wear of tire
3. Vehicle (travels fast when tire air pressure is
—
insufficient)
4. Vehicle (excessive tire pressure) —
1. Vehicle (travels fast under turning condition) —
2. Suspension (vehicle slides to one side when turning

Check and replace the suspension
at defect condition.
3. Wheel (imbalance: brake is nonuniform) Check and adjust it

Uneven tire wear
4. Wheel hub bearing (bearing clearance is too big) Replace wheel hub
5. Front wheel (positioning parameter is incorrect) Wheel alignment
6. Wheel rim (deformation makes wheel unbalanced) Replace.
1. Front wheel (imbalance) Check and adjust it
2. Front wheel tire (different air pressure on left and

Vehicle yaw Check if air pressure is consistent
right sides)
3. One of tires has serious abrasion. At the same time replace tires on both sides
LIFAN AUTO
33-9
Tires and Wheels - Wheel assembly
Wheel assembly
Tire rotation
1. Tire rotation
△ Hint:
To help increase tire life and distribute wear more evenly, you
should have the tires rotated every 10000km. However, the most
appropriate interval for tire rotation depends on the driver's usual
driving behaviors and conditions of road surfaces.
Replace
△ Hint:
• If there is any damage, such as distortion, crack or serious corrosion, to the wheel, be sure to replace the wheel.
• Not replacing the damaged wheels can cause the tires to break away the wheels or cause loss of control of the
vehicle.
1. Dismantling of wheel
(a). Park the car stably in the level ground; pull up the parking
brake lever and place delta woods against the wheels which
will not be removed.
△ Hint: 33
• Lay a stopper block under the wheel in diagonal
direction of wheel to be placed.
• If necessary, put the wheel blocks before the front
wheels or after the rear wheels.
(b). Loosen wheel nuts by a wrench.

△ Hint:
Before rising up vehicle, unscrew wheel nuts. Rotate the wheel
counterclockwise to unscrew the wheel nuts. To get maximum
tightening torque, put the wrench on nut and lay the wrench handle
on right side. Hold the wrench handle end socket and pull it up.
Attention:
Do not have the wrench slip away from the nuts. Never remove
but half unscrew the nut.
LIFAN AUTO
33-10
Tires and Wheels - Wheel assembly
(c). Prop up the car using a jack to a proper height for
installation of tires.
Attention:
• Place the jack under the correct jacking point of the car.
• Ensure that the jack is placed on the flat and solid
ground.
(d). Remove all wheel nuts in diagonal sequence and then take
off the wheel.
2. Installation of wheel
(a). Install wheel onto wheel hub and wheel nuts and tighten
them as much as possible.
△ Hint:
Push the wheel backward to see if it is possible to screw it more
tightly.
Attention:
Before mounting a wheel, Use a wire brush to clear all
corrosive materials on the mounting surface. In time of wheel
mounting, if the mounting surfaces cannot contact well, it will
have the wheel nuts loose and even cause the wheel fall off
during driving.
(b). Lower the vehicle completely, and install wheel nuts

according to diagonal sequence.
Torque: 120N•m
Attention:
• Never apply engine oil or grease around the bolts or
nuts, or the bolts will be damaged due to excessive
tightening of the nuts.
• Use only tire nut wrench to operate the nuts; do not use
other tools or leverage tools except for hands. Confirm
the wrench is tightly engaged around the nut.
Warning:
• While lowering the vehicle, confirm that all staff have
left to avoid injuries.
LIFAN AUTO
33-11
Tires and Wheels - Spare wheel
Spare wheel
Use
Warning:
Spare tire just can be used for a short time without high-speed driving (maximum speed should not exceed
90km/h; driving range should be within 50 km). Please go to service station authorized by LIFAN to replace it;
otherwise, it may cause serious injury or even death.
1. Open the truck lid, and move away the trim panel.
2. Remove the spare tire fixture rod
3. Take out the spare tire from the truck lid
4. Replace deflating tire or tire requiring a repair with
spare tire
Attention:
Do not continue using of the deflating tire for driving. Do not
use inflated tire to run the vehicle for even a short distance.
Otherwise the tire will be damaged so that it is unable to be
repaired well.
33
LIFAN AUTO
33-12
Tires and Wheels - Wheel balance
Wheel balance
Inspection and adjustment
△ Hint:
Tire imbalance of vehicle can cause vibration during high speed rotation of wheel, especially front wheel vibration
which can cause front wheel swing and affect safety and smoothness during vehicle traveling; meanwhile, it will
increase abrasion of tires. Inspection of dynamic balance of tire and adjustment are very important.
1. Clean and check wheels.

(a). Clean the inspected wheels and remove dirts and gravel.
Warning:
If impurities in the tire tread are not removed, they may fly
out under action of centrifugal force, easily leading to personal
injury.
Attention:
Check if tire tread and sidewall are defective. These defects
might impact balance of wheels.
(b). Remove the old balance weights.
(c). Inflate the tires to specified air pressure value.
LIFAN AUTO
33-13
2. Check the wheel balance by a balancing machine.
(a). Mount the wheel correctly on the balancing machine.
△ Hint:
Mount it by a lifter or under cooperation of two persons.
(b). Fix the tires and enter three parameters - wheel rim width,
diameter and distance of wheel rim edge from the balancing
machine.
(c). Lower protective cover, start balancing machine, and begin
to check.
33
(d). Stop rotating tires, and then release the protective cover;
rotate the tires and read unbalance amount by the display
screen in the left or right side; confirm the unbalance
position and then increase corresponding balance blocks.
LIFAN AUTO
33-14
3. Add balance weights.
(a). According to imbalance amount displayed in the balancing
machine, add corresponding balance weight on the
imbalance position.
Attention:
Before installation of balance weight, clean the mating surface
of wheels.
(b). When mounting balance weights onto the wheels, align the
balance weight center with position (or angle) specified by
the wheel balancing machine.
(c). If balance weight calculates exceeds 50g, mount 2 balance
weights on the one straight line.
Attention:
• Balance weight can not be reused; always use new one in
each time of replacement.
• Do not mount more than 3 balance weights.
• Always use original balance weight.
• Do not place one balance weight onto another one.
(d). Start again the wheel balancing machine to confirm that
remaining imbalance value is 5g or less; if remaining
imbalance value in one side is above 5g, repeat installation
steps of balancing machine.
LIFAN AUTO
33-15
Tires and Wheels - Four-wheel alignment
Four-wheel alignment
Inspection and adjustment
△ Hint:
The misalignment of the four-wheel alignment can cause deviation of direction, incorrect steering wheel return, tire
partial wear or zigzag wear and other undesirable phenomena.
1. Preparation before inspection

(a). Make sure that the size and pressure of tires comply with
the specifications of the factory.
(b). The deformation of the wheel rim should be within the
specified range(see the descriptions below).
(c). The ball pins of the suspension system should not be
loosened.
△ Hint:
You can grasp the wheel with your hand to move it move up and
down, left and right to check its swing.
(d). Make sure that the braking performance is good.
2. Field requirements
(a). Make sure that the ground surface of the inspection field is
level as much as possible.
33
(b). Put the two steering angle testers into the reserved pits with
the same thickness as that of the angle tester, respectively.
△ Hint:
If there is no reserved hole, after the two front wheels are placed
on a torque angle indicator, the two rear wheels should be padded
with a flat board of the same thickness as the indicator.
3. Proper placement of vehicle

(a). Lifting the vehicle, place the two front wheels on the angle
tester and make the extension line of the center line of the
kingpin is basically through the center of the steering angle
center.
(b). Turn the steering wheel, make the vehicle be in a straight
line status.
LIFAN AUTO
33-16
4. Installation of instrument
5. Inspection of sequence
(a). The four wheel alignment test and adjustment shall follow
the order below: wheel camber, caster, toe-in and front
wheel maximum steering angle.
△ Hint:
If it is necessary to adjust any one parameter of the four-wheel
alignment, be sure to perform a comprehensive adjustment in
accordance with the above sequences.
6. Check and measure front wheel camber.

(a). Turn the steering wheel to make it stay roughly level in both
direction (left and right).
(b). Read out front wheel camber in the instrument display.
Camber angle of front wheel α:0°05′±45′
△ Hint:
If the measured value does not meet the requirement, it needs to be
adjusted.
LIFAN AUTO
33-17
7. Check and measure kingpin caster angle
(a). Apply wheel brake force.
△ Hint:
In order to prevent rotation of steering wheel from leading to
front wheels rolling, you should keep wheels in braking status in
checking and measuring kingpin caster angle.
(b). Turn the steering wheel; after that, the instrument screen
may display the test report.
Caster angle β:5°30′±30′
△ Hint:
If the measured value does not meet the requirement, it needs to be
adjusted.
8. Adjustment of front wheel camber and kingpin caster

angle
(a). Unscrew fixed bolts of front steering knuckle and front
column.
(b). Adjust front steering knuckle position to adjust camber
angle of front wheel and caster angle to correct values.
(c). Tighten fixed bolts.
33
9. Check and measure front wheel toe-in

(a). Make the vehicle on direct traveling line position.
(b). Measure front wheel toe-in by an instrument.
Toe-in of front wheel: 2±2mm
△ Hint:
Check toe-in; if toe-in does not meet the technical requirement,
adjust it.
LIFAN AUTO
33-18
10. Adjustment of front wheel toe-in
(a). Unscrew the locknut of the steering tie-rod.
(b). Turn the steering tie-rod until you see the readings of the
instrument are correct.
△ Hint:
Adjust the other wheel reversely at the same time with the same
extent to achieve the correct toe-in value.
(c). After the completion of adjustment, tighten the locknut of

the steering tie-rod.
△ Hint:
Be sure to hold the steering tie-rod when tightening its locknut.
LIFAN AUTO
33-19
11. Inspection of maximum front wheel steering angle
(a). Maintain the vehicle placement state when inspecting the
front wheel alignment.
(b). Depress the brake pedal to make the wheel be in the braking
status.
(c). Turn the steering wheel left and right to the extreme
positions. Measure the maximum steering angle of the both
front wheels.
Maximum steering angle δ:38°50' (internal wheel)
31°40' (external wheel)
△ Hint:
If the maximum steering angle is inconsistent with the requirements,
be sure to check the various components of the suspension system
for bending or damage.
33
LIFAN AUTO
• Memo •
LIFAN AUTO
Drive shaft
Drive shaft................................................................... 41-1
Preparation............................................................. 41-1
Repair Specifications.............................................. 41-2
Precautions............................................................. 41-2
System Description................................................ 41-4
On-Vehicle Check.................................................. 41-4
Problem Symptoms Table...................................... 41-5
Drive shaft assembly.................................................. 41-6
Replace................................................................... 41-6
Check.................................................................... 41-10
Decompose and assemble..................................... 41-10
Sealing cover of drive shaft..................................... 41-19
Replace................................................................. 41-19
41
LIFAN AUTO
41-1
Drive shaft - Drive shaft
Drive shaft
Preparation
1. Special tool
Dismantle snap ring and

1 Nose pliers
retainer ring
2 Clamp tightening tool Tighten the seal cover clamp
41
3 Properller shaft remover Dismantle drive shaft
LIFAN AUTO
41-2
Repair Specifications
1. Technical Specifications
Length 653±3mm
Left drive shaft Maximum compression 24mm
Maximum extension 26mm
Length 995±3mm
Right drive shaft Maximum compression 24mm
Maximum extension 26mm
Item N•m
Steering knuckle and front column 200~220
propeller shaft slotted nut 180~240
Bolts of mounting bracket between the oil pipe and the wheel speed
20~25
sensor wiring harness
Precautions
1. Do not have seal parts (shield) of propeller shaft rub with or bump on sharp objects when seal parts are rotating
or removed with a car running. Otherwise seals parts will be damaged.
3. Do not contaminate parts in the process of repair. Do not have any impurity enter.
4. Clean the external surfaces of the components before dismantling or assembling them.
5. Decomposed parts (except for rubber parts) should be cleaned by kerosene and then dried by air, or wiped by
paper towel or cloth.
6. Conduct necessary alignment inspection after installation of system.
LIFAN AUTO
41-3
Components diagram
41
1 Slotted nut 12 Sealing cover on sliding end
2 Flat washer 13 No ear and no step clamp
3 Dustproof ring 14 Shaft-used snap ring and retainer ring
4 Split pin 15 T J87 constant speed universal
5 RF95 constant speed universal 16 Differential spring retainer ring
6 Steel wire retainer ring on fixed end 17 Long shaft
7 Single ear and no step clamp 18 Shock absorber
8 Sealing cover on fixed end 19 No ear and no step clamp
9 Single ear and no step clamp 20 Ball cage assembly
10 Short shaft 21 Three-fork pin assembly
11 No ear and no step clamp
LIFAN AUTO
41-4
System Description
LIFAN 720 series car uses front wheel drive. Its drive shaft refers to axle shaft of connecting left and right steering drive
wheel of transmission and differential. Inner end of left and right drive shafts are connected with spine and axle shaft
gear and fixed by snap ring. External fine spine inserts into spine hole of wheel hub and shaft end is locked by nut.
On-Vehicle Check
1. Check whether it is obviously damaged

(a). Check if the propeller shaft and the universal joint are loose and have other damages.
(b). Check if seal cover is cracked or has other damages.
2. While rotating, there is the sound of click
(a). When rotation of constant speed universal of worn or damaged front wheel drive shaft, it may produce the sound
of click.
(b). If there is the sound of click, inspect whether sealing cover of constant speed universal of front wheel drive shaft
has abrasion or damage.
3. When accelerating speed in sliding traveling condition, there is dull metal sound. If there is the sound of
click, while rotating, inspect the following conditions:
(a). Check if seal cover is damaged or broken.
(b). External universal joint is worn out or damaged.
4. Jerk or vibration in acceleration
(a). Starting jerking is vibration felt on steering wheel or from the car front when the car goes to intermediate
speed from start or is rapidly accelerating. During acceleration, starting jerking might be forward and rearward
vibration. In front wheel drive cars, starting jerking might be resulted from the following conditions:
• TJ87 Constant speed universal has abrasion or damage.
• RF95 Constant speed universal is worn into serious angle shape.
(b). Universal has serious angle shape, which is generally caused by too high height of front shock absorber spring.
The following faults may occur when mounting seat of power system has abrasion or misalignment:
• Universal joint angle is too large.
• Starting jerking.
(c). During rapid acceleration, the front suspension height may increase due to high torque of the powertrain. When
suspension height rises, angle of TJ87 constant universal becomes bigger. If the following conditions may also
cause vibration when starting:
• Universal joint wear.
• Angle is big before acceleration.
LIFAN AUTO
41-5
Drive shaft - Troubleshooting
Troubleshooting
Problem Symptoms Table
these parts.
1. Propeller shaft (wear. Damaged or bent) Replace.

Vibration
2. Propeller shaft and hub spline (abnormal sound) Replace.
1. Improper adjustment of car height cause poor

Adjust car body height
performance of universal joint
Jerk in acceleration
2. Angle (too high) Adjustment
3. Universal joint (wear) Replace.
1. Propeller shaft (wear. Damaged or bent) Replace.
2. Front hub spline (wear) Replace.
3. Propeller shaft hub spline (wear) Replace.

Loud noise
4. Propeller shaft (poor lubrication) Add grease
5. Hub nut (loose) Adjust or replace
6. Front suspension and steering gear (defective) Adjust or replace
41
LIFAN AUTO
41-6
Drive shaft - Drive shaft assembly
Drive shaft assembly

Replace.
1. Drainage of transmission oil
△ Hint:
sensor wiring harness from the front suspension bracket; do not
disconnect them.
4. Remove the front brake with steering knuckle assembly

(a). Dismantle cotter pin of front suspension steering knuckle
and slotted nut of drive shaft.
(b). Remove slotted nut of propeller shaft and take out the plain
washer.
△ Hint:
While dismantling this slotted nut, to facilitate dismantling, put the
transmission to reversing gear and press brake pedal, to avoid nut
and drive shaft rotates with wrench during dismantling.
LIFAN AUTO
41-7
(c). Make marks on the front shock absorber.
△ Hint:
according to marks, there is no need to carry out the four-wheel
alignment. If without marks, you must carry out the four-wheel
alignment after installation.
(d). Remove the connecting bolt between the front shock
absorber and the steering knuckle.
△ Hint:
After dismantling lower locknut, slightly rise up front brake with
steering knuckle assembly and unplug bolts.
5. Removal of drive shaft assembly

(a). Turn the front brake with the steering knuckle assembly to a
proper angle.
41
(b). Pull out the propeller shaft in wheel side from the steering
knuckle hub.
LIFAN AUTO
41-8
(c). Unplug differential of transmission from propeller shaft on
left and right sides.
△ Hint:
Propeller shaft detacher or equivalent tool must be used to remove
the propeller shaft assembly; do not use heavy-duty tool to knock
directly the drive assembly. Otherwise the propeller shaft will be
damaged.
Note:
Pay attention not to damage boot and oil seal.
Pay attention not to fall propeller shaft.
Do not directly pull propeller shaft, because this may cause
loosening of TJ87 constant speed universal of drive shaft, and
even cause damage of dustproof rubber sleeve.
6. Installation of drive shaft

(a). Inspect whether retainer ring of differential spring on
transmission side of propeller shaft is installed to proper
position.
△ Hint:
Try to replace the snap ring after each removal and installation.
(b). Smear gear oil on the universal joint spline shaft in the side
of propeller shaft and the transmission.
(c). Align inner end of drive shaft (T J87 universal end) with
center hole of differential, and slightly rotate drive shaft to
align teeth and push it with hard force to install transmission
of drive shaft into differential.
△ Hint:
Through rotation of propeller shaft, by hearing sound and feeling,
you can know whether spine shaft of universal on transmission
side is installed to proper position.
Use rubber hammer to punch spine shaft of universal of propeller
shaft into differential.
Note:
While installing, opening of retainer ring of differential spring
should be placed downwards.
Pay attention not to damage boot and oil seal.
LIFAN AUTO
41-9
7. Mount the front brake with steering knuckle assembly
(a). Turn the front steering knuckle and then mount the propeller
shaft steering knuckle laterally onto the steering knuckle
wheel hub.
(b). Rise front steering knuckle and install connecting bolts of

steering knuckle and front column assembly, and install
bolts and nuts, and tighten them.
Torque: 200 ~ 220N.m
Note:
Pay attention to align marks made in removal during
installation.
41
(c). Mount the propeller shaft slotted nuts and plain washers and
then tighten them to expose cotter pin mounting hole.
△ Hint:
When tightening this slotted nut, to facilitate tightening, it is
necessary to place transmission to 1st gear and press brake pedal,
to avoid nut and drive shaft rotates with wrench during tightening.
Note:
If pin hole isn't aligned, further tighten slotted nuts to make
the slotted section of slotted nut align with shaft lock pin hole.
(d). Install new cotter pin of slotted nut.
8. Re-fix brake pipe and wheel speed sensor wire harness
onto shock absorber bracket, and install fixed bolts and
tighten them.
Torque: 20 ~ 25 N.m
9. Mount the front wheels
10. Fill transmission gear oil
LIFAN AUTO
41-10
Check
1. Check the propeller shaft
△ Hint:
If any of abnormalities below is detected, always decompose the
drive and then repair or replace damaged parts.
(a). Check whether ball joint in the wheel side is obviously
loose.
(b). Check whether the ball joint in transmission may smoothly
slide in axial direction without seizure.
(c). Check whether the ball joint in transmission may slide in
radial direction without too large gap.
(d). Check if boot is damaged.
Note:
Keep the propeller shaft assembly in level in the process of
inspection.
2. Inspect length of drive shaft.

Length of left drive shaft: 653±3mm
Length of right drive shaft: 995±3mm
Decompose and assemble

1. Detach TJ87 constant speed universal assembly on
transmission side.
(a). Use screwdriver to pry no ear and no step clamp on 2 sides
of sealing cover on sliding side of drive shaft.
Note:
After the clamps are removed, they must be replaced; do not
damage seal cover in the process of removal.
(b). Unplug sealing cover from TJ87 constant speed universal

housing and move it to the middle of drive shaft.
(c). Use cloth or paper towel to clean lubricating oil inside T
J87 constant speed universal.
(d). Make an assembly mark on TJ87 constant speed universal
housing on transmission side and drive shaft.
Note:
Do not use a punching pin or engraving tool to make the mark.
Marking pen can be used to make a mark.
LIFAN AUTO
41-11
(e). Dismantle TJ87 constant speed universal from inside ball
joint assembly.
(f). Use snap ring to dismantle snap ring and retainer ring used
for shaft on inner shaft side of drive shaft.
41
(g). Make a mark on three-pin ball joint assembly to facilitate

installation.
Note:
Do not use a punching pin or engraving tool to make the mark.
Marking pen can be used to make a mark.
(h). Use copper bar or rubber hammer to strike three-pin ball
joint assembly off drive shaft.
Note:
Do not tap the roller in the process of removal.
LIFAN AUTO
41-12
(i). Remove sealing cover of T J87 constant speed universal
from drive shaft.
Note:
Wrap the spline by tapes to avoid damage of seal cover.
2. Detach RF95 constant speed universal assembly on

wheel side.
(a). Use screwdriver to loosen single ear and no step clamp on
both sides of sealing cover of fixed end.
Note:
After the clamps are removed, they must be replaced; do not
damage seal cover in the process of removal.
(b). Unplug sealing cover from RF95 constant speed universal

assemble and move it to the middle of drive shaft.
(c). Unplug RF95 constant speed universal assembly on wheel
side from drive shaft.
△ Hint:
Use a table vice to fix drive shaft, and use rubber hammer or
copper bar to strike RF95 constant speed universal assembly out
vertically.
LIFAN AUTO
41-13
(d). Take off the steel wire retainer ring and the seal cover in the
fixed end of the drive.
Note:
Wrap the spline by tapes to avoid damage of seal cover.
(e). Use copper bar and hammer slightly strike spacer of roller
bearing of constant speed universal, to make it tilt.
(f). When spacer of roller bearing of constant speed universal it
tilt, take the first steel ball.
(g). Tilt spacer of roller bearing of constant speed universal in
reversing direction, and take out corresponding steel ball.
(h). Take each of steel balls one by one through this method.
41
(i). Rotate spacer of roller bearing of constant speed universal

and inner seat ring rail to proper angle and take them out.
LIFAN AUTO
41-14
(j). Remove inner seat ring rail from spacer of roller bearing of
constant speed universal.
(k). Clean decomposed parts and clear off old grease and
contaminants; dry all parts.
(i). Inspect whether each part of constant speed universal
assembly has abnormal abrasion, breaking or damage. If
any, replace the parts.
3. Assembly T J87 constant speed universal assembly on

transmission side.
(a). Wrap the spline of propeller shaft by tapes with attention to
avoid damage of boot; mount the seal cover in the sliding
end onto the shaft.
Note:
Do not reuse seal cover clamps.
After installation, remove rubber adhesive around the spine of
drive shaft.
(b). Align mounting mark to install three-pin ball joint assembly.

Note:
Use copper bar or rubber hammer to install three-pin ball joint
assembly.
Make sure that three-pin ball joint is installed to proper
position.
LIFAN AUTO
41-15
(c). Install snap ring and retainer ring used for shaft on inner
shaft side of drive shaft.
(d). Apply lubricating oil on ball joint assembly.
(e). Align mounting mark to install T J87 constant speed

universal of drive shaft on transmission side.
(f). Add a proper amount of grease.
(g). Mount the seal cover in the sliding end onto the constant
velocity universal joint.
Note:
If grease sticks to the seal cover fitting surface, the seal cover
might fall off and therefore all grease should be cleaned off.
41
(h). Insert a "flat-blade" screwdriver from big diameter side

of sealing cover on sliding end, and exhaust air, and adjust
mounting length of sealing cover, to avoid deformation of
sealing cover.
Note:
If sealing cover is too long, it may cause damage of sealing
cover.
Attention should be paid when using flat-blade screwdrivers to
avoid damage of sealing cover.
LIFAN AUTO
41-16
(i). Mount new sliding end seal cover clamp.
(j). Tighten new seal cover clamp by a tool.
Note:
4. Assemble RF95 constant speed universal assembly on

wheel side.
(a). Adjust inner seat ring rail and spacer of roller bearing to
proper angle, and install them into spacer of roller bearing.
(b). Adjust spacer of roller bearing and inner seat ring rail to
proper angle, and install them into constant speed universal.
Note:
Make sure that fixed ring of inner seat ring rail points to drive
shaft rod.
LIFAN AUTO
41-17
(c). Install the first steel ball, and then tilt spacer of roller
bearing of universal in reversing direction, and install pairly
steel balls.
(d). Mount each of steel balls one by one in this method.
(e). Smear a proper amount of grease on the jagged holes of
universal joint subassembly until grease starts flowing
out from the circular groove and the jagged holes. After
smearing grease, clean off overflowing grease by a cloth.
(f). Use adhesive tape to wind spine on drive shaft, to avoid

damage of sealing cover. And install sealing cover at fixed
end onto the shaft.
Note:
drive shaft.
41
(g). Install steel wire retainer ring at fixed end onto the drive
shaft, to lay RF95 constant speed universal vertically. Insert
drive shaft into the center hole of RF95 constant speed
universal until it is completely installed.
△ Hint:
Confirm that the universal joint subassembly is correctly engaged
in rotating the driver shaft.
(h). Fill the seal cover with a proper amount of grease evenly
from the side with large diameter of the fixed end.
Note:
If lubricating oil sticks to the fixed face of sealing cover, the
sealing cover may fall off. Clean all lubricating oil from the
surface of sealing cover.
LIFAN AUTO
41-18
(i). Insert the flat screwdriver from the side with large diameter
of the fixed end seal cover and release air inside; adjust
mounting length of seal cover and avoid deformation of seal
cover.
Note:
cover.
(j). Mount new fixed end seal cover clamp.

(k). Use tools to fix new clamp of sealing cover.
Note:
LIFAN AUTO
41-19
Drive shaft - Sealing cover of drive shaft
Sealing cover of drive shaft

Replace.
1. Replace sealing cover at fixed end of drive shaft.
(a). Rise up vehicle and dismantle front wheel.
(b). Dismantle fixed bolts of brake oil pipe and wheel speed
sensor wire harness bracket.
△ Hint:
sensor wiring harness from the front suspension bracket; do not
disconnect them.
(c). Dismantle cotter pin of slotted nut of drive shaft and slotted
nut, and take out plain washer.
△ Hint:
While dismantling this slotted nut, to facilitate dismantling, put the
transmission to reversing gear and press brake pedal, to avoid nut
and drive shaft rotates with wrench during dismantling.
41
(d). Make a mark on front shock absorber, and dismantle

connecting bolts of front shock absorber and steering
knuckle.
△ Hint:
While dismantling, after fixed bolts and dismantling lock nut,
slightly rise up front brake with steering knuckle assembly to
unplug bolt.
Note:
according to marks, there is no need to carry out the four-
wheel alignment. If without marks, you must carry out the
four-wheel alignment after installation.
LIFAN AUTO
41-20
(e). Rotate and tighten front brake with steering knuckle
assembly to proper angle, and unplug drive shaft from
steering knuckle wheel hub.
(f). Use screwdrivers to loosen single ear and no step clamp on

both sides of sealing cover at fixed end of drive shaft on
wheel side.
(g). Dismantle RF95 constant speed universal assembly on

wheel side.
LIFAN AUTO
41-21
(h). Remove sealing cover at fixed end of drive shaft.
(i). Use adhesive tape to wind the spine of drive shaft, to avoid
damage of sealing cover.
(j). Install a new sealing cover onto the drive shaft.
Note:
drive shaft.
(k). Install steel wire retainer ring at fixed end onto the drive
shaft, and insert drive shaft into the center hole of RF95
constant speed universal, until it is completely installed.
△ Hint:
Confirm that the universal joint subassembly is correctly engaged
in rotating the driver shaft.
41
(l). Fix the small diameter side of sealing cover at fixed end by
using a new clamp.
(m). Apply proper amount of lubricating oil into the sealing
cover from big diameter side of sealing cover.
Note:
If lubricating oil sticks to the fixed face of sealing cover, the
sealing cover may fall off. Clean all lubricating oil from the
surface of sealing cover.
(n). Insert flat-blade screwdrivers from big diameter side of
sealing cover, exhaust air, and adjust mounting length of
sealing cover, to avoid deformation of sealing cover.
Note:
cover.
LIFAN AUTO
41-22
(o). Install a new clamp of sealing cover at fixed side.
(p). Use tools to fix a new clamp of sealing cover.
Note:
(q). Rotate and tighten front steering knuckle, and install

steering knuckle of drive shaft onto wheel hub of steering
knuckle.
(r). Rise front steering knock and install connecting bolts of

steering knuckle and front column assembly, and install
bolts and nuts, and tighten them.
Note:
Pay attention to align marks made in removal during
installation.
LIFAN AUTO
41-23
(s). Install plain washer and slotted nut of drive shaft, and
tighten them to make it expose mounting hole of cotter pin.
△ Hint:
When tightening this slotted nut, to facilitate tightening, it is
necessary to place transmission to 1st gear and press brake pedal,
to avoid nut and drive shaft rotates with wrench during tightening.
Note:
If pin holes are misaligned, further tighten slotted nuts to align
it with the shaft lock pin hole.
(t). Install cotter pin of a new slotted nut.
(u). Re-fix brake pipe and wheel speed sensor wire harness onto
the shock absorber bracket. Install fixed bolts and tighten
them.
Torque: 20 ~ 25 N.m
(v). Install front wheel.
2. Replace sealing cover at sliding end of drive shaft.

△ Hint:
Replace boot at sliding end of drive shaft. It is necessary to dismantle drive shaft whith its sealing cover to be replaced.
Detach T J87 constant speed universal assembly on transmission side of drive shaft. Replace with a new sealing cover
and sealing cover clamp.
(a). Dismantle drive shaft with its sealing cover at sliding end. (See Chapter 41 Transmission Shaft - Transmission
Shaft Assembly, Replacement)
41
(b). Dismantle T J87 constant speed universal on transmission side of drive shaft. (See Chapter 41 Drive Shaft -
Propeller Shaft, Detachment and Assembly)
(c). Replace with a new sealing cover and sealing cover clamp.
Note:
(d). Assemble T J87 constant speed universal on transmission side of drive shaft. (See Chapter 41 Drive Shaft -
Propeller Shaft, Detachment and Assembly)
(e). Install the drive shaft assembly.
LIFAN AUTO
• Remark •
LIFAN AUTO
01
Index
(Arranged in alphabetical order)...
Complete vehicle
A Check (Drive belt) ……………………………… 11-33
Check (Drive shaft assembly) …………………… 41-10
Check (Engine oil pump) ……………………… 16-15
Accelerated reaction is slow and unbalanced Check (Exhaust manifold) ……………………… 11-41
(Troubleshooting) ……………………………… 12-71
Check (Fuel filter) ……………………………… 13-21
Adjustment (Clutch pedal) ……………………… 22-8
Check (Fuel pipeline) …………………………… 13-25
Analysis of customer complaints (Vehicle
Check (Fuel tank) ……………………………… 13-11
troubleshooting) ………………………………… 01-21
Check (Housing assembly) ……………………… 21-95
Assembly (Differential assembly) ……………… 21-72
Check (Input shaft assembly) …………………… 21-42
Assembly (Fork shaft assembly)………………… 21-83
Check (Intake manifold) ………………………… 11-35
Assembly (Gear shift mechanism assembly) …… 21-90
Check (Oil pan) ………………………………… 16-12
Assembly (Input shaft assembly) ……………… 21-46
Check (Output shaft assembly) ………………… 21-59
Assembly (Output shaft assembly) ……………… 21-62
Check (Piston connecting rod) ………………… 11-94
Assembly (Transmission assembly) …………… 21-29
Check (Radiator) ………………………………… 15-7
Check (Rear wheel hub) ………………………… 32-13
B
Check (Reverse idler gear assembly) …………… 21-77
Check (Spark plug) ……………………………… 17-6
Check (Timing sprocket mechanism) …………… 11-45
Basic check (Engine control system) …………… 12-33
Check (Valve) …………………………………… 11-78
Check (Water pump) …………………………… 15-16
C
Check it completely (Transmission assembly) … 21-28
CMP sensor (Sensor actuator)…………………… 12-178
Component diagram (B) (Cooling system) ……… 15-4
Canister solenoid valve (Sensor actuator) ……… 12-189
Component diagram (B) (Fuel system) ………… 13-6
Check (Air filter pipe)…………………………… 14-13
Component diagram (B) (Intake and exhaust
Check (Air filter)………………………………… 14-7
system) ……………………………………… 14-4
Check (Camshaft) ……………………………… 11-60
Component diagram (I) (Cooling system) ……… 15-3
Check (Clutch assembly) ……………………… 22-17
Component diagram (I) (Fuel system) ………… 13-5
Check (Cooling pipeline) ……………………… 15-22
Component diagram (I) (Intake and exhaust
Check (Crankshaft and flywheel) ……………… 11-116
System) ……………………………………… 14-3
Check (Cylinder block) ………………………… 11-136
Component layout (Engine control system) …… 12-18
Check (Cylinder Hood) ………………………… 11-68
Components diagram (Camshaft) ……………… 11-59
Check (Differential assembly) ………………… 21-71
Components diagram (Clutch control mechanism)
LIFAN AUTO
02
(Clutch) ………………………………………… 22-3 D

Components diagram (Crankshaft and flywheel) 11-115
Components diagram (Cylinder block) ………… 11-135
Components diagram (Cylinder hood) ………… 11-67 Decompose and assemble (Drive shaft assembly) 41-10
Components diagram (Differential assembly) … 21-68 Diagnosis system description (Troubleshooting) 12-34
Components diagram (Drive belt) ……………… 11-32 Disassemble (Transmission assembly) ………… 21-24
Components diagram (Drive shaft)……………… 41-3 Dismantle engine assembly (Mechanical system of
engine)…………………………………………… 11-14
Components diagram (Exhaust manifold) ……… 11-40
Dismantling (Differential assembly) …………… 21-69
Components diagram (Fork shaft assembly) …… 21-79
Dismantling (Fork shaft assembly) ……………… 21-80
Components diagram (Front shock absorber assembly)
(Front overhang) ………………………………… 31-5 Dismantling (Gear shift mechanism assembly) … 21-87
Components diagram (Front overhang) (Front overhang) Dismantling (Input shaft assembly) …………… 21-35
31-4
Dismantling (Output shaft assembly) …………… 21-54
Components diagram (Gear shift mechanism
DTC (DTC) list (Troubleshooting) ……………… 12-52
assembly) …………………………………… 21-86
Components diagram (Generator) ……………… 18-18
Components diagram (Housing assembly) ……… 21-94 E
Components diagram (Ignition system) ………… 17-3
Components diagram (Input shaft assembly) …… 21-34
Electronic control system description (Engine control
Components diagram (Intake manifold) ………… 11-34
system) ………………………………………… 12-7
Components diagram (Lubrication system) …… 16-4
Electronic control unit（ECU） (Sensor actuator) 12-167
Components diagram (Output shaft assembly) … 21-53
Electronically controlled throttle valve housing (Sensor
Components diagram (Piston connecting rod) … 11-93 actuator) ………………………………………… 12-184
Components diagram (Rear shock absorber assembly) Engine assembly installation (Mechanical system of
(Rear overhang) ………………………………… 32-4 engine)…………………………………………… 11-22
Components diagram (Rear overhang) Engine will flame out when it runs at idle speed in cold
state (Troubleshooting) ………………………… 12-75
(Rear overhang) ………………………………… 32-3
Exhaust (Clutch slave pump) …………………… 22-16
Components diagram (Reverse idler gear
assembly) …………………………………… 21-76
Components diagram (Starter) ………………… 18-7 F
Components diagram (Steering knuckle) (Front
overhang) ……………………………………… 31-6
Components diagram (Timing sprocket Fault code clearing (Troubleshooting) ………… 12-43
mechanism) ………………………………… 11-44
Fault code reading (Troubleshooting) …………… 12-39
Components diagram (Tires and wheels) ……… 33-4
Fault diagnosis analysis (Troubleshooting) …… 12-37
Components diagram (Transmission control
Fault diagnosis procedure (Troubleshooting) …… 12-36
mechanism) ………………………………………21-8
Fault simulation (Vehicle troubleshooting)……… 01-21
Components diagram (Valve) …………………… 11-77
Fuel pump (Sensor actuator) …………………… 12-196
Coolant temperature sensor (Sensor actuator) … 12-173
Crankshaft Position Sensor (Sensor actuator)…… 12-176
Crankshaft rotates, but engine can't be started. G
LIFAN AUTO
03
General Information (Overview) ……………… 01-1 O

General Information (Vehicle troubleshooting) … 01-20
I On-Vehicle Check (Clutch) ……………………… 22-5

On-Vehicle Check (Cooling system) …………… 15-5
On-Vehicle Check (Drive shaft) ………………… 41-4
I/O Control functional unit (Troubleshooting) … 12-48 On-Vehicle Check (Front overhang) …………… 31-7
Idle speed is not stable (Troubleshooting) ……… 12-64 On-Vehicle Check (Fuel system) ……………… 13-7
Idle speed is too high (Troubleshooting) ……… 12-67 On-Vehicle Check (Ignition system) …………… 17-4
Ignition coil (Sensor actuator) ………………… 12-194 On-Vehicle Check (Intake and exhaust system) … 14-5
Index (Overview) ……………………………… 01-1 On-Vehicle Check (Lubrication system) ………… 16-5
Injector (Sensor actuator) ……………………… 12-192 On-Vehicle Check (Mechanical system of engine) 11-11
Inspection (Fuel pump) ………………………… 13-17 On-Vehicle Check (Starting and charging
Inspection (Generator) ………………………… 18-19 systems) ……………………………………… 18-5
Inspection (Starter) ……………………………… 18-8 On-Vehicle Check (Tires and wheels) ………… 33-5
Inspection (Thermostat) ………………………… 15-19 Oxygen sensor (Sensor actuator) ……………… 12-180
Inspection and adjustment (Four-wheel alignment) 33-15
Inspection and adjustment (Wheel balance) …… 33-12 P
Intake Air Temperature/Pressure Sensor (Sensor actuator)
12-170
Intake VVT valve (Sensor actuator) …………… 12-187
P0011 (Troubleshooting) ……………………… 12-78
International System of Units)（SI）Overview… 01-3
K P0026 (Troubleshooting) ……………………… 12-78
Knock sensor (Sensor actuator) ………………… 12-182
M P0076 (Troubleshooting) ……………………… 12-81
Maintenance hints (Maintenance guide) ………… 01-13
Maintenance procedures (Overview) …………… 01-1
Maintenance specifications: (Overview) ……… 01-1
LIFAN AUTO
04
P0131 (Troubleshooting) ……………………… 12-112 Poor acceleration and performance

(Troubleshooting) …………………………… 12-69
Precautions (Clutch) …………………………… 22-2
Precautions (Cooling system) …………………… 15-2
Precautions (Drive shaft) ……………………… 41-2
Precautions (Engine control system) …………… 12-5
Precautions (Front overhang) …………………… 31-3
Precautions (Fuel system) ……………………… 13-3
Precautions (Ignition system) …………………… 17-2
Precautions (Intake and exhaust system) ……… 14-2
Precautions (Lubrication system) ……………… 16-3
Precautions (Manual transmission) ……………… 21-5
Precautions (Mechanical system of engine) …… 11-10
Precautions (Rear overhang) …………………… 32-2
Precautions (Tires and wheels) ………………… 33-3
Preparation (Clutch) …………………………… 22-1
Preparation (Cooling system) …………………… 15-1
Preparation (Drive shaft)………………………… 41-1
Preparation (Engine control system) …………… 12-1
Preparation (Front overhang) …………………… 31-1
Preparation (Fuel system) ……………………… 13-1
Preparation (Ignition system) …………………… 17-1
Preparation (Lubrication system) ……………… 16-1
Preparation (Maintenance guide) ……………… 01-11
Preparation (Manual transmission) ……………… 21-1
Preparation (Mechanical system of engine) …… 11-1
Preparation (Overview) ………………………… 01-1
Preparation (Rear overhang) …………………… 32-1
Preparation (Starting and charging systems) …… 18-1
Preparation (Tires and wheels) ………………… 33-1
Problem symptoms table (Troubleshooting) …… 11-28
LIFAN AUTO
05
Problem symptoms table (Troubleshooting) …… 31-8 Replace (Exhaust manifold) …………………… 11-42
Problem symptoms table (Troubleshooting) …… 32-6 Replace (Front shock absorber assembly) ……… 31-9
Problem symptoms table (Troubleshooting) …… 33-8 Replace (Fuel filter) …………………………… 13-22
Replace (Fuel pump) …………………………… 13-18
R Replace (Fuel tank) ……………………………… 13-12
Replace (Generator) …………………………… 18-21
Replace (Housing assembly) …………………… 21-96
Read data stream (Troubleshooting) …………… 12-45 Replace (Intake manifold) ……………………… 11-36
Repair Specifications (Clutch) ………………… 22-2 Replace (Muffler) ……………………………… 14-21
Repair Specifications (Cooling system) ………… 15-1 Replace (Oil dipstick) …………………………… 16-29
Repair Specifications (Drive shaft) ……………… 41-2 Replace (Oil pan) ……………………………… 16-13
Repair Specifications (Engine control system) … 12-2 Replace (Piston connecting rod) ………………… 11-99
Repair Specifications (Front overhang) ………… 31-2 Replace (Radiator) ……………………………… 15-8
Repair Specifications (Fuel system) …………… 13-2 Replace (Rear axle assembly) …………………… 32-7
Repair Specifications (Ignition system) ………… 17-2 Replace (Rear shock absorber assembly) ……… 32-11
Repair Specifications (Intake and exhaust system) 14-1 Replace (Rear wheel hub) ……………………… 32-13
Repair Specifications (Lubrication system) …… 16-2 Replace (Reverse idler gear assembly) ………… 21-78
Repair Specifications (Manual transmission) …… 21-4 Replace (Sealing cover of drive shaft) ………… 41-19
Repair Specifications (Mechanical system of Replace (Spark plug) …………………………… 17-7
engine) ……………………………………… 11-6
Replace (Steering knuckle ……………………… 31-17
Repair Specifications (Rear overhang) ………… 32-2
Replace (Subframe assembly)…………………… 31-27
Repair Specifications (Starting and charging
Replace (Thermostat) …………………………… 15-20
systems) ……………………………………… 18-1
Replace (Three way catalytic converter) ……… 14-17
Repair Specifications (Tires and wheels) ……… 33-2
Replace (Transmission assembly) ……………… 21-15
Replace (Air filter pipe) ………………………… 14-14
Replace (Transmission control mechanism) …… 21-9
Replace (Air filter) ……………………………… 14-8
Replace (Transverse arm assembly) …………… 31-25
Replace (Camshaft)……………………………… 11-62
Replace (Valve) ………………………………… 11-84
Replace (Canister) ……………………………… 13-26
Replace (Water pump) ………………………… 15-17
Replace (Clutch assembly) ……………………… 22-18
Replace (Wheel assembly) ……………………… 33-9
Replace (Clutch master pump) ………………… 22-11
Replace (Clutch pedal) ………………………… 22-9
Replace (Clutch slave pump) …………………… 22-14 S
Replace (Cooling pipeline) ……………………… 15-22
Replace (Crankshaft and flywheel) ……………… 11-120
Schematic diagram (Cooling system) …………… 15-2
Replace (Crankshaft oil seal) …………………… 11-137
Schematic diagram (Fuel system) ……………… 13-4
Replace (Cylinder hood) ………………………… 11-69
Schematic diagram (Intake and exhaust system) 14-2
Replace (Drive belt) …………………………… 11-33
Schematic diagram (Lubrication system) ……… 16-3
Replace (Drive shaft assembly) ………………… 41-6
System Description (Clutch) …………………… 22-4
Replace (Engine oil filter) ……………………… 16-10
System Description (Drive shaft) ……………… 41-4
Replace (Engine oil pump) ……………………… 16-16
System Description (Front overhang) …………… 31-3
Replace (Engine oil) …………………………… 16-8
LIFAN AUTO
06
System Description (Tires and wheels) ………… 33-4

T
Terminal Definition (Engine control system) …… 12-27

The diagnosis tester cannot communicate with ECM
The engine will flame out when starting
(Standard bolt torques) ………………………… 01-24
Tire rotation (Wheel assembly) ………………… 33-9
Troubleshooting analysis (Vehicle
troubleshooting) …………………………… 01-20
Use (Spare wheel) ……………………………… 33-11
Vehicle Identification (Vehicle Identification) … 01-4
Vehicle lifting (Maintenance guide) …………… 01-18
Vehicle specifications (Vehicle specifications) … 01-5
Warning, Hint, and Attention (Overview) ……… 01-3

Wiring diagram (Charging system) (Starting and charging
systems) ………………………………………… 18-4
Wiring diagram(Engine control system) ………… 12-20
Wiring diagram (Starting system) (Starting and charging
systems) ………………………………………… 18-3
Wiring troubleshooting method (Vehicle
troubleshooting) …………………………………01-23
LIFAN AUTO
Foreword
This manual covers the product structures, working principles and technical parameters of all LF720 models, providing
reference for the LIFAN AUTO service technicians and managers to perform inspection, fault diagnosis, removal,
installation, adjustment and maintenance and service.
This manual includes Volume Ⅰ , Volume Ⅱ and Volume Ⅲ LF720 Wiring diagram available on request. This manual
has been edited with excellent pictures and their accompanying essays so that it is both popular and easy to understand.
Moreover, the manual also provides many maintenance skills to reduce working hours and improve efficiency.
Observe the following instructions before referring to this manual:
1. Take time to read this manual carefully before performing inspection, fault diagnosis, removal, installation,
adjustment and maintenance when your vehicle in trouble. Be sure to perform operation and maintenance as
required, and pay attention to the captions WARNING, ATTENTION, HINT,etc..
2. This manual describes every option and model variant available to the LF720 series products. Because of the
variations in vehicle model layout, some of the items (e.g., devices, facilities or features) covered herein may not
apply to some particular models.
3. To avoid damage to vehicle devices or even safety accidents, it is strictly forbidden to modify the existing
devices or add other devices to the vehicles by users without authorization, especially for the electrical system,
brake system, steering system and other systems related to driving safety.
4. When your vehicle needs replacement parts, be sure to go to the LIFAN MOTOR authorized service stations for
purchasing the original spare parts supplied by the LIFAN Industry(Group) Imp.& Exp. Co.,Ltd.
5. It is your own responsibility for the safety accidents or any direct/indirect loss due to not following the
precautions specified in the above Paragraphs 3 and 4.
6. With the progress and development of technology, the LF720 series products will be improved and perfected
continuously so that you may find descriptions of features not installed on your vehicle. LIFAN Industry(Group)
Imp.& Exp. Co.,Ltd. reserves the right, however, to change design at any time without prior notice. Revisions
of specifications or design will only be included in the second edition for any reason and without notice, and
without incurring any obligation whatsoever.
All rights reserved. No unit or individual is allowed to copy or print this manual without prior authorization from
LIFAN Industry(Group) Imp.& Exp. Co.,Ltd. Otherwise, LIFAN Industry(Group) Imp.& Exp. Co.,Ltd. reserves the
right to investigate for copyright liability in accordance with law.
Chongqing LIFAN Industry(Group) Imp.& Exp. Co.,Ltd.

October 2012
Volume 1
0 Overview Overview 01
1 Engine Mechanical System 11
Control System 12
Fuel System 13
Intake and Exhaust System 14
Cooling System 15
Lubrication System 16
Exhaust Emission Control 17
Electrical System 18
2 Transmission Transmission 21
Clutch 22
3 Running System Front Suspension 31
LIFAN AUTO Rear Suspension 32
Tires and Wheels 33
4 Drive System Drive Shaft 41
Volume Ⅱ
5 Brake System Service Brake 51
Parking Brake 52
6 Steering System Steering System 61
7 Electrical System A/C System 71
Safety Protection Device 72
Audio System 73
Driver Information System 74
Lighting System 75
Horn and Cigarette Lighter 76
8 Body and Accessories Accessories 81
Door and Lock 82
Windows and Rearview Mirrors 83
Seats 84
Dashboard and Console 85
Wiper and Washer System 86
Index
Service brake
Service brake.............................................................. 51-1

Preparation............................................................. 51-1
Precautions............................................................. 51-3
Components diagram(braking line)........................ 51-4
Components diagram(brake control )..................... 51-5
On-Vehicle check................................................... 51-6
Brake pedal............................................................... 51-11
Adjustment........................................................... 51-11
Replace................................................................. 51-12
Brake master cylinder............................................. 51-14
Replace................................................................. 51-14
Vacuum booster........................................................ 51-17
Replace................................................................. 51-17
Brake fluid................................................................ 51-20
Drain..................................................................... 51-20
Refilling................................................................ 51-20
Exhaust................................................................. 51-21
Front brake............................................................... 51-22
Replace................................................................. 51-23
51
Rear brake................................................................ 51-29
Replace................................................................. 51-30
Brake line.................................................................. 51-38
Replace................................................................. 51-38
LIFAN AUTO
Service Brake-Service brake 51-1
Service brake
Preparation
1. Special tool
For removing the nuts of

1 Pipe wrench
pipe joints
Rear brake piston Remove the rear brake

2
remover cylinder piston

51
Measure the front and rear

1 Dial gauge
brake disc
For measuring the brake disc

2 Micrometer screw gauge
thickness
LIFAN AUTO
51-2 Service Brake-Service brake
Height from brake pedal to the floor 100±5mm
Brake pedal free play ≤ 5mm
Clearance of brake pedal switch 5~15mm
Standard thickness 18.5mm

Front friction lining
Minimum thickness 9mm
Standard Thickness 15.5mm

Rear friction lining
Standard Thickness 22mm

Front brake disc
Standard Thickness 9mm

Rear brake disc
Minimum thickness 7.5mm
Maximum swinging amount of brake disc 0.1mm
Item N•m
Brake master cylinder retaining nut 20~26
Vacuum booster retaining nut 20~26
Master cylinder oil pipe nut 14~18
Front brake hose hollow bolt 35~45
Front brake caliper bolt 55~65
Front brake caliper bracket retaining bolt 80~110
Rear brake hose hollow bolt 35~45
Rear brake caliper bolt 55~65
Rear brake caliper bracket fixed bolt 80~110
Brake hose connector nut 14~18
Brake hose bracket fixed bolt 20~26
LIFAN AUTO
Precautions
1. It is recommended to use DOT4 brake fluid. Do not mix it with other brake fluids.
2. Do not reuse brake fluid that has been drained from the brake system. Brake fluid is highly hydrophilic, thus it
should be drained into the original container.
3. Brake fluid features strong corrosion; if it accidentally splashes over skin, clean off brake fluid immediately on
the skin by a cloth and then clean this position completely by soap and water; brake fluid is also very corrosive
for body paint; be careful not to splash brake fluid over the vehicle body paint; if brake fluid drops on the vehicle
body surface, wash it by water immediately.
4. During air exhaust, observe brake fluid level of fluid reservoir. If it is too low, fill fluid. 5. If the brake system
is bled manually, the bleeding should be performed several times until no air comes out. 6. After bleeding the
brake system and adding brake fluid, check the brake system for leak. In the case of leak, immediately repair it to
ensure the travel safety.
5. Use clean brake fluid to clean all parts inside brake caliper. Do not use gasoline or kerosene and other mineral oil
to clean, to avoid damage of rubber parts inside hydraulic system.
6. Use a dedicated wrench when removing or installing brake fluid pipes.
7. Be sure to check the torque when installing the brake fluid pipe joint.
8. Be sure to run in the brake system after repairing or replacing any brake disc or brake shoe, or when the brake
pedal becomes spongy after a short distance of vehicle travel.
9. While repairing brake caliper and brake friction lining, it is necessary to completely clean brake caliper and
brake friction lining to reduce damage caused by air particles and other materials in the air to minimum degree
10. While removing the brake slave cylinder, do not depress the brake pedal, to prevent the piston from springing out
hence damaging the dust boot.
11. Unless disassembling or replacing brake caliper, do not dismantle fixed bracket of brake caliper and bolts on
brake hose. After removing the bolts, hoist the brake slave cylinder using a rope, to prevent it from pulling the
brake hose.
12. Check that no brake fluid appear on the brake disc. Brake fluid left on the brake disc could cause brake failure 51
LIFAN AUTO
Components diagram(braking line)
1 ABS mechanism assembly 14 Rear right brake pipe I
2 ABS mechanism mounting sleeve 15 Rear left brake pipe I
3 ABS bracket components 16 Front right brake pipe I
4 Hexagon bolt with flange 17 Single pipe clamp
Through hole rubber sleeve of brake pipe of

5 Clutch hollow bolt 18
front wheel
6 Seal ring 19 Two-way valve components
7 Front left brake pipe II 20 Front right brake pipe II
8 Hexagon bolt with flange 21 Single pipe clamp B
9 E-shaped card 22 Rear left brake pipe II
10 Front left brake pipe I 23 Rear right brake pipe II
11 Single pipe clamp A 24 Five-pipe clamp
12 Secondary outlet hose of brake master cylinder 25 Rear left brake pipe
13 Main outlet hose of brake master cylinder 26 Hexagon bolt and plain washer assy.
LIFAN AUTO
27 Rear left brake pipe IV 29 Rear left brake pipe V
28 Rear right brake pipe IV 30 Rear right brake pipe III
Components diagram(brake control )
51
1 Brake pedal 11 Vacuum booster assembly
2 Lock pin 12 Strap elastic hoop
3 Axle pin 13 Hexagon bolt with flange
4 Hexagon bolt with flange 14 Boosting vacuum pipe
5 Brake pedal switch 15 Strap elastic hoop
6 Hex thin nut 16 Brake master cylinder assembly
7 Brake pedal bracket 17 Lock pin of brake fluid reservoir
8 Pad 18 Anti-sliding nut
9 Hexagon bolt with flange 19 Brake fluid reservoir
10 B-leaf spring nut 20 Brake fluid reservoir cap
LIFAN AUTO
System description
The brake system consists of brake pedal, vacuum booster mechanism, brake line and ABS. Functions of service brake
system are: Decelerate or stop the running vehicle according to the driver’s requirement; Securely stop the vehicle
under various road conditions (for example on a slope) when the engine has been turned off; Maintain constant vehicle
speed when the vehicle runs down a slope.
On-Vehicle check
1. Check the vacuum booster with brake master cylinder assembly for damage or oil leakage
(a). Check oil leakage occurring between the brake master cylinder and the booster.
(b). Check if pipe connectors around the brake master cylinder and the booster are damaged or leak oil;
(c). Check if leakage occurs in the master cylinder mounting surface, the oil reservoir mounting surface and the
brake pipe connector.
2. Check brake hose for damage or oil leakage:
(a). Check if pipe connectors and the integrated bolt connectors are damaged or leak oil;
(b). Check oil leakage occurring between the hose and the pipe.
(c). Check if piping is twisted or bent excessively.
3. Inspect the height of brake pedal.
(a). Measure height h from the brake pedal to the floor; if it is
too low or high, adjust the brake pedal.
Height to floor: 100 ± 5mm
4. Check brake pedal free play
(a). Stop the engine and repeat stepping brake pedal until there
is no vacuum inside booster.
(b). Step pedal until you feel there is resistance, and check the
pedal free stroke L.
Pedal free stroke: ≤5mm
△ Hint:
If the check free clearance of brake pedal doesn't meet requirement,
adjust pull rod to the required length.
LIFAN AUTO
5. Inspect brake fluid reservoir.
(a). Inspect whether brake fluid in brake fluid reservoir is

between maximum and minimum scale. If it is lower than
minimum scale, fill brake fluid.
(b). If fluid level is too low, inspect whether there is any leakage
around brake fluid reservoir and brake system. If any,
replace brake fluid reservoir or leaked oil pipe.
Attention:
If any oil leakage or brake fluid leakage is found from brake
system, replace relevant leaked parts.
(c). Starting the vehicle, loosen the parking brake lever and
observe the brake warning indicator. If the lamp does not go
out, please Check if the parking brake switch and the brake
fluid level switch have function.
6. Inspect vacuum booster.

(a). Operate and check it; if it malfunctions, replace the vacuum
booster.
• Place ignition switch to OFF position. After repeating
stepping pedal for several time, inspect and make sure
that pedal holding distance has no change.
• Step the pedal and start the engine.
△ Hint:
If the pedal sinks a little, it is normal operation.
Attention:
Internal to depress the brake pedal is 5s.
(b). Check air tightness. if it malfunctions, replace the vacuum 51
booster.
Good Not good
• Start the engine for 1~2min and then stop the engine,
and slowly step for several times.
△ Hint:
If the pedal sinks a few on first stepping, but gradually rises on the
second and third times, it indicates that the air tightness is good.
• When the engine is running, step the brake pedal and
then stop the engine.
△ Hint:
If brake the holding distance has no change after stepping the pedal
for 30s, it indicates that air tightness of booster is good.
(c). Check vacuum check valve.

• Move away the vacuum hose with steel strip elastic
Not ventilated
Ventilated hoop, and pull out the vacuum hose to disconnect the
check valve from the vacuum booster.
• Check and confirm that air flow exists from the booster
to the engine and but air flow does not exist from the
engine to the booster.
△ Hint:
If any fault is found, it is required to change the vacuum check
valve.
LIFAN AUTO
7. Inspect brake friction lining and brake disc.

(a). Check wear of front and rear brake ling; replace it if beyond
wear limit.
Standard thickness of front friction lining: 18.5mm
Limit thickness for abrasion: 9mm
Standard thickness of rear friction lining: 15.5mm
(b). Check if the steel plates in the front and rear brake wear
indicator are enough flexible and are not deformed, broken
or damaged; replace it when necessary.
△ Hint:
If there is any rust, stains and other foreign matters, they should be
cleaned out.
(c). Inspect abrasion condition of front and rear brake discs. If
there is any serious abrasion, please replace it.
(d). Measure brake disc thickness by a screw micrometer;
replace the brake disc if beyond minimum thickness.
Standard thickness of front brake disc: 22mm
Standard thickness of rear brake disc: 9mm
Limit thickness for abrasion: 7.5mm
(e). Mount nuts to fix the brake disc. Measure swinging amount
of brake disc at 10mm away from the brake disc edge using
a centimeter.
Maximum swing amount of brake disc: 0.1mm
△ Hint:
If swinging amount reaches or exceeds limit value, check radial
gap of wheel hub bearing and vibration of wheel hub; if bearing
and wheel hub work normally, replace the brake disc.
LIFAN AUTO
Service Brake-Troubleshooting 51-9
Troubleshooting
these parts.
1. Hydraulic system of brake system (with

Empty the air in the hydraulic system
air)
2. Oil pipe connector (loose or oil leakage in Tighten pipe connectors; check parts with oil leakage;
oil pipe) replace oil pipes
3. Brake line (blockage) Check and repair brake line
4. Cups of brake master cylinder, slave

cylinder piston(deformation, aging, Replace the cup
damaged or seized duo to expansion)
5. Brake lining (badly worn, surface

Replace brake lining
hardening, with oil stains)
Adjust brake pedal stroke to keep it reach maximum of

6 . Brake pedal stroke (too large)
60mm
Insufficient braking force,
and poor braking effect
7. Vacuum booster (damaged) Replace the vacuum booster
8. Brake fluid (insufficient) or brake line

Add more brake fluid and check and repair brake lines
(clogged)
9. Holes of brake master cylinder and slave

Replace the cylinder assembly
cylinder (badly worn)
Replace the slave cylinder piston and the complete slave

10. Piston of brake caliper (seized, can't move)
cylinder
11. B r a k e d i s c ( s e r i o u s w a r p a g e a n d
Repair or replace the brake disc by processing it
deformation)
51
12. Brake clearance self-adjusting mechanism
Check and repair the clearance automatic adjustment
fails; clearance between the shoe and the
mechanism
brake is too large.
1. Brake pedal (no free stroke) Adjust brake pedal free stroke
2. Maladjustment of parking brake (fail to be

Re-adjust it
disengaged completely)
3. Brake line (blockage, and clogged oil

Replace brake fluid and then clean brake line
return)
4. Brake master cylinder or slave cylinder

Check and repair the master cylinder or slave cylinder
piston (seized, and failure in returning)
5. Brake disc (serious warpage and

Repair or replace the brake disc/drum by processing it
deformation)
6. Rear brake clearance self-adjusting

Adjust or replace it
Brake dragging mechanism (failure)
7. Caliper (loose or misadjusted) Check tightening mechanism of the caliper
It is necessary to dismantle brake caliper and clean it,

8. Caliper (seized or stuck) and apply brake fluid on sliding pin. The brake caliper
should freely slide when pulling it.
9. Brake lining (cracking or deformation) Replace brake lining
10. Brake lining (with oil stains) Clear off it
No clearance exists between the vacuum booster

11. Air valve of vacuum booster (bad air
push rod and the brake master cylinder piston; adjust
tightness and there is air leakage)
clearance to specified value
LIFAN AUTO
51-10 Service Brake-Troubleshooting
Check out cause of too little brake fluid and then

1. Brake fluid (too little)
eliminate the fault; and then add brake fluid
Replace the damaged pipe or tighten the loose

2. Brake line (broken or loose)
connection
Brake failure
3. Brake master cylinder or oil cylinder (seal
Replace sealing elements
part failure)
4. Brake lining (surface with oil stains) Clean or replace the brake lining
5. Mechanical connection part (falling) Check the connection parts
Check if vacuum pipe is broken and that connectors are

1. Vacuum brake booster (failure) loose; confirm that the vacuum booster is faulty, and
then replace it.
Brake pedal force is too
large 2. Vacuum tube (broken or loose) Replace or tighten it
3. Brake master cylinder and brake cylinder

Check and repair it or replace it
piston (seized)
1. B r a k e l i n i n g ( d a m a g e d ; s u r f a c e i s
Replace it
degraded, hardened or damaged)
2. Brake disc (contacting surface is damaged It is necessary to brake disc, brake drum or clean foreign
or has foreign matter) matters.
Abnormal noise or vibration
3. Brake (stuck) Repair it according to situation
occurs in braking
4. Brake caliper (loose installation) Tighten mounting bolts
5. Moving parts in brake (poor lubrication) Add more grease
6. Hub bearing (loose or too large clearance) Replace wheel hub bearing
1. Clearance between left, right wheel brake

Adjust it
friction lining and brake disc (too big)
2. Clearance automatic adjustment mechanism

Repair or replace it
fails or can not work
3. One brake lining (badly worn, hardening,

Replace or adjust it
with poor contact)
4. Some brake lining (with oil or grease) Replace this brake lining
Braking deviation
5. B r a k e d i s c ( s e r i o u s w a r p a g e a n d
Replace it
deformation)
6. Brake cylinder (stuck or failed) This brake caliper should be repaired.
7. Air pressure between the left/right wheel

Inflate the tires to specified air pressure value
tires is too large (large difference)
8. Front wheel alignment (misalignment) or

suspension direction guidance mechanism It is necessary to re-inspect, adjust, repair or replace.
(severely deformed)
LIFAN AUTO
Service Brake-Brake pedal 51-11
Brake pedal
Adjustment
1. Adjust the brake pedal height
(a). Dismantle lower panel assembly of dashboard. (See

Chapter 85 Dashboard and Console - Left Lower Panel of
(b). Disconnect the brake pedal switch connector.
(c). Unscrew locknut of brake pedal switch.
(d). Unscrew the brake pedal switch.
(e). Unscrew locknut of pull rod of vacuum booster. Rotate pull

rod to adjust its length, so as to adjust brake pedal to proper
height.
(f). Tighten the vacuum booster push rod lock nuts.
(g). Mount the brake pedal switch and connect the brake pedal
switch connector.
(h). Push brake pedal 5~15mm downwards, and then rotate
brake pedal switch until brake lamp flames out. Lock it to 51
this position by using lock nut.
(i). After mounting it, the brake lamp shall light up while
depressing the brake pedal for 5~15mm.
LIFAN AUTO
51-12 Service Brake-Brake pedal
Replace
1. Dismantling left lower panel assembly dashboard (See
of Dashboard, Replacement)
2. Remove brake pedal

(a). Disconnect the connector from the stop lamp switch.
(b). Loosen the brake pedal switch lock bolt, and remove the
brake pedal switch.
(c). Check if the brake pedal switch operates normally; if not,
replace it.
• Use the multimeter to test 2 terminals of the brake pedal;
and then check connectivity when pressing down the
releasing the brake pedal switch.
• When pressing switch to more than 4mm, terminals are
not connected; while releasing the switch, terminals are
connected. This indicates that brake pedal switch works
normally.
(d). Dismantle lock pin of connecting axis pin between pull rod
of vacuum booster and brake pedal, and remove axis pin.
(e). Remove the bolt for connecting the brake pedal to the
bracket. Remove the brake pedal.
LIFAN AUTO
Service Brake-Brake pedal 51-13
3. Install brake pedal
(a). Mount the brake pedal onto the pedal bracket and then
mount the connecting bolts.
(b) . Use axis pin to connect pull rod of vacuum booster and
brake pedal, and install lock pin.
△ Hint:
Inspect and adjust height and free stroke of brake pedal.
51
(c). Install adjusting clearance of brake pedal switch, and

tighten lock nut.
(d). Connect brake pedal switch connector.
4. Install left lower panel assembly of dashboard (See
LIFAN AUTO
51-14 Service Brake-Brake master cylinder
Brake master cylinder

Replace
2. Drain brake fluid in brake fluid reservoir and pipeline

(See Chapter 51 Service Brake - Brake Fluid, Drainage)
Attention:
Brake fluid features strong corrosion. Be careful not to splash
brake fluid over skin or vehicle body paint; if brake fluid drops
on skin or vehicle body surface, wash it immediately.
3. Unplug connector of warning lamp switch of lower fluid
level.
4. Remove the brake master cylinder oil pipe
(a). Dismantle inlet pipe of clutch master cylinder and steel

elastic loop clamp of inlet pipe, and disconnect inlet pipe of
clutch master cylinder.
(b). Remove the brake master cylinder outlet oil pipe by an oil
pipe wrench.
Attention:
Mount the brake pipe connector end by a rubber cap or plug to

avoid loss of brake fluid and prevent brake fluid from leading
to pollution.
5. Remove the brake master cylinder with oil pot assembly
(a). Remove the brake master cylinder with 2 retaining nuts.

(b). Pull out brake master cylinder with fluid reservoir assembly.
(c). Drain all brake fluid in fluid reservoir of master cylinder.
LIFAN AUTO
Service Brake-Brake master cylinder 51-15
6. Dismantle brake fluid reservoir.
(a). Clamp and fix brake fluid reservoir on table vice, and use a
punching pin to punch out brake master cylinder and lock
pin of fluid reservoir.
(b) Remove brake fluid reservoir and seal ring.

△ Hint:
Push the brake fluid reservoir upward to facilitate removing of it
from pump body of brake master cylinder, and dismantle seal ring
from the groove of brake fluid reservoir. Inspect whether brake
fluid reservoir has crack or deformation. If necessary, replace brake
fluid reservoir. Use clean alcohol to clean brake fluid reservoir. Use
compressed air without lubricating oil to dry brake fluid reservoir.
51
7. Install brake fluid reservoir.
(a). Apply lubricating oil onto the seal ring of fluid reservoir
and then install it into the brake master cylinder, and install
brake fluid reservoir.
LIFAN AUTO
51-16 Service Brake-Brake master cylinder
(b). Use a punching pin to install lock pin of brake fluid

reservoir.
8. Install brake master cylinder
(a). Mount the brake master cylinder and the pot assembly onto
the vacuum booster and then mount and tighten retaining
nuts.
9. Mount the brake master cylinder oil pipe
(a). Use steel elastic loop clamp to connect inlet pipe of clutch
master cylinder.
(b). Remove the plastic cap or rubber plug and then mount the
brake master cylinder outlet oil pipe and tighten the oil pipe
nuts.
10. Install fluid level warning lamp switch connector.

11. Install air filter with bracket assembly (See Chapter 14
Intake and Exhaust - Air Filter, Replacement)
12. Fill brake fluid and exhaust air from brake system.
LIFAN AUTO
Service Brake-Vacuum booster 51-17
Vacuum booster
Replace
2. Dismantle boosting vacuum pipe.
(a). Dismantle steel elastic loop clamp of boosting vacuum pipe,
and disconnect boosting vacuum pipe.
(b). Remove the check valve from the vacuum booster .
Attention:
Inspect the smoothness of one-way valve.
3. Remove the brake master cylinder oil pipe and the fluid
level warning light switch connector
(a). Drain brake fluid from brake fluid reservoir and pipeline.
Attention:
Brake fluid features strong corrosion. Be careful not to splash
brake fluid over skin or vehicle body paint; if brake fluid drops
on skin or vehicle body surface, wash it immediately.
(b). Unplug fluid level warning lamp switch connector.
(c). Dismantle inlet pipe of clutch master cylinder and steel 51
elastic loop clamp of inlet pipe, and disconnect inlet pipe of
clutch master cylinder.
(d). Remove the brake master cylinder outlet oil pipe connector
by an oil pipe wrench.
Attention:
Mount the brake pipe connector end by a rubber cap or plug to
avoid loss of brake fluid and prevent brake fluid from leading
to pollution.
4. Remove vacuum booster with brake master cylinder
assembly
(a). Dismantle lock pin of connecting axis pin between pull rod
of vacuum booster and brake pedal, and remove axis pin.
(b). Dismantle fixed nuts of connecting bolts between vacuum
booster with brake master cylinder assembly and vehicle
body.
LIFAN AUTO
51-18 Service Brake-Vacuum booster
(c). Take out vacuum booster with brake master cylinder

assembly and pad from engine compartment.
5. Remove the brake master cylinder and the fluid pot.
(a). Remove the retaining nuts of the brake master cylinder

on the vacuum booster and then take off the brake master
cylinder and the fluid pot.
6. Install vacuum booster with brake master cylinder
assembly
(a). Mount the brake master cylinder and the pot assembly onto
the vacuum booster and then mount and tighten fixed bolts.
(b). Mount the vacuum booster with brake master cylinder

assembly and the gasket into the vehicle body from the
engine compartment.
LIFAN AUTO
Service Brake-Vacuum booster 51-19
(c). Mount retaining nuts of the vacuum booster bolts from the
cab and tighten them.
(d). Mount the pin shaft connecting the vacuum booster push
rod and the brake pedal and then mount the lock pin.
7. Mount the brake master cylinder oil pipe and the fluid
level warning light switch connector
(a). Use steel elastic loop clamp to connect inlet pipe of clutch
master cylinder.
(b). Use oil pipe wrench to install outlet hose joint of brake
master cylinder.
(c). Install fluid level warning lamp switch connector.
51
8. Mount the booster vacuum pipes
(a). Mount the vacuum booster check valve.

(b). Connect the booster vacuum pipe by steel strip elastic
hoops.
9. Adjust height and free stroke of brake pedal.
10. Fill brake fluid and exhaust air from brake system.
11. Install air filter with bracket assembly (See Chapter 14
Intake and Exhaust - Air Filter, Replacement)
LIFAN AUTO
51-20 Service Brake-Brake fluid
Brake fluid
Drain 1. Park the vehicle on smooth rod and place transmission
to neutral gear, and start parking brake system.
2. Unscrew brake fluid reservoir cap.

(a). Open engine hood, and pry cowl top grille above brake fluid
reservoir.
(b). Unscrew brake fluid reservoir cap.
3. Drain brake fluid
(a). Make one transparent plastic pipe cover the brake air
bleeding plug and place another end of the pipe into the
brake fluid container.
(b). Loosen the bleeder plug. Depress the brake pedal
continuously several times until no brake fluid flows out.
Attention:
Conduct this operation to each wheel to ensure that all brake
fluid is drained.
Refilling
1. Add brake fluid
(a). Pry cowl top grille above brake fluid reservoir, and unscrew
brake fluid reservoir cap.
LIFAN AUTO
Service Brake-Brake fluid 51-21
(b). Fill brake fluid into brake fluid reservoir, and observe the
height of fluid reservoir level to make sure that brake fluid
level is between maximum and minimum scales.
Brake fluid model: DOT4
Attention:
• Brake fluid should not be used with other model of
brake fluid.
• Brake fluid features strong corrosion. Be careful not
to splash brake fluid over skin or vehicle body paint; if
brake fluid drops on skin or vehicle body surface, wash
it immediately.
Exhaust
△ Hint:
If air enters the brake system when repairing and replacing the brake parts, carry out all bleeding procedures. Before
bleeding the brake, the front and rear bleeding cylinder piston must return to the highest position; preferred method is
to use a fault diagnostic scanner to conduct the returning procedures. If the fault diagnostic scanner can not be used, use
the second procedure; conduct the diagnosis in strict accordance with steps specified. If air enters due to low fluid level
or disconnection of brake pipe of master cylinder, it is necessary to drain all 4 brake hydraulic systems; if brake hose or
brake is disconnected on some wheel, drain air from this wheel brake caliper; if brake pipe or hose is disconnected on
any joint between master cylinder and brake, it is necessary to drain brake system related to this disconnected pipe or
hose.
1. Manual air exhaust of brake oil pipe.
(a). Lift up the car to proper height. 51

(b). Mount the transparent plastic exhaust hose onto the brake
caliper bleeding plug.
(c). Immerse one end of transparent plastic exhaust hose into
the container containing clean brake fluid.
(d). Depress the brake pedal several times, and then keep
depressing it; loosen the bleeding bolt.
(e). When brake fluid stops flowing out, tighten air valve bolt
and release brake pedal.
(f). Repeat (d) and (e) until all air in brake fluid is released.
(g). Repeat above steps. Exhaust air from wheel brake caliper
according to the sequence of rear right - rear left - front
right - front left.
Attention:
During exhausting, inspect whether brake fluid level in brake
fluid reservoir is lower than minimum scale. If necessary, fill
brake fluid.
LIFAN AUTO
51-22 Service Brake-Front brake
Front brake
Components diagram
1 Front brake disc 6 Hexagon bolt with flange
2 Front wheel hub assembly 7 Front brake caliper assembly
3 Front brake bottom plate assembly 8 Front external brake lining
4 Steering knuckle 9 Front internal brake lining
5 Hexagon bolt with flange
LIFAN AUTO
Service Brake-Front brake 51-23
Replace
2. Remove the front brake caliper
(b). Remove the front brake line hollow bolt and take off the
seal ring; and then move away the brake hose.
△ Hint:
If it is impossible to replace the brake caliper assembly, do not cut
the brake hose in the brake caliper.
(c). Fix the front brake caliper sliding pin by a wrench, remove
the brake caliper fixed bolts and take off the front brake
caliper.
△ Hint:
When the caliper is being removed from the brake caliper bracket
and the brake hose still keeps connecting, prop up the brake caliper
by a thick steel wire or equivalent tool. Otherwise, the brake hose
may carry weight of the brake fluid so that the brake hose might be
damaged, leading to brake fluid leakage.
(d). Remove brake friction lining from brake caliper bracket,
and inspect the thickness of brake friction lining to confirm
whether it requires to be replaced.
△ Hint:
Measure thickness of the brake lining; beyond wear limit, replace
the brake lining.
51
(e). Dismantle fixed bolts of brake caliper bracket, and remove

brake caliper bracket from steering knuckle.
LIFAN AUTO
3. Remove the front brake disc
(a). Remove the front brake disc from the front wheel hub;
Check if the brake is required to be changed.
△ Hint:
In the process of removal, insert the bolt into the brake disc bolt
hole and push the bolt out.
4. Remove the front brake caliper sliding pin
(a). Take out the sliding pin from the brake caliper bracket.
(b). Remove the sliding pin dust cover from the front brake
caliper bracket.
5. Dismantle the brake caliper.
(a). Pry out the brake cylinder dust cover fixed ring by a
screwdriver and take off the dust cover.
Attention:
Before using the screwdriver, wrap it in the end of it by tape.
LIFAN AUTO
(b). Lay a wooden block between piston of brake caliper and

brake cylinder.
(c). Blow the piston out of the brake cylinder by compressed air.
Warning:
Do not place fingers in the front of piston when blowing
compressed air.
Attention:
Do not let brake fluid spray out.
(d). Remove oil seals from the brake cylinder by a screwdriver.

Attention:
Replace oil seals after removal of oil seal.
(e). Check cylinder wall and piston for rust or scratch; carry out
necessary replacement.
51
6. Install brake caliper
(a). Smear grease on new piston oil seal; mount it inside the
brake cylinder.
LIFAN AUTO
(b). Apply lubricating oil to upper dustproof sleeve of brake

piston sleeve and install it into brake cylinder hole. And
slowly press piston down to the bottom of brake cylinder.
Attention:
Do not screw the piston into the brake cylinder forcedly.
(c). Mount the brake cylinder dust cover onto the brake cylinder.
△ Hint:
Mount the dust cover stably in the brake cylinder and the piston
groove.
(d). Mount the dust cover retaining rings by a screwdriver.
Attention:
· Be careful not to damage the brake cylinder dust cover.
· The retaining ring should be fixed onto the brake

cylinder dust cover.
7. Mount the front brake caliper bracket
(a). Smear grease on the front brake caliper bracket sliding pin
dust cover, and then mount the front brake caliper.
(b). Mount 2 sliding pins of the front brake caliper.
LIFAN AUTO
(c). Mount the front brake disc onto the front wheel hub.
Attention:
No oil stains should exist in contacting surface between the
brake disc and the brake lining.
(d). Mount the brake caliper bracket onto the front steering
knuckle; mount and tighten fixed bolts.
51
8. Mount the brake lining
(a). Mount the brake lining onto the mounting position in the
both sides of the brake caliper bracket.
Attention:
LIFAN AUTO
9. Mount the front brake calipers
(a). clamp brake caliper onto brake pad on both sides, and use
wrench to fix sliding pin of front brake caliper, and install
fixed bolts of brake caliper and tighten them.
(b). Mount the front brake hose hollow bolts and the seal bolts.
(c). Mount the front wheels

(d). Add brake fluid, and bleed the brake system.
LIFAN AUTO
Service Brake-Rear brake 51-29
Rear brake
Components diagram
51
1 Rear brake disc 5 Rear external brake lining
2 Rear wheel hub assembly 6 Rear internal brake lining
3 Hexagon bolt with flange 7 Rear brake caliper assembly
4 Rear brake mudguard 8 Hexagon bolt with flange
LIFAN AUTO
51-30 Service Brake-Rear brake
Replace
1. Lift up the vehicle, and remove rear wheels
2. Dismantle rear brake caliper
(b). Dismantle rear end cable of parking brake from rear brake,
and remove return spring.
(c). Remove the rear brake hose hollow bolt and the seal oil;
and then move away the brake hose.
△ Hint:
If it is impossible to replace the brake caliper assembly, do not cut
the brake hose in the brake caliper.
(d). Fix the rear brake caliper sliding pin by a wrench, remove
the brake caliper fixed bolts and take off the rear brake
caliper.
△ Hint:
When the caliper is being removed from the brake caliper bracket
and the brake hose still keeps connecting, prop up the brake caliper
by a thick steel wire or equivalent tool. Otherwise, the brake hose
may carry weight of the brake fluid so that the brake hose might be
damaged, leading to brake fluid leakage.
(e). Remove brake friction lining from brake disc, and inspect
the thickness of brake friction lignin to confirm whether it
requires to be replaced.
LIFAN AUTO
(f). Take out two sliding blocks of a holder.
(g). Remove the brake caliper bracket fixed bolts and take out
the brake caliper bracket.
51
3. Remove the rear brake disc
(a). Remove the rear brake disc from the rear wheel hub; heck if
the brake is required to be changed.
△ Hint:
In the process of removal, insert the bolt into the brake disc bolt
hole and push the bolt out.
LIFAN AUTO
4. Remove the rear brake caliper sliding pin
(a). Take out the sliding pin from the brake caliper bracket.
(b). Remove the sliding pin dust cover from the front brake
caliper bracket.
5. Dismantle rear brake caliper
(a). Remove the rear brake caliper parking brake cable bracket
retaining nut and the inner hex bolt; take out the brake cable
bracket.
(b). Use screwdriver to pry fixed ring of dustproof sleeve of

brake cylinder, and remove dustproof sleeve.
Attention:
Before using the screwdriver, wrap it in the end of it by tape.
LIFAN AUTO
(c). Rotate the piston out of the brake cylinder.
(d). Remove oil seals from the brake cylinder by a screwdriver.

Attention:
Replace oil seals after removal of oil seal.
(e). Check cylinder wall and piston for rust or scratch; carry out
necessary replacement.
51
6. Install rear brake caliper.
(a). Smear grease on new piston oil seal; mount it inside the
brake cylinder.
LIFAN AUTO
(b). Apply lubricating oil to brake piston and install it onto the
brake cylinder, and rotate and install it into brake cylinder
hole.
(c). Smear grease on the brake cylinder dust cover and mount it
onto the brake cylinder.
△ Hint:
Reliably install dustproof sleeve into the groove of brake cylinder
and piston.
(d). Use a screwdriver to mount retaining rings.
Attention:
Wrap the screwdriver end by cloth. Be careful not to damage
the brake cylinder dust cover.
(e). Install parking brake cable bracket and fixed bolts and
tighten them.
LIFAN AUTO
7. Mount the rear brake caliper bracket
(a). Smear grease on the rear brake caliper bracket sliding pin
dust cover, and then mount the rear brake caliper.
(b). Mount 2 sliding pins of the rear brake caliper.
(c). Mount the rear brake disc onto the rear wheel hub.
Attention:
51
(d). Mount the brake caliper bracket and then mount and tighten
fixed bolts.
LIFAN AUTO
8. Mount the brake lining

(a). Mount the brake lining holder sliding block.
(b). Install brake friction lining onto the mounting positions on

both sides of rear brake bracket.
Attention:

9. Install rear brake caliper.
(a). Fasten the brake caliper on the brake lining in both sides of
brake lining; mount the rear brake caliper sliding pin by a
wrench; mount and tighten fixed bolts of brake caliper.
(b). Mount the rear brake hose hollow bolts and the seal rings.
LIFAN AUTO
(c). ”Mount the brake backend cable and the return spring.
(d). Mount the rear wheel.
(e). Add brake fluid, and bleed the brake system. (See Chapter
51 Serve Brake - Brake Fluid, Exhaust)
51
LIFAN AUTO
51-38 Service Brake-Brake line
Brake line
Replace
1. Remove the front brake hose
(a). Drain the brake fluid.

(b). Remove the front brake hose hollow bolts and the seal
rings.
(c). Remove fixed bolts between the front brake line and the
wheel speed sensor wiring harness bracket
(d). Remove the oil pipe connector nuts by an oil pipe wrench
and then unplug the front brake line E-type clip and then
take off the front brake oil pipe.
2. Mount the front brake line.
(a). Make the front brake oil pipe pass through the body
mounting bracket and mount the E-type clip to fix the oil
pipe.
(b). Tighten the oil pipe connector nut.
Torque: 14 ~ 8N•m
(c). Mount fixed bolts between the front brake line and the
wheel speed sensor wiring harness bracket, and then mount
and tighten fixed bolts.
(d). Mount the front brake hose hollow bolt and the seal ring
onto the brake, and then tighten the hollow bolt.
(e). Install front wheel.

(f). Fill brake fluid, and exhaust air from brake system.
LIFAN AUTO
Service Brake-Brake line 51-39
3. Remove the rear brake oil pipe
(a). Drain the brake fluid.

(b). Remove the rear brake hose hollow bolts and the seal bolts.
(c). Remove the oil pipe connector nuts by an oil pipe wrench
and then unplug the E-type clip and then take off the rear
brake hose.
51
4. Mount the rear brake line.
(a). Connect the brake hoses and tighten the oil pipe connector
nut.
Torque: 14 ~ 8N•m
(b). Mount the E-type clip to fix oil pipe.
LIFAN AUTO
51-40 Service Brake-Brake line
(c). Mount the rear brake hose hollow bolt and the seal ring
onto the rear brake, and then tighten the hollow bolt.
(d). Install front wheel.

(e). Add brake fluid, and bleed the brake system. (See Chapter
51 Serve Brake - Brake Fluid, Exhaust)
LIFAN AUTO
Parking brake
Parking brake............................................................. 52-1

Preparation............................................................. 52-1
Precautions............................................................. 52-1
Parking brake control................................................ 52-5
Check...................................................................... 52-5
Replace................................................................... 52-5
Adjustment........................................................... 52-12
52
LIFAN AUTO
Parking Brake-Parking brake 52-1
Parking brake
Preparation
Remove locking plate in the

1 Needle-nose pliers
parking brake cable rear end
Item N•m
Parking brake cable fixed bolt 6~12
Parking brake lever fixed bolt 6~12
Console bracket fixed bolt 6~12
Precautions
1. Inspect and adjust parking brake under normal brake condition. 52

2. Be careful when replacing any part. Use of incorrect part could affect the performance of the parking brake
system and cause danger.
3. Before Checking the parking brake system, stop the vehicle on level ground and secure the wheels with triangle
wood blocks.
4. Removed snap-fit and cable tie should not be used again.
5. The parking brake cable is provided with a plastic jacket, requiring no periodical lubrication.
6. It is necessary to conduct regular inspection and inspect once every 10000km.
• Check the function of the parking brake.
• Inspect parking brake control rod stroke.
• Check the connections for looseness.
• Check that the parking brake system operates normally.
LIFAN AUTO
52-2 Parking Brake-Parking brake
Components diagram
1 Hexagonal flange bolt 6 Hexagon bolt with flange
2 Left parking brake cable assembly 7 Hex thin nut
3 Left parking brake cable assembly 8 Hexagon bolt and plain washer assy.
4 Front/ rear cable bracket 9 Parking brake
5 Front end components of parking brake cable. 10 Parking brake control rod assembly
LIFAN AUTO
Parking Brake-Parking brake 52-3
System description
1. General overview
Parking brake is a remote mechanical control type. Control handle of parking brake control mechanism is
installed inside driver's cab and connected by manual brake cable to conduct remote control.
When vehicle is braking, driver pull up parking brake control rod to parking position, to make brake friction
lining supported on the surface of brake disc, so as to produce friction and achieve parking brake function.
2. Main purposes of the parking brake system:
(a). Securely park the vehicle on a slope so that the vehicle can start without difficulty.
(b). Stop the vehicle when the service brake fails, or in emergency stop the vehicle in conjunction with the service
brake.
On-Vehicle check
1. Parking lever stroke
(a). Pull up parking brake control rod with 100N force to ensure
that pawl is in the specified range.
Standard value: 5~8 teeth
△ Hint:
A tick sound can be heard when one tooth is passed through.
Inspect it by calculating tick sound of pawl.
2. Check parking brake performance
(a). If the service brake operates normally, depress the brake
pedal to stop the vehicle on a slope, then apply the parking
brake.
(b). Slowly rise up brake pedal and inspect whether the
vehicle has falling condition. If any, adjust parking brake.
(See Chapter 52 Parking Brake - Parking Brake Control, 52
Adjustment)
3. Parts inspection
(a). Check that each part is securely fixed.
(b). Check whether parking brake control rod assembly has bending, damage or crack. If any, replace the lever.
(c). Check whether parking brake cable has abrasion and damage. If any, replace the cable.
4. Check switch of parking brake indicator lamp
(a). Check if the parking brake warning lamp switch works normally. Check or replace the switch if it does not
operate normally.
• When parking brake control rod is pulled up, parking brake indicator will light up.
• When parking brake control rod is lower down, parking brake indicator will flame out.
LIFAN AUTO
52-4 Parking Brake-Troubleshooting
Troubleshooting
these parts.
1. Indicator light (damaged) Check and replace the instrument cluster

Indicator light stays
constantly bright or fails to 2. Parking brake switch (damaged) Replace.
illuminate
3. Wire harness (open circuit or short circuit) Inspect wire harness
1. Cable connecting plate (damaged) Replace.

Insufficient braking force or
2. Lock nut (thread sliding) Replace.
braking failure
3. Braking distance (too large) Replace the friction lining
1. Pull rod spring of parking brake control rod (invalid

Replace the parking brake lever
or broken)
Parking brake control rod
2. Pawl and pawl tooth of parking brake control rod
can’t be positioned. Replace the parking brake lever
(excessive abrasion)
3. Parking brae control rod (deformed) Replace the parking brake lever
LIFAN AUTO
Parking Brake-Parking brake control 52-5
Parking brake control

Check
1. Check that button moves freely. If button cannot move
back, replace it.
2. Inspect whether pawl of parking brake control rod has
abrasion.
Replace
1. Remove console (See chapter 85, Dashboard and

Console - Dashboard , Replacement)
2. Pull up the parking brake lever, and disconnect the
brake lamp switch connector.
52
3. Dismantle the front section of parking brake cable.

(a). Place the parking brake lever to the lowest position.
(b). Remove the adjusting nut and lock nut at the front end
of parking brake cable.
LIFAN AUTO
52-6 Parking Brake-Parking brake control
(c). Disconnect parking brake cable from parking brake control

rod.
△ Hint:
Pull up parking brake control rod to facilitate separation of front
stud section of cable from control rod.
4. Dismantle front/ rear cable bracket.
(a). Dismantle fixed bracket of console.
(b). Remove the front section of parking brake cable from front/
rear cable bracket.
(c). Rotate cable assembly outwards to 90° to opening of front/
rear cable bracket.
(d). Remove front/ rear cable bracket.
LIFAN AUTO
5. Dismantle parking brake control rod.
(a). Dismantle fixed bolts of parking brake control rod, and

remove parking brake control rod assembly.
6. Dismantle parking brake left, right cable assembly.
(a). Rise up and support vehicle.

(b). Dismantle rear tire and wheel assy.
(c). Separate cable from rear brake caliper.
52
(d). Press lock plate at the end of parking brake cable, and
separate the rear section of parking brake cable from
bracket.
LIFAN AUTO
(e). Dismantle fixed bolts of parking brake cable on rear

overhang.
(f). Dismantle muffler and heat insulator. (See Chapter 14

Intake and Exhaust System - Muffler, Replacement)
(g). Dismantle fixed bolts of parking brake cable.
(h). Dismantle all fixed bolts of the bracket of parking brake
cable on the chassis, and remove left, right parking brake
cable.
7. Install parking brake left, right cable assembly.
(a). Make the front end of left and right parking brake cable
pass through mounting hole at the bottom of chassis and
install in under the bottom of vehicle body, and install fixed
bolts and tighten them.
Torque: 6~12N•m
(b). Install other fixed bolts of left, right parking brake cable,
and fix it onto the chassis of vehicle body.
LIFAN AUTO
(c). Install fixed bolts of parking brake cable on rear overhang.
(d). Make left, right parking brake cables pass through bracket
hole of rear brake caliper and install it onto the rear brake
caliper. And use calipers to separate lock plate outside and
fix it onto the bracket.
(e). Install the rear wheels.
52
8. Install parking brake control rod assembly.
(a). Install parking brake control rod and fixed bolts, and tighten
fixed bolts.
Torque: 6~12N•m
LIFAN AUTO
(b). Install the front section of parking brake cable onto the
parking brake control rod.
(c). Install flange adjusting nut and locknut.
△ Hint:
Make sure the exposed distance of nut L = 10±2mm.
9. Install front/ rear cable bracket.

(a). Front/ rear cable bracket to the front section of parking
brake cable and left, right parking brake cables.
△ Hint:
While installing, lay the parking brake control rod to the lowest
position to facilitate installation.
(b). Install fixed bracket and fixed bolts of console.

Torque: 6~12N•m
LIFAN AUTO
10. Install brake light switch connector.
(a). Pull up parking brake control rod, and install brake light
switch connector.
11. After installation, adjust parking brake. (See Chapter
52Parking Brake - Parking Brake Control, Adjustment)
12. Install console (See chapter 85, Dashboard and Console
- Console , Replacement)
52
LIFAN AUTO
Adjustment
Attention:
As long as the rear brake cable is disconnected, the parking brake cable system must be adjusted manually.
1. Adjust parking brake control

(a). Remove the console. (See chapter 85, Dashboard and
Console - Console , Replacement)
(b). Remove the lock nut with the parking brake lever at the
lower position.
(c). Make sure that the front section of parking brake cable
exposes adjusting nut distance L=10±2mm.
(d). After adjustment, pull up parking control rod with 100N

force vertical to control rod. This force can pull up 5~8
teeth; otherwise, re-adjust flange nut to adjust the length of
L.
△ Hint:
• Detailed adjusting method: if less than 8 teeth are pulled up,
reduce L value; if more than 8 teeth are pulled up, increase
L value.
• A tick sound can be heard when one tooth is passed through.

Inspect it by calculating tick sound of pawl.
LIFAN AUTO
Anti-lock braking system.......................................... 53-1

Preparation............................................................. 53-1
Precautions............................................................. 53-2
System components................................................ 53-3
Hydraulic schematic diagram................................. 53-4
Wiring diagram....................................................... 53-5
Terminal definition................................................. 53-7
Preliminary inspection items.................................. 53-8
Diagnostic steps.................................................... 53-10
ABS diagnostic description.................................. 53-10
DTC (DTC) list.................................................... 53-14
C190004,C190104............................................... 53-18
C001004, C001104, C001404, C001504, C001804,
C001904, C001C04, C001D04, C109504,
C007208..........................................................53-18
C002004............................................................... 53-19
C003200, C00A000, C00A100, C00A900, C003500,
C00A200, C00A300, C00AA00, C003800, C00A400,
C00A500, C00AB00, C003B00, C00A600, C00A700,
C00AC00, C109904 - WSS circuit has fault........ 53-19
C003108, C00A900, C003408, C00AA00, C003708,
C00AB00, C003A08, C00AC00, C109904 ........ 53-20
C100004, C101008.............................................. 53-21
U000500, U000700, C100104, U000104, 53
U100104.. ................................................... 53-21
C006B06 ............................................................. 53-21
ABS indicator light stays constantly bright or fails to
illuminate.............................................................. 53-22
Wheel speed sensor.................................................. 53-23
Replace................................................................. 53-23
ABS hydraulic regulator......................................... 53-26
Cross validation.................................................... 53-26
Replace................................................................. 53-26
ABS artificial exhaust.............................................. 53-29
LIFAN AUTO
Anti-lock Braking System-Anti-lock braking system 53-1

Preparation
1. Special tool
1 Diagnostic scanner ABS system fault diagnosis
Tire type 205/55R16
Item N•m
Fixed bolts of ABS assembly 20~25
53
LIFAN AUTO
53-2 Anti-lock Braking System-Anti-lock braking system
Precautions
1. Only technicians who received professional training and are familiar with repair skills can repair the ABS
system. Only original parts can be used for replacement.
2. If the basic brake system has faults, these faults should be eliminated firstly before diagnosis of the ABS
system, such as:
(a). Brake system noise.
(b). Tough operation of brake pedal
(c). Brake pedal or the car vibrates in normal braking operation.
(d). Braking deviation
(e). Parking brake system malfunctions.
3. ABS assembly (including ABS electronic control unit and hydraulic regulator assembly, excluding
auxiliary devices, such as brake line and sensor attachments) must be replaced completely in doing so; do
not repair it or replace it partially or interchange it. LIFAN will not provide individual spare parts and
doesn't guarantee repair for detached ABS assembly, and won't take any responsibility for consequence
after detachment, or partly replacing/ interchanging ABS hydraulic adjuster.
4. The following two cases indicate that ABS system faults have been detected:
(a). Turn on the ignition switch, system self-test is completed, the ABS warning light illuminates.
(b). ABS warning light remains lit in driving the car.
Warning:
The driver may conduct normal braking operation now, but should minimize braking force to avoid locking up
the wheels. After the warning light illuminates, you should drive carefully and immediately go to a service station
authorized by LIFAN for the check and repair to avoid more failures and traffic accidents.
5. You need to pay attention to the following points in connecting/disconnecting ABS sensor wiring harness:
(a). Before removing the ABS wiring harness and the sensor wiring harness, turn the ignition switch to OFF and
disconnect the battery negative terminal.
(b). Confirm that connectors are dry and clean; prevent any foreign matter from entering.
(c). ABS wiring harness connectors must be mounted vertically and horizontally to avoid damaging connectors.
6. Ensure correct connection when connecting ABS braking pipes. The ABS ECU can not judge whether the
brake line is connected correctly or not. Wrong connection might cause serious accident. Always conform
to marks on the ABS assembly when connecting the brake line:
(a). MC1: Connect brake line 1 of the brake master cylinder.
(b). MC2: Connect brake line 2 of the brake master cylinder.
(c). FL: Connect brake line of the front left wheel brake wheel cylinder
(d). FR: Connect brake line of the front right wheel brake wheel cylinder
(e). RL: Connect brake line of the rear left wheel brake wheel cylinder
(f). RR: Connect brake line of the rear right wheel brake wheel cylinder
7. ABS may generate noise in the following cases:
(a). When the vehicle is being electrified or the engine is being started, it may emit short time noise "buzz", which is
sound of the ABS in self-test and is a normal phenomenon.
(b). When ABS is working normally, sound comes from the following sources:
• Sound generates when the motor, solenoid valve and the reflux pump are operating.
• The brake pedal may generate sound in rebounding.
• Sound of impacting between the suspension and the vehicle body due to emergency brake.
LIFAN AUTO
System components
53
ABS hydraulic adjusting module equipped with

1 Wheel speed sensor 2
electric control unit
LIFAN AUTO
Hydraulic schematic diagram

LF720 ABS system uses X-type arrangement. ABS hydraulic regulator consists of electric motor, 2 reflux pumps, 2
accumulators and 8 electromagnetic valves.
MC1 First circuit of brake master cylinder RR Rear right wheel
MC2 Second circuit of brake master cylinder FLEV Oil inlet valve of front left wheel
M Motor FLAV Oil outlet valve of front left wheel
RP1 Reflux pump 1 FREV Oil inlet valve of front right wheel
RP2 Reflux pump 2 FRAV Oil outlet valve of front right wheel
A1 Accumulator 1 RLEV Oil inlet valve of rear left wheel
A2 Accumulator 2 RLAV Oil outlet valve of rear left wheel
FL Front left wheel RREV Oil inlet valve of rear right wheel
FR Front right wheel RRAV Oil outlet valve of rear right wheel
RL Rear left wheel
LIFAN AUTO
53
53-5
ABS power supply, ground, data line

5-loop fuse box Driver compartment
central control box
Anti-lock Braking System-Anti-lock braking system
LIFAN AUTO
Motor power supply Solenoid valve relay IG1 PWR
power supply
Brake signal
Wiring diagram
Brake lamp switch CAN system
ABS sensor
signal power supply signal power supply signal power supply signal power supply
Anti-lock Braking System-Anti-lock braking system
LIFAN AUTO
Front left wheel speed sensor Front right wheel speed sensor Rear left wheel speed sensor Rear right wheel speed sensor
53-6
Terminal definition
Terminal Terminal
Color Function table Color Function table
No. No.
1 R Power supply of motor 20 - -
2 - - 21 - -
3 - - 22 - -
Front right wheel speed sensor

4 GB 23 - -
signal
5 - - 24 - -
6 - - 25 R Valve relay power supply
7 - - 26 W CAN_H
Front left wheel speed sensor

8 YB 27 - -
signal
9 - - 28 RW ECU power supply
Rear right wheel speed sensor

10 - - 29 BrB
signal
11 - - 30 GrG Brake lamp switch
Power supply of rear left wheel

12 - - 31 O
speed sensor 53
13 B Motor ground 32 - -
14 WB CAN_L 33 - -
15 - - 34 - -
Power supply of front right

16 G 35 - -
wheel speed sensor
Power supply of rear right wheel

17 Br 36 - -
speed sensor
Rear left wheel speed sensor

18 OB 37 - -
signal
Power supply of front left wheel

19 Y 38 B ECU ground
speed sensor
LIFAN AUTO
System description
1. ABS system is used to avoid off-tracking of wheels when braking on wet and sliding road. This helps to
ensure stability and steering performance of vehicle under above conditions.
2. When the anti-lock braking system is functioning, you may feel the pulsation of the brake pedal and can
hear the noise; in this case, depressing brake pedal with heavy force may activate the antilock braking
system.
3. With car speed above 15km/h, the ABS is in the working status; with car speed below 15km/h, the ABS is
deactivated.
4. When the ABS is working, the following conditions may occur, which does not mean fault:
(a). When you hear the operation sound of the ABS and feel the vibration of the brake pedal, the vehicle body and
the steering wheel, You still may hear motor sound from the engine compartment even if the car stops.
(b). When the ABS operation is completed, the brake pedal might move forward a little.
Preliminary inspection items

△ Hint:
Before diagnosing ABS system, first inspect parts which are easy to cause ABS system fault. Appearance inspect steps
can quickly determine fault. Hence it is unnecessary to conduct further diagnosis.
1. Make sure that only tires and wheel hubs with
recommended sizes are installed on the vehicle. Pattern
and depth of the tires with the same shaft must be the
same.
2. 3.12 Check ABS hydraulic regulator and brake lines and connectors for leakage
3. 3.13 Check the ABS system fuses, and ensure that the fuse is not burned and its model is correct The ABS
system has three kinds of fuses, as following:
Pump motor fuse: 40A
Solenoid valve fuse: 25A
Electronic control unit fuse: 5A
4. Check if the battery is fully charged, and check the battery connection for corrosion and the terminals for
looseness. ABS system’s normal operating voltage range is 9. 3V ~16. 8V.
5. Check if the ABS ground wire’s grounding point is loose, and that ground location is changed
6. ABS grounding wire must have good air tightness performance to avoid losing function resulting from
water and moisture ingress into the ABS ECU connectors from the hole of the wiring harness due to
siphonage.
7. Check the following electrical parts visually and their appearance:
LIFAN AUTO
(a). Check if ABS parts harness and terminals are properly connected and damaged due to clamping or cutting.
(b). Check if the wiring harness is arranged close to any device with high voltage or big current, such as high voltage
power supply or parts, generator, electric motor, or additionally-installed stereo amplifier after purchasing the car.
Attention
Devices with high voltage or big current might cause circuit to generate induced noise, consequently interfering
with the normal working of the circuit.
(c). ABS parts is sensitive to electromagnetic interference (EMI). If an intermittent fault is in doubt, inspect whether
after-sale optional anti-theft device, lamps and mobile telephone are improperly installed.
8. ABS is an active safety system. Its main function is to make full use of ground adhesion to keep the car
controllable and stable in running. But when traveling with speed exceeding physical limit or on wet and
sliding road, ABS can't completely prevent sliding movement of vehicle.
9. If ABS noise is too loud, it may be caused by the following reasons:
(a). The bracket between the ABS assembly and the ABS is loose.
(b). Connection between the ABS bracket and the car vehicle is loose.
(c). Plastic washers in the ABS bracket are missed or damaged.
53
LIFAN AUTO
53-10 Anti-lock Braking System-Troubleshooting
Troubleshooting
Diagnostic steps
1. Read the DTC

(a). If there is DTC, go to step 3.
(b). If there is no DTC, go to step 4.
2. Record the DTC, and then clear the DTC
3. Confirm and reproduce the failure: with car speed above 15km/h, simulate the fault occurrence state and
read the DTC again.
4. If no DTC exists, go to step 7.
5. Conduct the troubleshooting according to DTCs table; and then go to step 7
6. Eliminate fault according to fault symptom; and then go to step 7
7. Confirm that the fault is eliminated; and then the system works again.
8. The diagnosis ends
ABS diagnostic description
The wheel speed sensor mounted on the wheels collects wheel speed signal and sends it to the ECU to calculate the
wheel speed and further calculate the car deceleration speed and the sliding rate of wheels. ABS electric control unit
based on calculated parameters and through hydraulic control unit, adjust brake pressure during braking, to achieve ABS
function. Each time when the ignition switch is turned on, ABS may conduct self-test; if any fault is found, ECU may
automatically interrupt the ABS function and illuminate the ABS warning light. Now the brake system will work as if
no ABS system is equipped.
Read and clear DTCs

1. Use the diagnostic scanner to read the diagnostic DTC
(DTC)
(a). Connect the LIFAN V30 diagnostic tester to the diagnostic

interface.
LIFAN AUTO
Anti-lock Braking System-Troubleshooting 53-11
(b). Turn on the diagnosis tester, and enter into "Chongqing

Series selection
LIFAN Dedicated Others
Chongqing LIFAN
System
Help About Power off
configuration
"OK".
Demo
OK
Cancel
Software of this version can test the engine, transmission,
ABS, airbag and anti-theft system of Lifan.
53
(d). Select and enter "ABS".
Chongqing LIFAN LIFAN Dedicated\Chongqing Lifan\V5.0\

Anti-theft system
Vehicle body system
A/C System
Return
LIFAN AUTO
(e). Select "ABS system (BOSCH ABS9 720 CAN)
ABS LIFAN Dedicated\Chongqing LIFAN\V5.0\ABS

ABS (Wanxiang) Previous page
ABS (APG)
ABS (TRW) Next page
ABS (Mando MGH25)
ABS (BWI DBC78) Print
ABS (BOSCH ABS9 720 CAN)

Return
ABS (BOSCH ABS9 520K)
(f). Click and select "Read DTC".

△ Hint:
ABS (BOSCH ABS9.0) LIFAN Dedicated\Chongqing LIFAN If any previous DTC exists in the diagnostic scanner, firstly you
Read DTC Previous page
should clear off it before reading.
Clear DTC
Artificial exhaust function
Print
Return
(g). Read and record the displayed diagnostic DTCs.
Fault code list

ECU supply voltage is high
Previous Next page Help Print Return

page
LIFAN AUTO
(h). If no DTC is found, select "OK" to return.
Information
Fault code not found!

OK
2. Clearing of DTCs
(a). Click "Clear DTC" to clear off DTC.

ABS (BOSCH ABS9.0) LIFAN Dedicated\Chongqing LIFAN

Clear DTC
Print
Return
53
(b). Select "OK" to clear off DTCs.
△ Hint:
Information
Information If the DTC cannot be removed, it is an indication that the fault has
Do you want to clear all the fault codes?
not been troubleshooted. You should remove the fault based on the
OK DTC before trying to remove the DTC again.
Cancel
LIFAN AUTO
DTC (DTC) list

Attention:
DTC (DTC) DTC description Suspected Area
• Battery
C190004 ECU supply voltage is high
• ABS ECU
• Battery voltage
C190104 Too low voltage in ECU power supply
• ABS ECU
ECU failure (hardware, microprocessor

C100004 • ABS ECU
failure)
C101008 ECU failure (software error) • ABS ECU
Unreasonable ABS control (too long control • Wheel speed sensor and ring gear
C006B06
time) • ABS ECU
• Front left wheel speed sensor

Front left wheel speed sensor signal fault:
C003108 out of range; missed; noisy; intermittently • Wheel speed sensor wiring
interrupted
• Front left wheel speed sensor signal wheel
Front left wheel speed sensor wiring fault:

C003200 • Wheel speed sensor wiring
open-circuit
Front left wheel speed sensor wiring fault:

C00A000 • Wheel speed sensor wiring
short-circuited to ground
front left wheel speed sensor wiring fault:

short-circuited to power supply
• Front left wheel speed sensor

front left wheel speed sensor fault: fault cause
is impossible to be detected
• Front left wheel speed sensor signal wheel
• Front right wheel speed sensor

front right wheel speed sensor signal fault:
interrupted
• Front right wheel speed sensor signal wheel
Front right wheel speed sensor wiring fault:

open-circuit


• Front right wheel speed sensor

Front right wheel speed sensor fault: fault
C00AA00 • Wheel speed sensor wiring
cause is impossible to be detected
• Front right wheel speed sensor signal wheel
• Rear left wheel speed sensor

Rear left wheel speed sensor signal fault:
interrupted
• Rear left wheel speed sensor signal wheel
Rear left wheel speed sensor wiring fault:

open-circuit
LIFAN AUTO
DTC (DTC) DTC description Suspected Area


• Rear left wheel speed sensor

Rear left wheel speed sensor fault: fault cause
C00AB00 • Wheel speed sensor wiring
is impossible to be detected
• Rear left wheel speed sensor signal wheel
• Rear right wheel speed sensor

Rear right wheel speed sensor signal fault:
C003A08 out of range; missed; noisy; intermittently • Wheel speed sensor wiring
interrupted
• Rear right wheel speed sensor signal wheel
Rear right wheel speed sensor wiring fault:

C003B00 • Wheel speed sensor wiring
open-circuit


• Rear right wheel speed sensor

Rear right wheel speed sensor fault: fault
C00AC00 • Wheel speed sensor wiring
cause is impossible to be detected
• Rear right wheel speed sensor signal wheel
Wheel speed sensor group failure (wheel • Wheel speed sensor

speed sensor interchangeable, each wheel
speed difference is too large, several wheel
speed sensors malfunction) • Wheel speed sensor signal wheel
• ABS ECU
U000500 CAN bus voltage is too high.
• CAN bus
• ABS ECU
U000700 CAN bus voltage is too low.
• CAN bus
• ABS ECU
C100104 CAN hardwire has fault
• CAN bus 53
• ABS ECU
U000104 CAN bus is turned off
• CAN bus
• ABS ECU
U100104 CAN negative error
• CAN bus
• Front left inlet fluid valve

C001004 Front left fluid inlet valve is defective
• ABS ECU
• Front left outlet fluid valve

C001104 Front left fluid outlet valve is defective
• ABS ECU
• Front right inlet fluid valve

C001404 Front right fluid inlet valve is defective
• ABS ECU
LIFAN AUTO
DTC (DTC) DTC description Suspected area
• Front right outlet fluid valve

C001504 Front right fluid outlet valve is defective
• ABS ECU
• Rear left inlet fluid valve

C001804 Rear left fluid inlet valve is defective
• ABS ECU
• Rear left outlet fluid valve

C001904 Rear left fluid outlet valve is defective
• ABS ECU
• Rear right inlet fluid valve

C001C04 Rear right fluid inlet valve is defective
• ABS ECU
• Rear right outlet fluid valve

C001D04 Rear right fluid outlet valve is defective
• ABS ECU
• Fuse
C109504 Valve relay is defective
• ABS system circuit
• Fuse
C002004 Reflux pump electric motor failure
• ABS system circuit
Valve body failure (overheating protection, Fuse

C007208
valid signal, hardware damaged) • ABS system circuit
LIFAN AUTO

Attention:
If no DTC is displayed during inspection but the parts in the system can not work normally, check circuit
according to fault symptoms presented in the table below.
these parts.
1. Confirm that DTC outputs normal system

Check the service brake system
codes
ABS does not work
2. Brake piping leaks, damages or deforms etc. Repair or replace
3. ABS ECU Replace.
1. ABS indicator light circuit (short-circuited) Repair or replace the harness and connectors
ABS indicator light stays
2. Instrument cluster (damaged) Replace.
constantly bright.
3. ABS ECU (damaged) Replace.
1. ABS indicator light circuit (open-circuited) Repair or replace the harness and connectors
ABS indicator light fails to
illuminate
3. ABS ECU (damaged) Replace.
53
LIFAN AUTO
C190004,C190104-Power supply voltage is high or low


Were the preliminary inspection items carried out?
• DTC generating conditions: Perform
preliminary
1 In the beginning when the vehicle is being electrified, voltage is below 4.5V; To Step 2
inspection
Ignition switch is in the "ON" position, and voltage is lower than 7.7V or higher than items
16.8V;
Vehicle speed higher than 6km / h, and voltage is 7.7-9.2V.

2 • Measure battery voltage and Check if it is about 12V. To Step 4 To Step 3
Any fault was found?
Check ABS ECU

• Conduct cross validation to ABS assembly; if confirm that ABS ECU is damaged,
3 To Step 4
replace ABS assembly.
Was this fault eliminated?
4 Eliminate detected fault and test if the fault is eliminated? Diagnosis is over.
C001004, C001104, C001404, C001504, C001804, C001904, C001C04,

C001D04, C109504, C007208 - solenoid and valve group relay have fault.
1 Stop the car and keep this status it for 5min; Check if the failure is eliminated? To Step 2

• DTC generating conditions:
Power supply to supply is abnormal (power supply is short-circuited to ground or open-
circuited to grounding wire); Perform
preliminary
2 To Step 3
Solenoid valve temperature (overheating protection); inspection
items
More than 5 solenoid valves are short-circuited (fuse);
Drive corresponding solenoid valve, but no response occurs;
Solenoid valve failure;
Group valve relay is defective
Inspect electric circuit.

• Inspect whether fuse SB08 is burned out.
• Check if wiring harness connectors, wiring harness and grounding wire are open-
circuited or short circuited.
• Check if voltage in the solenoid valve power supply connector pin is battery voltage;
Check ABS ECU

4 To Step 5
Eliminate detected fault and test if the fault is eliminated? Diagnosis is over.
5 Hint:
Stop the car after accelerating it above 15km/h, and confirm that this fault occurs again?
LIFAN AUTO
C002004 - pump motor has fault.

1 Stop the car and keep this status it for 5min; Check if the failure is eliminated? To Step 2

• DTC generating conditions:
Pump motor works with overload, leading to too high temperature (overheating
Perform
protection);
preliminary
2 To Step 3
After reflux pump motor relay works 60ms, the reflux pump monitor can not detect inspection
voltage signal yet; items
The reflux pump motor relay does not work, the reflux pump monitor detects voltage for
above 2.5s;
The reflux pump motor relay stops working; the reflux pump monitor detects that voltage
does not drop

• Inspect whether fuse SB07 is burned out.
• Check if connectors, wiring harness and grounding wire are open-circuited or short
circuited.
• Check if voltage in the pump motor power supply connector pin is battery voltage;
Check ABS ECU

4 To Step 5
5 Hint:
C003200, C00A000, C00A100, C00A900, C003500, C00A200, C00A300, 53

C00AA00, C003800, C00A400, C00A500, C00AB00, C003B00,
C00A600, C00A700, C00AC00, C109904 - WSS circuit has fault.

Were the preliminary inspection items carried out? Perform
preliminary
1 • DTC generating conditions: To Step 2
inspection
ECU detects that the wheel speed sensor signal wire is short-circuited to ground; items
Wheel speed sensor circuit is open-circuited.

• Check if all wheel speed sensors' connectors works normally; Check if wheel speed
2 sensor line in harness is To Step 4 To Step 3
open-circuited and short-circuited.
Check ABS ECU

3 To Step 4
LIFAN AUTO
4 Hint:
C003108, C00A900, C003408, C00AA00, C003708, C00AB00, C003A08,

C00AC00, C109904 - WSS signal has fault.

Perform
• DTC generating conditions: preliminary
1 To Step 2
ECU detects that the wheel speed sensor signal wire is short-circuited to power; inspection
items
ECU detects that the wheel speed sensor power supply wire is short-circuited to ground;
Wheel speed sensor signal is abnormal.

• Check if all wheel speed sensors' connectors works normally; Check if wheel speed
2 sensor line in harness is To Step 8 To Step 3
open-circuited and short-circuited.
Check wheel speed sensor and gear ring

• Check air gap between wheel speed sensor and gear ring
3 • Check if gear ring is contaminated and has foreign matter; and that teeth are missed. To Step 8 To Step 4
• Check if number of teeth in gear ring is correct.
Check the data stream

• Lift up the car by a lifter and rotate wheels. Observe by data from an oscilloscope that
the wheel speed sensor signal output conforms to the standard.
Check the wheel speed sensor

• Disconnect the wheel speed sensor connector, apply 12V voltage between two pins of the
wheel speed sensor connector.
5 The power supply connects the ammeter in series; power supply electrode connects the To Step 2 To Step 7
power supply pin, and the cathode connects the
signal pin. Slowly turn the wheel and observe whether the number displayed in the
ammeter is in the vicinity of approximately 7mA and 14mA?
Check ABS ECU

6 • Conduct cross validation to ABS assembly; if confirm To Step 7
that ABS ECU is damaged, replace ABS assembly.
Replace the wheel speed sensor

7 • Refer to repair steps specified in repair manual for replacement of wheel speed sensor. To Step 8
8 Hint:
LIFAN AUTO
Attention:
• For wheel speed sensor signal fault, after elimination, it is necessary to start the vehicle and accelerate
speed to about 15km/h, and ABS warning lamp can flame out.
• Do not measure the wheel speed sensor supply voltage to the ECU; as long as open circuit exists in the
wheel speed sensor circuit, ECU automatically stops power supply and then provides electricity when the
next ignition self-test is finished.
C100004, C101008 - ECU fault


Perform
Were the preliminary inspection items carried out? preliminary
1 To Step 2
• DTC generating conditions: inspection
items
ECU power supply malfunctions or ECU damages.
Check ABS ECU

2 To Step 3
U000500, U000700, C100104, U000104, U100104 - CAN bus fault


• Were the preliminary inspection items carried out?
Perform
• Hint: preliminary
1 To Step 2
Make sure that ECU at each node of CAN bus is set properly and never be replaced. inspection
items
• DTC generating conditions: 53
Communication, configuration information and circuit of CAN bus have fault.
Inspect CAN system

2 • Diagnose hardware and software of CAN bus. To Step 4 To Step 3
Make sure whether the fault is found and eliminated?
Check ABS ECU

3 To Step 4
C006B06 - ABS control irrational


Perform
• Were the preliminary inspection items carried out? preliminary
1 To Step 2
• DTC generating conditions: inspection
items
ABS connects with the continuous working instructions (greater than 1min).
LIFAN AUTO
Check wheel speed sensor and gear ring

2 • Is the wheel speed sensor mounted wrong? To Step 4 To Step 3
• Were signal gears scratched or did they absorb scrap metal or external objects?
Check ABS ECU

3 • Conduct intersection verification to ABS assembly. If it is confirmed that ABS ECU is To Step 4
broken, replace ABS assembly and see whether the fault is eliminated?
ABS indicator light stays constantly bright or fails to illuminate

Perform
Preliminary inspection items preliminary
1 To Step 2
Were the preliminary inspection items carried out? inspection
items
Check instrument cluster power supply

• Disconnect ABS ECU connector U17.
• Turn the ignition switch to ON.
• Inspect whether voltage between No.28 and No.38 terminals of U17 is battery voltage.
Check harness
• Turn ignition switch to OFF, and disconnect instrument cluster connector I14.
• Inspect whether the resistance between No.27 and No.26 terminals of I14, and No.26 and
No.14 terminals of ABS ECU connector U17 is less than 2Ω.
Replacement of instrument cluster

4 • To replace the instrument cluster, refer to the maintenance procedures in the Repair To Step 6
Manual.
Check harness
5 To Step 6
• Repair or replace the faulty harness
LIFAN AUTO
Anti-lock Braking System-Wheel speed sensor 53-23
Wheel speed sensor

Replace
1. Removal of front wheel speed sensor
(a). Rise up vehicle and dismantle front wheel assy.

(b). Dismantle fender and disconnect sensor connector.
(c). Dismantle fixed bolts front wheel speed sensor, and take out
wheel speed sensor.
Attention:
Do not pull the wheel speed sensor wiring harness with heavy
force.
2. Removal of rear wheel speed sensor
(a). Rise up vehicle and dismantle rear wheel assy.

(b). Disconnect rear wheel speed sensor connector.
Attention:
Do not pull the wheel speed sensor wiring harness with heavy
force.
53
(c). Disconnect rear wheel hub assembly. (See Chapter 32Rear

Overhang - Rear Wheel Hub, Replacement)
LIFAN AUTO
53-24 Anti-lock Braking System-Wheel speed sensor
(d). Pry rear wheel speed sensor from rear wheel hub assembly.
△ Hint:
While dismantling, make a position mark to facilitate installation.
3. Installation of front wheel speed sensor
(a). Check if no foreign matters exist inside the sensor mounting

hole and that no impurities such as metal scrap exist in the
surface of the brake disc.
Attention:
Clean the sensor mounting hole and the brake disc surface
prior to installation.
(b). Mount he front wheel speed sensor and then mount and
(c). Connect wheel speed sensor connector and install fender.
Attention:
Wiring harness should not be twisted when the installation is
finished.
(d). Install front wheel assy.
4. Installation of rear wheel speed sensor

(a). Install rear wheel speed sensor.
Attention:
While installing, align with mounting position of wheel speed
sensor.
LIFAN AUTO
Anti-lock Braking System-Wheel speed sensor 53-25
(b). Install rear wheel hub assembly. (See Chapter 32Rear

Overhang - Rear Wheel Hub, Replacement)
(c). Connect wheel speed sensor connector.

Attention:
Wiring harness should not be twisted when the installation is
finished.
(d). Install rear wheel assy.
53
LIFAN AUTO
53-26 Anti-lock Braking System-ABS hydraulic regulator
ABS hydraulic regulator

Cross validation
1. Dismantle ABS assembly and install it to the other vehicle with the same model but without fault.
△ Hint:
Only installing oil pipe without ABS ECU connector is allowed, but it is necessary to make sure that the plug will not
loosen during vehicle traveling condition.
2. Start the vehicle and make sure the speed is no less than 20km/h. Let ABS conduct dynamic self-
inspection.
Replace
1. Removal of ABS hydraulic regulator
(a). Turn the ignition switch to "OFF" position and disconnect

the battery cathode cable.
(b). Disconnect the ABS ECU connector.
△ Hint:
Turn up the ABS ECU connector snap-fit and then unplug the ABS
ECU connector.
(c). Remove the brake line and then block the thread hole and
the oil hole of the brake lines of the ABS assembly by a
stopper.
△ Hint:
Depress the brake pedal to the bottom and fasten the pedal bracket
to prevent brake fluid from flowing out after the brake line is
removed from the brake master cylinder.
LIFAN AUTO
Anti-lock Braking System-ABS hydraulic regulator 53-27
(d). Remove fixed bolts of ABS in the mounting bracket and

then take off the ABS assembly.
2. Install ABS hydraulic adjuster.
(a). Install ABS assembly onto the mounting bracket and tighten
fixed bolts.
53
(b). Mount the brake oil pipes.
△ Hint:
Remove plugs on the thread hole of the ABS assembly and the oil
hole of the brake line; mount corresponding pipes onto the ABS
assembly holes.
LIFAN AUTO
53-28 Anti-lock Braking System-ABS hydraulic regulator
(c). Connect ABS ECU connector.

(d). Connect negative pole of battery.
LIFAN AUTO
Anti-lock Braking System-ABS artificial exhaust 53-29
ABS artificial exhaust

1. ABS artificial exhaust
(a). Select to "ABS system (BOSCH ABS9 720 CAN)".

ABS LIFAN Dedicated\Chongqing LIFAN\V5.0\ABS
ABS (Wanxiang) Previous page
ABS (APG)
ABS (TRW) Next page
ABS (Mando MGH25)
ABS (BWI DBC78) Print
ABS (BOSCH ABS9 720 CAN)

Return
ABS (BOSCH ABS9 520K)
(b). Click to select artificial exhaust function and conduct

exhaust operation.
ABS (BOSCH ABS9.0) LIFAN Dedicated\Chongqing LIFAN

Clear DTC
Print
Return
53
(c). Read warning instructions of diagnostic scanner and click

"OK".
Information
Warning:
1. Refilling pressure of refiller must be OK
exceeded 2 bar
2. The sequence of exhaust is: rear left / Cancel
front left/ front right / rear right.
3. In order to prevent the hydraulic unit
assembly from damaging due to excessive
heating, repeat certain phrase or the
whole exhaust procedure and must be
waited for at least 5 min.
LIFAN AUTO
53-30 Anti-lock Braking System-ABS artificial exhaust
(d). Conduct procedures displayed in the diagnostic scanner and

then click "OK".
Information
Hint:
All systems that failed during on line OK
vacuum pumping/refilling, or substituted
dry parts, shall be perform artificial Cancel
exhaust under special procedure. In order
to make the hydraulic governor to reach
enough pressure, the brake pedal shall be
depressed reciprocatingly during the
entire drainage procedure. That procedure
is basically same with the normal
exhaustion, and it is to meet the exhaust
requirement of hydraulic governor's
secondary loop.
(e). Conduct procedures displayed in the diagnostic scanner and

then click "OK".
Information
Hint:
Connected with exhaust equipment and oil OK
storage tank
Connected with electrical continuity Cancel
Switch on the ignition switch
Note: car has been assembled well before
start exhaust. To fulfill the electric link
via the connection with V30 diagnostic
unit of vehicle DLC (OBD16). Operator
shall ensure the ignition key of vehicle
switched to "ON" position.
(f). Conduct procedures displayed in the diagnostic scanner and

then click "OK" to start artificial exhaust.
Information
Hint:
OK
The brake pedal shall be depressed
reciprocatingly during the entire exhaust Cancel
procedure at the frequency of 0.5
times/sec!
Please follow the tips to operate the
entire procedure
Do you want to start artificial exhaust?
LIFAN AUTO
Anti-lock Braking System-ABS artificial exhaust 53-31
(g). Open exhaust bolts of the rear left wheel and then click
"OK" to next step.
Information
Open exhaust bolt of rear left wheel,

OK
and then press "OK" to continue.
Cancel
(h). Conduct procedures according to instructions displayed

in the diagnostic scanner and then complete ABS artificial
exhaust.
53
LIFAN AUTO
• Memo •
LIFAN AUTO
Power steering
Power steering............................................................ 61-1

Preparation............................................................. 61-1
Precautions............................................................. 61-2
On-Vehicle check................................................... 61-5
Power steering oil pump.......................................... 61-10
Replace................................................................. 61-10
Steering gear............................................................. 61-12
Replace................................................................. 61-12
61
LIFAN AUTO
Anti-lock Braking System-Power steering 61-1
Power steering
Preparation
1. Special tool
Check the steering hydraulic

1 Fuel pressure gauge
system
Remove the transverse arm

2 Ball joint remover and the steering knuckle
connecting all head
Tighten dust-proof boot

3 Clamp tightening tool
clamp
2. Recommended tools 61
1 Bracket Lift up the front subframe
LIFAN AUTO
61-2 Anti-lock Braking System-Power steering
Steering fluid temperature 75~80℃
Steering force applying in steering wheel <6N•m
Tighten torque of steering gear ball joint <3.43N•m
Item N•m
Steering pump fixed bolt 60
Ball head lever lock nut 120
Oil pipe nut 45
Steering gear retaining bolt 110~130
Engine right mounting fixing bolts 85~90
fixed bolts of steering gear oil pipe bracket 23
Precautions
1. Place the vehicle on level dry ground when checking the steering system.
2. All bolts of the steering system must be tightened to specified torques.
3. Check the wheel alignment after repairing the steering gear or other steering parts.
4. Maximum flow of system must not exceed 10L/min and maximum working oil pressure should not exceed
8MPa.
5. Hydraulic oil should be replaced after the new steering gear has been used for 2,500km; at the same time, the
filter screen in the oil reservoir should be cleaned; after that, each 2 years or 50,000 km, hydraulic oil should be
replaced and the oil reservoir should be cleaned.
6. Check the tire pressure if necessary. Ensure that it meets the requirement.
7. Once abnormal clearance, seizure and swinging condition are found, first analyze where is the possible fault
position, steering drive device, dynamic steering system or steering tie rod, and solve the problems.
8. If necessary, check carefully the parts of steering system for abnormal impact. Be sure to replace immediately the
damaged or faulty parts.
9. Never weld any parts of the steering gear and any rods of the steering system.
10. ALWAYS ensure that piping is not bumped or worn during use and that all connection should be tights without
blocked corner.
11. Check monthly that hydraulic oil becomes less and degrades with excessively impurities; if any abnormality is
found, hydraulic oil should be replaced on time; add hydraulic oil with same brand and model with the original
hydraulic oil used in the power steering system. Do not used mixed hydraulic oil.
LIFAN AUTO
Components diagram
61
1 Hexagon thin slotted nut 6 Power steering pipe

2 Split pin 7
component
3 Hex 8 Clamp of power steering fluid reservoir
4 Steering gear 9 Power steering reservoir assembly
5 Power steering pump assembly
LIFAN AUTO
System description
1. Overview of power steering system

Power steering system is designed to reduce the driver's work intensity. In the development beginning, it is used
mainly on the heavy-duty vehicle. With sedan developing rapidly and load on the steering wheels increasing, the
power steering mechanism becomes necessary and then has wider application in modern cars. Power steering
system has the following advantages:
• Reduce force applying on the steering wheel, especially when turning in the same place or making a big turn
at low vehicle speed.
• Improve steering sensitivity.
• Reduce impact on the steering wheel from ground recoil strength.
• In the case of a tire blasting, it may better prevent wheels from abruptly turning, thereby improving safety of
traveling.
• Allow larger load on the steering wheels; it is possible to increase freedom degree of the whole arrangement.
2. Compositions of power steering system
Vehicle's power steering system consists of power steering gear, power steering oil pump, power steering
reservoir and hydraulic pipe. Power steering gear is an actuation component for hydraulic boosting of steering
system; steering oil pump and engine combined together to supply hydraulic power source for the system; while
steering fluid reservoir takes an action of storage, temperature reduction and filtering fluid.
3. Structure instruction of rack and pinion power steering
mechanism
Rack and pinion type power steering gear consists of three

components of control valve, mechanical steering gear,
power steering oil pump. Control valve is a rotating valve
with advanced structure and high sensitivity. Mechanical
steering gear is rack and pinion type.
(a). Control valve
As shown in figure below: control valve is an opening
rotating valve consisting of 1 torque rod, 2 input shaft,
3 valve sleeve. Make the hydraulic oil flow into 2 oil
chambers through pre-open gap of 2 input shaft and 3 valve
sleeve.
Inlet To right cavity Oil return
(b). Mechanical steering part

Mechanical steering part is of rack and pinion type, consisting of gear oil, rack piston assembly and steering rod.
(c). Power steering oil pump
Power steering pump is metal housing. Rack piston inside separates it into two oil chambers (left, right), and
respectively to two oil ports of control valve.
(d). How does it work
• Middle position: when vehicle travels in direct line (steering wheel doesn’t move), oil pump supplies
hydraulic oil from oil inlet ports. After passing through re-opened clearance of rotating valve, hydraulic
oil returns to oil reservoir because rotating valve doesn’t rotate. At this moment, oil pressure in the same 2
working chambers of steering gear is the same and doesn’t produce boosting force.
• Steering process: when turning the steering wheel, valve groove gap between the valve sleeve and the input
shaft is changing to generate oil pressure difference in hydraulic oil flowing back two working chambers. This
oil pressure difference acts on the piston to push the piston to overcome resistance and generate displacement
so that the steering tie rod assembly moves to realize power steering.
• Returning process: After steering is completed, force on the steering wheel is gone; under action of torsion
rod elastic force, the input shaft returns to a balance position related to the valve sleeve; oil pressure
difference in two working chambers of the steering gear disappears; and then the car front wheels return to
LIFAN AUTO
the straight position; under action of returning torque, the car will trend to move to straight ahead direction
until the direction comes.
• Road feel effect: road feel effect is the ability to produce steering feel. When a driver applies force on the
steering wheel, the force also acts on the torsion rod of the steering gear to generate torsion deformation.
Deformation amount depends on wheel steering resistance; W h e n s t e e r i n g r e s i s t a n c e i s i n c r e a s e d ,
deformation amount also increases. Therefore, the driver can adjust the change of steering resistance
according to the size of force he exerted on the steering wheel, to obtain “road feel” effect.
On-Vehicle check
1. Inspect drive belt of steering pump.

(a). Inspect whether drive belt of steering pump has excessive abrasion, curtain line abrasion. If any, replace drive
belt of steering pump.
△ Hint:
If it is found that the belt tooth edge has cracks, there is no need to replace it; if it is found that belt teeth fall of, replace it.
2. Completely exhaust air from power steering system.

(a). Check oil level.
Normal Abnormal (b). Prop up the vehicle front part using jack to support its front
securely.
(c). Turn the steering wheel.
△ Hint:
When the engine stops, gently turn the steering wheel from one
side “lock position” to another side “lock position”; repeat
this process several times.
(d). Lower the vehicle and start the engine and keep it idling for
a few minutes.
(e). Turn the steering wheel.
△ Hint:
Engine runs at idle speed. Rotate steering wheel front left and right
side to a limit position and keep 2~3s, and then rotate steering
wheel to the other limit position in reversing direction and keep
2~3s. Repeat this process for several times. 61
(f). Turn off the engine.
(g). Inspect whether there is foam or emulsification. If the
system requires to exhaust air due to foam or emulsification,
inspect whether there is leakage.
(h). Inspect fluid level height.
3. Check fluid level
(a). Stop the vehicle in the level ground.
(b). Stop the engine, and inspect fluid level height in fluid
reservoir.
△ Hint:
If necessary, add steering fluid.
Attention:
• The fluid level should be within HOT range.
• If temperature of steering fluid is low, inspect whether it
is in COOL range.
LIFAN AUTO
(c). Start the engine and idle it.

(d). Rotate steering wheel from one limit position to another
Normal Abnormal limit position for several times to increase steering fluid
temperature.
Oil temperature: 75~80°C
(e). Check for bubbles or emulsification. If any foam or
emulsification is found, drain steering fluid.
(f). With engine idling, check fluid level in the oil reservoir.
(g). Stop the engine and wait a few minutes and then measure
height of oil reservoir fluid level.
Maximum ascending amount of fluid level: 5mm
Engine Idling Speed Engine cut-out
4. Check steering fluid pressure

(a). Detach the fuel pipe from the steering boosting pump and mount the pressure gauge special tool.
Attention:
Check if the valve of the pressure gauge special tool is in the opening statue.
(b). Drain steering boosting fluid.
(c). Start the engine and idle it.
(d). Rotate steering wheel from one limit position to another limit position for several times to increase steering fluid
temperature.
Oil temperature: 75~80°C
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(e). Keep the engine at idle speed, and close special tool valve
and observe reading of pressure gauge.
Oil pressure: 5900~6400kPa
Attention:
• Do not close valve for more than 10s.
• Do not keep the steering fluid temperature too high.
(f). When engine is at idle speed, all valves are open.

(g). Check oil pressure when engine speed is 1000r/min and
3000r/min.
Oil storage tank
Oil pressure: <490kPa
Attention:
Steering
Do not turn the steering wheel.
gear
On
Power steering
pump
(h). When engine is at idle speed and all valves are open, turn
steering wheel to limit position. 61
Oil pressure: 5900~6400kPa
Oil storage tank
Lock position
Attention:
• Do not keep steering wheel on limit position for more
Steering
gear than 10s.
• Do not keep the steering fluid temperature too high.
On
(i). Remove special tool of pressure gauge.
(j). Connect pressure supply pipe to power steering oil pump.
Power steering
pump
(k). Completely exhaust air from power steering system.
LIFAN AUTO
5. Check steering force
(a). Dismantle cover plate of steering wheel horn. (See Chapter

62Steering Mechanism - Steering Wheel, Replacement)
(b). Align steering wheel to center position, and start the engine
and keep the engine at idle speed.
(c). Check steering force in 2 direction.
Steering force: < 6N•m
△ Hint:
Before judging, type of tire, pressure and contact surface should be
taken into account.
(d). Install fixed nuts of steering wheel.
(e). Install cover plate of steering wheel horn. (See Chapter 62
Steering Mechanism - Steering Wheel, Replacement)
LIFAN AUTO
Troubleshooting
these parts.
1. Tires (pressure is too low or tire is badly

Check air pressure to replace worn tire
worn)
2. Front wheel alignment (wrong) Conduct the four-wheel alignment
3. Steering fluid (inadequate or air enters) Add steering fluid or exhaust air in the system
4. Power steering pump (underpowered) Replace the power steering pump

Understeering
5. Steering gear (damaged) Repair or replace the steering gear
6. Steering tie rod ball head (worn or with

Replace the steering tie rod ball head
poor lubrication)
7. Steering knuckle lower ball pin (worn or

Replace the steering knuckle lower ball pin
with poor lubrication)
8. Front column bearing (damaged) Replace front column bearing.
1. Tires pressure(pressure is too low or tire is

Check air pressure to replace worn tire
badly worn)
2. Front wheel alignment (wrong) Conduct the four-wheel alignment
3. Steering gear fixed bolt (loose) Tighten steering gear fixed bolts
Steering wheel vibration 4. Steering gear (clearance is too large) Repair or replace the steering gear
5. Steering gear tie rod ball head (clearance is

Replace the steering gear tie rod ball head
too large)
6. Steering knuckle lower ball pin (clearance

Replace the steering knuckle lower ball pin
is too large)
7. Front column bearing (damaged) Replace front column bearing.
1. Steering shaft universal joint (clearance is

too large or the part is damaged)
Replace the steering shaft universal joint 61
Free clearance of steering 2. Steering tie rod ball head (clearance is too
wheel is too large Replace the worn steering tie rod ball head
large)
3. Steering gear assembly fixed bolt (loose) Tighten the fixing bolts.
1. Drive belt (too loose) Replace the drive belt
Week steering boosting force
3. Steering gear (damaged) Repair or replace the steering gear
4. Power steering pump (damaged) Replace the power steering pump
2. Steering drive belt (too loose) Replace the drive belt

Abnormal steering noise
3. Power steering pump (damaged) Replace the power pump
4. Steering driving parts (loose or excessively

Check loose or worn parts and replace it when necessary
wear)
LIFAN AUTO
61-10 Anti-lock Braking System-Power steering oil pump
Power steering oil pump

Replace
1. Drain power steering boosting fluid.
2. Dismantle power steering oil pipe.
(a). Dismantle power steering oil pipe clamp, and disconnect
power steering oil pipe.
(b). Remove the pressure supply pipe joint bolt, and disconnect
the pressure supply pipe.
3. Disconnect power steering pump assembly.
(a). Dismantle engine belt.

(b). Dismantle fixed bolts of power steering pump assembly.
(c). Remove power steering pump assembly
4. Install power steering pump assembly.
(a). Install power steering pump assembly onto the engine, and
Torque: 60N•m
(b). Install engine belt.
LIFAN AUTO
Anti-lock Braking System-Power steering oil pump 61-11
5. Install power steering oil pipe.
(a). Install power steering oil pipe, and fixed bolts of power
steering oil pipe clamp.
(b). Install pressure supply pipe and joint bolt.
6. Fill power steering boosting fluid.
7. Exhaust air from power steering system.
8. Inspect whether power steering fluid has leakage.
61
LIFAN AUTO
61-12 Anti-lock Braking System-Steering gear
Steering gear
Replace
1. Dismantle power steering pipe.
(a). Use oil pipe wrench to dismantle power steering pipe.
(b). Remove the fixing bracket of the steering gear oil pipe on
the steering gear.
2. Dismantle connecting lock bolts of steering gear and

steering pipe column.
(a). Pry boot of steering pipe column from engine compartment,

and dismantle connecting lock bolt of steering column and
steering gear.
LIFAN AUTO
Anti-lock Braking System-Steering gear 61-13
3. Dismantle steering gear assembly.
(a). Rise up vehicle and dismantle front wheel.

(b). Dismantle cotter pin of slotted thin nut of connecting ball
joint of steering gear tie rod.
(c). Dismantle slotted thin nut of connecting ball joint of
steering gear tie rod.
(d). Use ball joint detacher to dismantle ball joint of pull rod of
steering gear.
(e). Dismantle fixed bolts of engine right mounting on front sub

frame.
61
LIFAN AUTO
(f). Dismantle fixed bolts of steering gear on front subframe.
(g). Lay a support under front Subframe, and dismantle front

Subframe assembly. (See Chapter 31 Front Suspension -
Front Subframe, Replacement)
(h). Lower front subframe a little, and take out steering gear
assembly.
4. Dismantle steering hydraulic pipe of steering gear.
(a). Use the oil pipe wrench to remove the hydraulic steering
pipe.
(b). Remove O-ring from steering hydraulic pipe.
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5. Dismantle pull rod of ball joints on both sides.
(a). Make an assembly mark on the end of pull rod of ball joint
and rack.
(b). Dismantle lock nut, and remove pull rod of ball joint and
lock nut.
6. Inspect pull rod of ball joint.
(a). Fix pull rod of ball joint onto the table vice.
(b). Install nuts on stud bolts.
(c). Slightly strike ball bolts for 5 times front and rear
directions.
(d). Use tightening wrench to ratite nut with speed of 0.25~0.5r/
s, and read the torque value when rotating the 5th circle.
Rotation torque: < 3.43 N•m
7. Dismantle boot of steering rack.
(a). Strike and open clamps on both sides of boot, and remove
boot of steering rack.
8. Dismantle end joint of steering rack.

61
(a). Fix steering rack, and dismantle rack end joint.
△ Hint:
Make marks on left and right rack end joints.
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9. Dismantle rack guide spring cover.
(a). Dismantle rack guide spring cover.

(b). Remove guide spring and guide block.
10. Install rack guide spring cover.
(a). Install rack guide block and guide spring.
(b). Mount the rack guide spring and tighten it to a specified
pre-loading value.
(c). Smear sealant on 2-3 screw threads of spring lock nut.
11. Install steering rack end joint.
(a). Fix steering rack according to marks made during

dismantling, and install rack end joint.
12. Install boots of steering rack.
(a). Install boots on both sides onto steering gear.

(b). Install clamps on both sides of boots, and use special tools
to fix it onto the steering gear.
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13. Install ball head pull rods on both sides.
(a). Install ball head pull rods on both sides onto steering gear,
align mark made during dismantling to tighten locknut.
Torque: 120N•m
14. Install steering hydraulic pipe of steering gear.
(a). Install O-ring of steering hydraulic pipe.

(b). Use oil pipe wrench to install hydraulic pipe onto steering
gear, and tighten it.
Torque: 45N•m
15. Assemble the steering assembly. 61

(a). Install steering gear onto front auxiliary frame, and install
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(b). Use support to rise up and install front subframe.

(See Chapter 31 Front Suspension - Front Subframe,
Replacement)
(c). Install connecting ball head of pull rod of steering gear onto
steering knuckle.
(d). Install slotted thin nut of connecting ball head of pull rod of
steering gear.
(e). Install cotter pin of slotted thin nut of connecting ball head
of pull rod of steering gear.
(f). Install fixed bolts and nuts of right mounting of engine on

front subframe, and tighten them.
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16. Install connecting lock bolt of steering gear and steering

pipe column.
(a). Install steering pipe column onto steering gear and install
tightening bolts.
Torque: 23N•m
17. Install power steering pipe.
(a). Use oil pipe wrench to install power steering pipe.
(b). Install fixed bolts of oil pipe bracket of steering gear, and
fix oil pipe onto steering gear.
61
LIFAN AUTO
• Memo •
LIFAN AUTO
Steering mechanism
Steering mechanism................................................... 62-1

Preparation............................................................. 62-1
Precautions............................................................. 62-2
On-Vehicle check................................................... 62-4
Steering wheel............................................................. 62-6
Adjustment............................................................. 62-6
Replace................................................................... 62-6
Combination lever...................................................... 62-9
Replace................................................................... 62-9
Steering pipe column............................................... 62-12
Check.................................................................... 62-12
Replace................................................................. 62-12
62
LIFAN AUTO
Steering Mechanism-Steering mechanism 62-1
Steering mechanism
Preparation
Remove the ignition switch

1 Crossbite tap
special bolt
Remove the combination

2 Pliers
switch fixing clip
Check steering shaft

3 Dial gauge
clearance
62
LIFAN AUTO
62-2 Steering Mechanism-Steering mechanism
Maximum free travel of steering wheel 40mm (stop engine)
Item N•m
Steering wheel fixed nut 85~105
Steering column fixed bolt 20~26
Connecting lock bolt between the upper steering shaft and the lower
20~26
steering shaft
Connect lock bolt of steering pipe column and steering gear 20~26
Fixed bolts of steering column cover. 5~6
Precautions
1. When conducting repair operation, it is necessary to disconnect battery negative cable.

2. In the case of abnormal noise, poor return or hard steering, immediately stop the vehicle to find and remove the
malfunction.
3. To avoid damage to the parts of steering system, do not move the vehicle with the steering wheel locked.
4. Replace any stuck or loose bearing detected.
5. Replace any bolt or nut detected to have three or more damaged threads
6. Check the performance of the steering system. For example, check the steering wheel for hard steering or
excessive play. Measure the maximum steering angle of the front wheel.
LIFAN AUTO
Steering Mechanism-Steering mechanism 62-3
Components diagram
1 Steering wheel horn cover plate 6 Hexagonal bolt and spring washer assemblies
62
Plastic nut of inner dustproof sleeve of steering
2 Hexagon bolt with flange 7
drive shaft
3 Steering wheel assembly 8 Steering pipe column boot I
4 Steering shaft,upper 9 Dustproof sleeve mounting bracket components
5 Steering shaft,lower 10 Steering pipe column dustproof sleeve II
LIFAN AUTO
62-4 Steering Mechanism-Steering mechanism
System description
Install SRS safety airbag and horn switch on steering wheel. Steering column consists of the upper steering shaft
assembly and the lower steering shaft assembly. The upper steering shaft assembly connects with the steering wheel
through spline and with the lower steering shaft assembly through universal joint. It is equipped with steering wheel
height adjusting mechanism. Its main function is to transmit power to steering gear through controlling of steering
wheel, so as to achieve steering operation. It may have direct impact on control stability and safety at high driving
speed. Steering power transmission mechanism is to transmit force output by steering gear and movement to the steering
knuckles on both sides of steering axle, to make steering wheels on both sides off-track and the second steering wheel
deflection angle change according to proper relation, so as to reduce relative sliding between wheel and ground when
the vehicle is steering.
On-Vehicle check
1. Check the steering wheel free stroke
(a). Park the vehicle and make the tires towards Front right
direction.
(b). Slightly rotate steering wheel, and inspect free stroke of
steering wheel.
Maximum free stroke: 40mm (stop engine)
2. Steering mechanism
(a). Inspect the installation conditions of steering mechanism
assembly and steering column.
(b). Inspect whether there is movement clearance when
vibrating steering wheel in upper and lower, left and right
and axial directions.
(c). Inspect whether fixed nuts and bolts of steering mechanism
assembly are loose.
LIFAN AUTO
Steering Mechanism-Troubleshooting 62-5
Troubleshooting
these parts.
1. Steering shaft universal joint (loose) Replace the steering shaft universal joint
2. Steering shaft bearing (damaged) Repair or replace the steering shaft

Free clearance of steering
wheel is too large
3. Steering gear (fault) Repair or replace the steering gear
4. Steering tie rod ball head (damaged) Replace the steering gear tie rod ball head
Abnormal steering noise
2. Steering shaft fixed bolt (loose) Tighten all bolts according to specified torque
1. Steering shaft bearing (damaged) Repair or replace the steering shaft
Hard steering 2. Steering shaft universal joint (worn) Replace the steering shaft universal joint
3. Steering shaft bearing (damaged) Replace steering shaft or repair
62
LIFAN AUTO
62-6 Steering Mechanism-Steering wheel
Steering wheel
Adjustment
1. Steering wheel adjustment
(a). Push off the steering wheel adjusting handle.

(b). Adjust angle of steering wheel forward and rearward.
(c). After adjustment, push the steering wheel adjusting handle
to locking position.
Warning:
• Do not adjust the steering wheel in the driving process.
Otherwise, it may cause accidents due to driver mistake
in controlling the car, resulting in serious injury or
death.
• Adjust the steering wheel to ensure that the steering
wheel is securely locked. Otherwise, steering wheel may
suddenly move, causing the accident and resulting in
serious injury or death.
• Do not keep the steering wheel toward your front face;
otherwise, the airbag in the accident will not be able to
provide effective protection. After adjustment, ensure
that the steering wheel is toward the driver chest.
Replace
1. Disconnect cable from negative battery terminal
2. Remove the steering wheel horn cover

(a). Use screwdriver to pry snap ring of steering wheel horn
cover plate, and remove steering wheel horn cover plate.
(b). Disconnect the steering wheel horn cover connector.

• Disconnect safety airbag connector.
• Disconnect horn switch wiring harness connector.
LIFAN AUTO
Steering Mechanism-Steering wheel 62-7
3. Remove the steering wheel
(a). Remove the steering wheel fixed nut and take out nuts and
gaskets.
(b). Make assembly marks on steering shaft and steering wheel,

and unplug steering wheel.
△ Hint:
Before pulling out the steering wheel, make fitting marks on the
steering shaft and the steering wheel to ensure that parts will be
mounted to the original position in the time of fitting.
4. Mount the steering wheel
(a). Align marks made in removing and mount the steering

wheel. 62
LIFAN AUTO
62-8 Steering Mechanism-Steering wheel
(b). Install fixed nuts and tighten them.

5. Mount the steering wheel horn cover
(a). Install steering wheel horn cover plate connector.

• Install safety airbag connector.
• Install horn switch wire harness connector.
(b). Install snap ring of steering wheel horn cover plate.

(c). Install steering wheel horn cover plate.
(d). Connect negative pole of battery.
LIFAN AUTO
Steering Mechanism-Combination lever 62-9
Combination lever
Replace
1. Dismantle steering wheel assembly (See Chapter 62
Steering Mechanism - Steering Wheel, Replacement)
2. Remove steering column cover
(a). Remove the steering column shroud fixed bolt.
(b). Take out the steering column upper and lower covers.
3. Dismantle clock spring
(a). Make a mark on clock spring, and disconnect clock spring

connector.
62
(b). Remove clock spring, and disconnect clock spring

connector.
LIFAN AUTO
62-10 Steering Mechanism-Combination lever
4. Remove the combination switch
(a). Dismantle clamp of combination lever and remove

combination lever assembly.
(b). Disconnect combination lever connector.
5. Mount the combination switch
(a). Install combination lever connector.

(b). Install combination lever assembly and clamp and fix it.
LIFAN AUTO
Steering Mechanism-Combination lever 62-11
6. Install clock spring
(a). Install clock spring connector.
(b). Install clock spring after aligning marks made during

dismantling.
△ Hint:
Make sure that wheel is in straight line traveling condition, and
install clock spring according to the mark made during dismantling.
7. Mount the steering column cover
(a). Mount the steering column upper cover and lower cover to
the mounting position and join tightly the upper and lower 62
cover.
(b). Mount the steering column cover fixed bolts and tighten
them
Torque: 5 ~ 6N•m
8. Mount the steering wheel assembly
LIFAN AUTO
62-12 Steering Mechanism-Steering pipe column
Steering pipe column

Check
1. Check steering shaft gear clearance
(a). Mount the steering shaft to the universal joint yoke and
tighten the yoke by a vise.
(b). Support the steering shaft by a v-shaped bracket.
(c). Place the micrometer probe on the surface of the steering
column spline center.
(d). Correct the pointer to zero.
(e). Rotate the movable end in radial and even force and read
the value.
(f). Judge whether the value is in required range.
2. Check the lower steering shaft assembly
△ Hint:
Hold 2 ends of cross shaft, and then rotate it in reversing direction.
If any clearance is found, replace it.
Replace
1. Dismantle steering wheel assembly (See Chapter
62Steering Mechanism - Steering Wheel, Replacement)
2. Dismantle combination lever assembly (See Chapter
6 2 S t e e r i n g M e c h a n i s m - C o m b i n a t i o n L e v e r,
Replacement)
3. Dismantle steering column assembly.
(a). Dismantle lower panel assembly of dashboard. (Chapter
85 Dashboard - Console - Left Lower Trim Panel of
(b). Disconnect ignition switch connector, and pry ignition
switch decoration.
LIFAN AUTO
Steering Mechanism-Steering pipe column 62-13
(c). Pry steering pipe column boot from engine compartment,

and dismantle connecting lock bolt of steering column and
steering gear.
(d). Dismantle fixed bolts of steering column, and remove

steering column assembly.
(e). When dismantling, make assembly marks on upper steering

shaft and lower steering shaft.
(f). Dismantle fixed bolts, and remove steering column 62
assembly.
LIFAN AUTO
62-14 Steering Mechanism-Steering pipe column
4. Remove the ignition switch assembly.
(a). Use electric drill to drill holes on fixed bolts of ignition

switch.
(b). Remove the ignition switch clip fixed bolt by a crossbite tap
and then take off the ignition switch assembly.
△ Hint:
Fixed bolts of ignition switch are special bolts. After dismantling,
it is necessary to replace fixed bolts.
5. Mount the ignition switch assembly.
(a). Mount the ignition switch and the clip.

(b). Mount the ignition switch fixed bolts and tighten them.
Attention:
• When install steering lock assembly and steering lock
bracket onto steering column, align lock notch of
steering column and temporarily lock steering lock.
• After making sure that steering lock has correct action,
lock the special bolts until the head of bolt is twisted off.
6. Install steering column assembly.
(a). Assemble upper steering shaft and lower steering shaft by

aligning assembly marks made during dismantling, and
LIFAN AUTO
Steering Mechanism-Steering pipe column 62-15
(b). Install steering column onto steering gear and fixed bolts.
(c). Install steering column assembly onto instrument console

bracket and fixed bolts and tighten them.
(d). Install ignition switch connector and ignition switch

decoration.
7. Install left lower panel assembly of dashboard (See
62
8. Install combination lever assembly (See Chapter 62
Steering Mechanism - Combination Lever, Replacement)
9. Install steering wheel assembly (See Chapter 62 Steering
Mechanism - Steering Wheel, Replacement)
LIFAN AUTO
• Memo •
LIFAN AUTO
A/C System
A/C system.................................................................. 71-1

Preparations............................................................ 71-1
Precautions............................................................. 71-4
Operating Principle................................................ 71-8
Wiring diagram..................................................... 71-11
Terminal definition............................................... 71-14
System maintenance............................................. 71-18
Parts identification................................................ 71-19
On-Vehicle check................................................. 71-23
System troubleshooting........................................ 71-32
Read and clear DTCs............................................ 71-39
Fault code (DTC) list............................................ 71-43
B190011............................................................... 71-44
B190013............................................................... 71-44
B190111............................................................... 71-44
B190113............................................................... 71-44
B190211............................................................... 71-45
B190213............................................................... 71-45
B190700 .............................................................. 71-46
B190800 .............................................................. 71-46
B190900 .............................................................. 71-47
Refrigerant................................................................ 71-49
Check.................................................................... 71-49
Replace................................................................. 71-53
HVAC assembly........................................................ 71-58
Replace................................................................. 71-58
A/C compressor........................................................ 71-65
Check and repair................................................... 71-65 71
Condenser and drying tank assembly.................... 71-71
Check and repair................................................... 71-71
LIFAN AUTO
A/C System-A/C system 71-1
A/C system
Preparations
1. Special tools
For measure the resistances

1 Digital multi-meter and voltages of circuits and
sensors.
Non-visible light with For detecting A/C system

2
high luminous intensity refrigerant leak
3 Nose pliers For removing wires
For adding and discharging

refrigerant of the A/
R-134A manifold
4 C system, and for
measuring instrument
troubleshooting the A/C
system
71
For detecting A/C system

5 Halogen leak detector
refrigerant leak
LIFAN AUTO
71-2 A/C System-A/C system
Trace indication color

6 Use to can refrigerant
syringe
Used to seal A/C pipeline

R134a trace indication
7 connector and avoid ingress
pigment
of dust
Used to measure the

8 Precision thermometer air conditioning system
performance
For installation the seal ring

9 Shaft seal protection
on A/C line.
For storing and recovering

10 50-pound recovery tank
refrigerant
Used to check if the

11 Pressure test adapter
condenser leaks
LIFAN AUTO
Used to check wiring for

12 Passive test lamp
connectivity
Used to remove the valve

13 Valve core remover core in the high/low pressure
pipeline in A/C
For removing and instaling

14 Spring calipers
springs
Refrigerant recovering,
For recovering refrigerant
15 regenerating and adding
from the A/C system
system
71
Make the A/C system
16 Vacuum pump
vacuum
LIFAN AUTO
Precautions
△ Hint:
Always comply with following instructions when checking and repairing A/C system; otherwise it is likely to cause
damage of vehicle and personal injury.
1. Switch off power supply

(a). Before removing or mounting any electrical mechanism, or when the tool or the device is easily contacting the
naked electrical pin, firstly the battery cathode must be disconnected to avoid personal injury or damage of car.
△ Hint:
If equipped with center control lock, do not leave the key in the car before disconnecting the battery cathode cable.
Otherwise you can not take the key out when the car is locked.
(b). If there are no special notes, ignition switch must be turned off.
2. Disconnecting negative cable of battery can zero clear one-day milemeter and timer on instrument cluster.
△ Hint:
Total mileage will not be zeroed.
3. Disconnecting negative cable of battery may lose the stored setting.
△ Hint:
After re-connecting negative cable of battery, it is necessary to reset audio system (Refer to " LIFAN 720 User's
Manual).
4. Do not conduct operation in closed place or near fire source.
5. Do not conduct welding operation to parts which are filled with refrigerant.
6. Please always wear protective glass.
7. Do not let liquid refrigerant enter eyes or contact with skin.
8. Do not heat it up or place the tank body onto the open flame. If liquid refrigerant enters eyes or contacts
with skin,
(a). Use a large amount of cooling water to flush contact position.
Attention:
Do not rub your eyes and skin.
(b). Apply clean vaseline.
(c). Immediately see the doctor.
9. When moving it, attention should be paid not to let it fall off and impact it.
10. D o n o t o p e r a t e t h e c o m p re s s o r w h e n t h e c o o l i n g s y s t e m h a s i n s u f f i c i e n t re f r i g e r a n t .
If not enough refrigerant in the cooling system, it is probably to provide sufficient lubrication and the
compressor might be burnt. So please pay attention to this case.
11. When the compressor is running, do not open the high-pressure pipeline.
If the high-pressure valve is opened and the refrigerant will flow backward, this will cause the compressor
cylinder body to be broken. Therefore you must open and close low pressure valve.
12. Do not fill refrigerant with excessive amount If adding excessive refrigerant, it will lead to poor abstraction
of heat, poor fuel economy and overheating engine.
13. After opening refrigeration system, timely cover or seal it, to avoid water and steam in air or foreign
matters entering.
14. Tighten the coolant container lid securely at all time; mark the model of coolant (PAG56). Do not use
mixed coolant with different brand. Otherwise oil quality and viscosity will decrease.
15. After replacing refrigerant, first fill refrigeration oil into system, and then add refrigerant.
16. Repair tool must be clean and dry, and installation and repair place must be clean.
17. Various sealing soft pad (washer) must be made of rubber sealing material having good compatibility with
refrigerant.
18. Connecting hose must be made of material specially for refrigeration. Connecting hose suitable for R134a
must use nylon as lining.
LIFAN AUTO
19. Refrigerant must be drained slowly to avoid refrigeration oil being carried out, and it must not contact
with polish metal surface.
20. Low-pressure end can't be filled with liquid refrigerant. When filling refrigerant from high-pressure end,
do not turn on compressor.
21. Do not use steam to clean condenser and evaporator, only use cooling water or compressed air to clean
them.
23. When refrigeration system isn't filled with cooling medium, do not start compressor.
24. If you intend to store the compressor (used) for a long term, exhaust all air in the compressor and then top
up the compressor by coolant or dry nitrogen in order to avoid corrosion.
25. After installation is completed, inspect whether action of each part of vehicle is normal and cooling pipe,
cooling system and circuit are in good condition, and inspect whether air conditioner performance is good.
26. When installing vehicle parts, inspect the clearance between each part. Do not let them contact or near
each other. It is necessary to use insulation material to insulate them.
(a). Clearance between fan cover and condenser (or water tank): ＞ 5mm
(b). Clearance between cooling fan (steel) and condenser or water tank: ＞ 15mm
(c). Clearance between cooling fan (plastic) and condenser or water tank: ＞ 20mm
(d). Clearance between cooling fan and coolant fan cover (or radiator): ＞ 15mm
(e). Clearance between cooling fan and crankshaft (or tension pulley): ＞ 4mm
(f). Clearance between cooler fan and the condenser hose: ＞ 15mm
(g). Clearance between V-belt loose side and A/C hose: ＞ 20mm
27. When installing metal parts, it is necessary to add spring washer.
28. Parts mount on the engine must be tightened by specified torque.
29. Do not use hard pipe for connection when various assemblies are fitted with parts with different
overhanging body or different vibration frequency.
30. Cautions related to electric wire
(a). To avoid wire has short-circuit, before installing parts, it is necessary to dismantle negative cable of battery (or
grounding cable)
(b). Wire must be connected reliably and fixed firmly.
(c). If wire needs to pass through vehicle metal plates, it is necessary to add rubber ring (to protect wire).
(d). If other cables are removed or moved away in the process of repair, they must be restored.
(e). Cables must be fixed on the original wiring harness of the car by plastic tape or original fasteners.
(f). Do not clip the wiring harness when mounting other parts of A/C. 71
(g). If new cables will be welded with original cable, the cable with the same diameter must be used and the
connecting point must be wrapped by tape.
(h). Wire can't approach movable parts or high temperature parts (such as exhaust pipe of engine, cylinder block,
etc.), and keep away from heat source for more than 50mm.
(i). Wire must be separated with fuel pipe and keep away from fuel pipe for more than 100mm.
(j). Check carefully that cables contact with sharp object or movable parts.
LIFAN AUTO
Components diagram
LIFAN AUTO
Cross recessed pan head screw and plain washer Air conditioner high and low pressure pipe
1 16
assemblies clamp A
Hexagonal flange bolt and plain washer

2 Hexagon bolt and plain washer assy. 17
assemblies.
3 HVAC 18 High and low pressure pipe bracket assembly
4 Hexagonal nut and plain washer assemblies 19 Hexagon bolt with flange
Air conditioner high and low pressure hard pipe

5 Air conditioner drain pipe sealing ring 20
B
Air conditioner high and low pressure pipe

6 Hexagon bolt and plain washer assy. 21
clamp assembly
7 Drip pipe 22 Air conditioner low pressure hose assembly B
8 Spacer of heat water inlet and outlet pipe 23 A/C compressor
9 Clamp 24 Hexagon bolt with flange
10 Heater water outlet pipe 25 Air conditioner high pressure hose assembly
11 Heater water inlet pipe 26 Hexagon bolt with flange
12 Hexagon bolt with flange 27 High pressure pipe clamp
13 Air conditioner high pressure hard pipe clamp C 28 Air conditioner high pressure hard pipe A
14 Air conditioner low pressure pipe clamp B 29 Over-cooled condenser assembly
15 Air conditioner low pressure hose assembly A
71
LIFAN AUTO
Operating Principle
1. Heater system
1 Radiator 6 Blower assembly
2 Radiator inlet hose assembly 7 Heat exchanger outlet water pipe
3 Engine 8 Water pump
4 Heat exchanger inlet water pipe 9 Engine inlet water pipe
5 Heat exchanger 10 Radiator fan
1. The heater leads engine coolant into the radiator inside and then transfers heat energy, radiated
by coolant, to the passenger compartment or windshield to increase temperature in the passenger
compartment or defrost.
2. The heat exchanger of the heater is mounted on the heater housing, and hot coolant from the engine flows
into the heat exchanger inlet pipe, and the outlet pipe connects with the engine water pump.
3. Hot coolant circulates in the heat exchanger to radiate heat energy which will be transferred to the
passenger compartment or windshield by a blower and the guide air pipe. The thermostat in the engine
outlet controls water flow of the heat exchanger, and the out air temperature is controlled by the flower
speed adjusting switch and the output temperature adjusting switch.
LIFAN AUTO
2. Cooling system
1 Drying tank 6 Low pressure pipeline
2 High pressure pipeline 7 High pressure pipeline
3 Expansion valve 8 Condenser fan

71
4 Evaporator 9 Condenser
5 Blower 10 A/C compressor
1. Compressor driven by engine will pump gas type refrigerant from evaporator, and pump it into condenser.
2. High-pressure gasified refrigerant is liquefied when passing though the condenser and conducts heat
exchange (release heat). The released heat exhausts with air outside vehicle.
3. High pressure liquid refrigerant reduces its pressure through the throttle effect of expansion valve. Low
pressure liquid refrigerant is gasified in evaporator and exchanges heat with warm air outside evaporator
(absorbing heat). Hot air blew by blower enters into the car after cooling in evaporator.
4. The gaseous refrigerant is then drawn by the compressor and compressed into the condenser. The
refrigerant circulates in a closed circuit, continuously carrying heat from the passenger compartment to
outside air, and reducing inside air temperature to the specified value.
LIFAN AUTO
3. A/C control system

△ Hint:
• Air conditioner control system consists of power supply control circuit, compressor clutch control circuit and
safety protection control circuit, data communication circuit, etc. It mainly consists of air controller (electric air
conditioning system), coolant temperature sensor, pressure switch, relay and temperature controller, etc.
• The function of A/C control system is to guarantee the A/C system can working normally under any
circumstance, and ensure the safety running of A/C system and engine.
(a). Refrigeration Temperature Control
• Mainly consists of circuits of evaporator temperature sensor and A/C controller circuit and other related parts;
• When the temperature changes within the evaporator, the resistance of the sensor changes accordingly, so
that the A/C controller obtains a signal corresponding to voltage; after this signal is amplified by the amplifier
circuit in the controller, it can used to control the electromagnetic clutch relay.
• When the electromagnetic clutch relay is turned on, the compressor electromagnetic clutch engages and the
compressor works and temperature may drop; When the electromagnetic clutch relay is switched off,
the compressor electromagnetic clutch disengages and the compressor stops working and temperature may
rise. Through the control over compressor working conditions, A/C system can keep the cooling temperature
within the specified range.
(b). Engine control.
EFI engine controls working condition of compressor in order to reduce engine load under some special working
conditions: such as engine starting, sharp acceleration and overspeed running, air compressor will also stop
working.
(c). Control of Safety Protection
Safety protection control is to ensure the normal working of the system; it can monitor pressure and temperature
of the system by pressure switch mounted in the high pressure pipe to realize safety protection.
• Low pressure protection: when the pressure is lower than 0.196 ± 0.02 MPa, the pressure switch
disconnected, the compressor clutch power is cut off and the compressor stops working.
• Overpressure protection: when the pressure is higher than 3. 14±0.2 MPa, pressure switch will be switched
off and compressor clutch will be disconnected, and the compressor will stop working;
• Control high pressure: when the pressure is higher than or equal to 1. 77 ± 0.08 MPa, pressure switch is
turned on to send the engine ECM a trigger signal to have the electronic fan run at high speed;
• Low-temperature protection: when the temperature sensed by evaporator temperature sensor is lower than 1℃,
compressor clutch will be disconnected, and the compressor will stop working;
• High temperature protection: When the coolant temperature sensor sense temperature is above 110.
25 °C, thermal protection may activate and the compressor clutch power is cut off and the compressor stops
working.
(d). Control of Engine Cooling System (Electric Fan)
Engine cooling system control consists of coolant temperature sensor, engine ECM, fan control relay, cooling
fan, condenser fan and relevant circuits, etc. ECM turns on and off the fan control relay according to the signal
from the switch and temperature sensor as follows.
• When coolant temperature is 93°C~96°C, engine ECM will make relay of fan 2switch on, and 2 electric fan
motors are connected in series way meanwhile rotate at low speed.
• When coolant temperature is 98°C~100°C, engine ECM will make relay of fan 1 switch on, and 2 electric fan
motors are connected in parallel way meanwhile rotate at high speed.
• When coolant temperature is 110°C, coolant temperature shown in instrument cluster is too high and warning
lamp lights up.
• After compressor works, whether the coolant temperature is low or high, electric fan runs at low speed.
• When air conditioner refrigeration system pressure is higher or equal to 1. 77±0.08MPa, electric fan runs
at high speed.
• If coolant temperature sensor signal is abnormal (coolant temperature sensor is damaged), engine ECM will
think that engine is on big load running condition, and electric fan will run at high speed.
LIFAN AUTO
71
71-11
A/C system power, ground, signal

Driver compartment
central control box
Interior
LIFAN AUTO
Seat heating
dimming lamp
A/C System-A/C system
Background ACC power supply Battery power supply A/C request signal F/R seat F/L seat
light power heating signal heating signal
A/C control unit
Wiring diagram
CAN system
A/C system sensor, actuator
Mode motor Air fixing motor
LIFAN AUTO
Position feedback signal Face-blowing Front defroster Position feedback signal Hottest Coldest
A/C control unit
Sensor signal Sensor signal Sensor signal Sensor signal External circulation Internal circulation
71-12
Solar sensor Indoor temperature sensor Outdoor temperature sensor Evaporator temperature sensor Air charging motor
71
71-13
Blower control
Driver compartment central control box
A/C control unit
LIFAN AUTO
Regulating control Feedback signal
Blower
Regulator module
Terminal definition A01 to mode motor
U04 to outdoor temperature sensor
Terminal Color Function

No.
1 GrG Defroster drive of mode motor (+)
2 Gr Face blowing drive of mode motor (+)

No.
3 BlW Feedback signal of mode motor
1 VG Sensor signal
4 RW 5V reference power supply
2 WY Sensor (-)
5 RB Grounding
A02 to inner and outer circulation motor

U08 to fan

No.
1 Bl Inner circulation (+)
Terminal 2 Br Outer circulation (+)

Color Function
No.
3 - -
1 B Grounding
4 - -
2 RW Fan (+)
5 - -
3 RB Fan (-)
4 RG Fan (+) A03 to evaporator temperature sensor
I21 to indoor temperature sensor

No.
1 VR 5V reference power supply
2 VB Sensor signal
No.
A04 to mixed air gate motor
1 WY Sensor (-)
2 VW Sensor signal
I36 to sun sensor

No.
Mixed air gate motor cooling air drive

1 V
(+)
2 O Mixed air gate motor warm air drive (+)

No. 3 BlB Mixed air gate motor feedback signal
1 VY Sensor signal
4 RW 5V reference power supply
2 WY Sensor (-)
5 RB Grounding
LIFAN AUTO
A05 to air conditioner control unit
Terminal Terminal
Color Function Color Function
No. No.
1 RB Grounding 17 Bl Inner circulation drive output
2 P Sun sensor signal 18 Br Outer circulation drive output
Hottest drive output of mixed air gate

3 B Grounding 19 O
motor
Coldest drive output of mixed air gate

4 GW CAN_L 20 V
motor
Face blowing drive output of mode

5 GR CAN_H 21 Gr
motor
6 - - 22 GrG Defroster drive output of mode motor
Feedback signal input of mode actuator

7 BlW 23 - -
position
Feedback signal input of mixed air gate

8 BlB 24 YB Grounding
actuator position
9 GrY Indoor temperature sensor signal input 25 W Rear defroster signal output
10 RY Outdoor temperature sensor signal input 26 RW 5V reference power supply
11 Y Evaporator temperature sensor signal input 27 YG Blower air speed control signal output
Blower air speed voltage feedback

12 B Grounding 28 WB
signal input
13 G A/C request signal output 29 BlR Background light power
14 BrB Front right seat heating signal output 30 R Battery power supply
15 BG Front left seat heating signal output 31 - -

71
16 B Grounding 32 RBl ACC Power
A06 to speed adjusting module A07 to blower
Terminal Terminal
No. No.
1 Bl Blower (-) 1 R Blower
2 B Grounding 2 Bl Blower (-)
3 WB Blower feedback signal
4 YG Blower speed adjusting control
LIFAN AUTO
E01 to ECM
Terminal Terminal
No. No.
1 LgW No. 3 cylinder ignition coil control 29 - -
2 B Power ground 30 G CPS high voltage level signal
3 B Power ground 31 - -
4 LgR No. 1 cylinder ignition coil control 32 - -
5 RG Main relay power supply 33 GrR Brake lamp
6 OB No. 1 cylinder injector control 34 - -
7 PY No. 3 cylinder injector control 35 - -
8 YR No. 2 cylinder injector control 36 W KS high electric-level signal
9 GrY Pump relay control 37 B KS low electric-level signal
10 GrBl Air conditioner compressor control 38 WB CAN_H
11 Bl CPS low voltage level signal 39 W CAN_L
12 - - 40 G Intermediate voltage switch signal
13 - - 41 RY APS signal
14 - - 42 Gr APS signal
15 - - 43 YW VVT valve control
16 - - 44 WB Main relay control
17 GrV High speed fan control 45 - -
18 - - 46 - -
19 - - 47 OY Front HO2S signal
20 V TB motor（-） 48 GO Rear HO2S signal
21 Y TB motor（+） 49 YB CTS signal
22 - - 50 - -
23 GV Rear HO2S heating (-) 51 OG VSS
24 VW Front HO2S heating 52 BlG TPS signal
25 GY No. 4 cylinder injector control 53 - -
26 - - 54 P MAPS signal
27 P TPS signal 55 - -
28 - - 56 - -
LIFAN AUTO
57 - - 70 RB 5V Reference Voltage
58 - - 71 Bl IATS signal
59 WB G sensor signal 72 - -
60 BlG Power steering switch signal 73 VB HO2S Signal GND
61 - - 74 W Signal GND
62 Br No. 4 cylinder ignition coil control 75 GrG KW2000 communication
63 - - 76 WB Signal GND
64 WG CPV control 77 LgW CMPS signal
65 GrO Low speed fan control 78 - -
66 RW 5V Reference Voltage 79 RG A/C request signal
67 R ECM battery power supply 80 - -
68 RG Ignition switch power supply 81 PG No. 2 cylinder ignition coil control
69 GrW Brake switch
E24 to air conditioner magnetic switch

No.
71
LIFAN AUTO
System maintenance
Item Period Contents
Check the pipe joints for any leakage or traces of oil, and check
Piping, fittings Quarterly various hoses and pipes for cracks, aging, brittle, bruised,
crushed and damage or some other symptoms.
Observe pressure from the inspection glass or measure pressure

in high/low pressure side by a manifold pressure gauge.
Refrigerant quantity Quarterly
If refrigerant is not adequate, add refrigerant; if too much
refrigerant, drain some.
Check if condenser radiator fins are in good conditions. Check if

Condenser Quarterly channel is blocked; ensure that cooling air must flow smoothly;
clear off dirt, leaves, insects, plastic bags and other garbage.
Clear off dirt in the evaporator core and air vents; Check if the
Evaporator Quarterly draining system may successfully exhaust water moisture out of
the car.
Check if bolts in the compressor mounting bracket are loose.

Check if pulley has cracks and damage or that the compressor
Quarterly
runs with abnormal sound. Check if compressor bearing has oil
leakage.
Compressor
If the compressor are not used any more, check it weekly; each
Weekly time of inspection, have the compressor run a few minutes;
Check if all parts are in good conditions.
Check A/C compressor belt for looseness and wear. If damaged,

A/C compressor belt Quarterly
replace it on time.
After electrifying the electromagnetic clutch, Check if it can

Electromagnetic clutch Quarterly
quickly engage and disengage and that it slips.
Check the fan blade is damage; after electrifying the fan, Check
Blower Once each 9 months
if it can run normally.
Check if switch in the A/C control panel may operate smoothly

Control panel Once each 9 months and that the circuit is short or open and that wiring is in correct
layout.
LIFAN AUTO
Parts identification
1. Evaporator
(a). Evaporator structure
It is mounted in the housing of evaporator (as shown in left
figure).
(b). Function of evaporator.
Low pressure liquid refrigerant after throttling and pressure
reduction by expansion valve evaporated with some
refrigerant through heat absorption and evaporation, so as to
achieve temperature drop and dehumidification in the car.
(c). Operating process of evaporator.
Refrigerant after throttling enters into evaporator and
will boil after heat absorption and becomes saturated
evaporation. In this process, evaporation pressure remains
unchanged and corresponding evaporation temperature also
remains unchanged. Blower constantly blows air outside
evaporator with low temperature into the car to lower the
temperature inside car.
2. Condenser and drying tank

△ Hint:
Dry tank and condenser are integrated.
(a). Structure of condenser and drying tank
The condenser uses the all-aluminum parallel flow type
structure, which is mounted in the front of the engine
radiator; it use air from the radiator fan and the front of the
car in moving for forced cooling.
(b). Functions of condenser and drying tank
The condenser is used to radiate heat energy of high-
temperature high-pressure gaseous refrigerant drained by
the compressor and transfer the gaseous refrigerant into
liquid refrigerant. The dry tank is used to absorb moisture,
filter impurities and store refrigerant for normal operation
of the filling system. 71
(c). Operating process of condenser.
• During high temperature and pressure refrigerant
evaporates and changes into vapor, overheat refrigerant
vapor enters condenser pipe and quickly reduces to
saturation temperature through the radiation effect of
condenser pipe.
• The process where saturated refrigerant vapor is
converted into the saturated liquid. In this process,
refrigerant temperature does not change, and a big
number of heat is radiated in the liquefaction process of
refrigerant. Most heat is radiated through this process
during circulation of refrigerant.
• The process where saturated liquid refrigerant is
cooled to subcooled liquid. Temperature of saturated
liquid refrigerant is higher than that around ambient
environment, therefore, saturated liquid will further cool
in t his condenser pipe.
LIFAN AUTO
3. Expansion valve
(a). Expansion valve structure
Installed on inlet and outlet hoseport of evaporator (as
shown in left figure).
(b). Functions of expansion valve.
Under throttling function, the expansion valve reduces
pressure of high-pressure liquid refrigerant; it can
automatically adjust flow rate of refrigerant according to
refrigerant temperature of compressor and ensure that the
compressor refrigerant is gaseous.
(c). Operating process of expansion valve.
The expansion valve has two refrigerant channels i.e. the
inlet channel and the outlet channel. Ball valve below the
inlet channel may control flow rate of refrigerant; spring
force of ball valve may close the ball valve and cut off the
refrigerant flowing; push rod pushed by the diaphragm
may move downward and open the ball valve and then the
refrigerant flows through the channel for opening.
When outlet temperature of evaporator rises, temperature-
sensing element above diaphragm will expand to bend
the diaphragm and push top rod move downwards and
increase the opening of ball valve. At this moment, flow
rate of refrigerant will increase. With the increase of
refrigerant flowing to evaporator, when it leaves evaporator,
temperature will drop and temperature-sensing element
shrinks. Pressure under diaphragm reduces and ball
valve opening becomes small under the effect of spring.
Refrigerant flow rate also reduces.
4. Blower
(a). Blower structure
It should be installed inside blower tank (as shown in left
figure).
(b). Functions of blower
Use air entry port motor to switch air mode inside and out
side, and absorb indoor air or outdoor air.
5. Speed regulator resistor

(a). Configuration of speed adjusting resistance (as shown in left
figure).
(b). Functions of speed regulating resistor
Adjust speed of the blower motor randomly according to
change of output current.
LIFAN AUTO
6. Pressure switch
(a). Configuration of pressure switch (as shown in left
figure).
(b). Functions of pressure switch
Three-state pressure switch refers to a kind of 2-state
pressure switch which adds a middle pressure switch. When
system pressure increases, middle pressure switch starts
and sends signal to engine control unit. At this moment,
water tank fan and condenser fan run at high speed, to avoid
performance decreases due to the increase of pressure. And
it can protect air conditioning system when pressure (high
pressure/ low pressure) is in abnormal condition.
△ Hint:
Air conditioning system of LIFAN 720 car is equipped with a
three-state pressure switch, i.e. high pressure protection, low
pressure protection and middle pressure protection.
7. Temperature switch
(a). Structure of temperature switch.
It is installed inside evaporator core (as shown in left
figure).
(b). Functions of temperature switch.
It is used to feel temperature of evaporator core and
transmit it to air conditioner controller to avoid freezing of
evaporator.
8. Ventilation door motor

△ Hint:
This air conditioning system includes three ventilation door motor
- ① mode ventilation door motor ② internal/external circulation
ventilation door motor ③ mixed air ventilation door motor.
(a). Configuration of air gate motor (as shown in left
figure).
(b). Functions of ventilation door motor
• Operating mode ventilation door motor conducts 71
selection of air vent position.
• Internal/external circulation ventilation door motor
conducts selection of internal and external circulation of
A/C.
• Mixed air ventilation door motor conducts operation of
heating temperature.
LIFAN AUTO
9. Exterior temperature sensor

(a). Structure of exterior temperature sensor.
It is installed between bass horn and alt speaker horn in
front of vehicle (as shown in left figure).
(b). Functions of exterior temperature sensor.
It is used to feel outdoor temperature and transmit it to air
conditioner controller to make the outlet temperature and
air volume meet driver's demand.
10. A/C compressor

(a). Configuration of compressor (as shown in left
figure).
(b). Functions of compressor.
The compressor is heart of the cooling system and is used
to draw in and compress refrigerant to circulate refrigerant
continuously.
• Suction function of compressor Pumping of compressor
(through the cooperation of throttling effect of expansion
valve) is to reduce refrigerant pressure inside evaporator
pipe, and achieve the conversion of refrigerant from
liquid to gas form. So as to carry the heat inside car
through heat exchange and absorption.
• Compression function of compressor Compressor
compresses low-pressure gaseous refrigerant, such
as high-temperature high-pressure saturated gas,
realizing the process from gaseous refrigerant to liquid
refrigerant; the condenser releases heat to radiate heat
energy outside of the car.
• Circulation pump function of compressor Constant
pumping and compression of compressor achieves
circulation flow of refrigerant, therefore compressor is
also a power source for circulation flow of refrigerant.
LIFAN AUTO
71
71-23
Listen to the sound of compressor body using connecting rod

Measure the pressure via pressure gage (high, low pressure end)
A/C switch is switched on
Inspect the flowrate of refrigerant (at liquid tank)

Check the compressor actuating (sucking disc)
Enable engine inspection
Service according to the Problem Symptoms Table

Judge fault location according to the symptom
A/C use info
Make a preliminary judge about the

Check blower and condenser fan is working
likely position of the fault
LIFAN AUTO
A/C switch is not switched on

User info collection
Vehicle check
Defective
vehicle
Listen to the belt pulley does not exist abnormal sound

Check whether the pipe joint of the entire system does not exist oil stains
Fault info
Vehicle parking status check

Check whether the outer surface of A/C pipe does not wore
On-Vehicle check
Check the belt condition of compressor

Inspect the clean condition of condenser and evaporator
1. Check the A/ C air filter

(a). Open the glove box.
(b). Grasp both sides of the glove box and draw it outward, and
then remove the glove box.
(c). Remove the A/ C air filter cover.

△ Hint:
Lift up the A/C air filter cover from the right side.
LIFAN AUTO
(d). Take out the filter cartridge from the vent of the A/C air
filter.
(e). Clean the filter cartridge.

If the filter is too dirty, clean it by blowing compressed air
from the bottom.
△ Hint:
Keep the airgun 5cm away from the filter; blow it 2min by
compressed air of 500kPa.
(f). Mount the A/C air filter cartridge.

△ Hint:
"AIR FLOW" arrow must be placed downwards.
71
LIFAN AUTO
(g). Mount the A/C air filter cover.
(h). Mount the glove box.
(i). Close the glove box.
LIFAN AUTO
2. Check A/C compressor belt.

(a). Turn on the A/C and check by listening that the A/C
compressor belt is slipping.
If it is, please adjust tension of air conditioner compressor
belt or replace compressor belt.
(b). Check if the A/C compressor belt is loose.

• Press the center of the longest free edge by your thumb
and check its deflection.
△ Hint:
• Press it with force of 98N, and its belt deflection should be
7~8mm (5~5mm for new belt).
• If belt is loose, it is necessary to tighten the belt.
(c). Check if the A/C compressor belt is degraded, corroded and

loose.
△ Hint:
71
Inspect carefully each section of belt. If there is any of the
following damages, please replace with new belt.
• Rubber on back side is ageing and polish, no sign and
elasticity occur when scratching it with fingers
• Back rubber is cracked.
• Bottom of the belt teeth is cracked.
LIFAN AUTO
3. Check the A/C compressor

(a). Turn on the A/C and check by listening that the A/C
compressor clutch is engaged with "Pa" sound.
If it is, it indicates that air conditioner compressor is normal;
if it is not, it indicates that air conditioner compressor
doesn't work.
4. Check temperature of air conditioning system

△ Hint:
Measure temperature and Check if the A/C works normally.
(a). Operate the A/C setting to meet temperature measurement
conditions.
Conditions of temperature measurement:
• After the engine warms up, increase rotation speed to
3000r/min, and close engine hood tightly.
• Turn on the A/C control switch.
• Adjust the blower to maximum speed, and open all
vents.
(b). After the cooling system works 3min, measure temperature

(Ta) of center vent and the ambient temperature outside (Tb)
by a thermometer and then adjust whether temperature is
normal.
LIFAN AUTO
(c). If it is detected that the intersection of Ta and Tb is not in

normal area, it indicates that the temperature of refrigeration
system isn’t normal. (As shown in figure and table below)
Air status outside car Vent nearest to evaporator
Relative humidity (%) Drying air temperature (° C) Supply air temperature (° C)
20 2~5
25 6~9
50~60 30 10~13
35 14~17
40 19~22
20 4~7
25 8~11
60~70 30 12~15
35 16~19
40 21~24
△ Hint:
Optionally check temperature of A/C by hands; checking method is as follows:
1. Touch the high pressure pipe and the low pressure pipe of the cooling system by hand; it is ok if obvious
temperature difference exists and temperature of high pressure pipe is high and temperature of low pressure pipe
is low; but low pressure pipe should not frost.
2. Touch temperature of inlet and outlet pipes by hands; temperature in them should be consistent without
temperature difference.
3. Touch inlet and outlet pipe temperature of the condenser by hands; temperature of inlet should be higher
temperature of outlet. 71
4. Touch pipes from the condenser to the expansion valve by hands; temperature between the front and the rear
should be consistent.
LIFAN AUTO
5. Check pressure of air conditioning system

△ Hint:
Measure pressure in the high and low pressure sides of the cooling
system by a pressure gauge to diagnose fault of cooling system.
(a). Close completely valves in the low pressure and high
pressure sides of the manifold pressure gauge.
(b). Connect one end of the filling hose to the manifold pressure
gauge; connect another end to the connection port of the
vehicle side.
△ Hint:
Do not have any objects connect the center of the manifold
pressure gauge.
Attention:
• Tighten filling hose only by hands in the process of
connection. Do not use any other tool.
• If seal parts connecting the filling hose are damaged, replace
them.
• Due to different connecting dimensions between low
pressure side and high pressure side, when connecting hose,
do not install it in reverse order.
• When connecting hose and repair valve on vehicle side,
connect quick coupler to repair valve and slide it until "tick"
sound is produced.
• Do not bend the pipe when connecting with multifunction
gauge.
(c). Operate the A/C setting to meet pressure measurement
conditions.
Conditions of pressure measurement:
• Engine speed: 1500r/min.
• Adjust the temperature control switch to "Max Cold"
position.
vents.
• Completely open all vehicle doors.
LIFAN AUTO
(d). Check pressure displayed in the manifold gauge when the

A/C is running.
Reference standard:
Reference value in high pressure side: 1.422 ~ 1.471 MPa
Reference value in low pressure side: 0.147 ~ 0.196 MPa
△ Hint:
See Chapter 71 Electric Air Conditioner - Troubleshooting for
possible causes and remedies for abnormal pressure in high and
low pressure sides of the cooling system.
6. Check A/C pipes.

(a). Check if all naked copper pipes, hoses and pipes connector
of A/C system have interference, wear, squeezing and
looseness. If any symptom above is found, repair or replace
the related part according to actual situation.
△ Hint:
When replacing A/C pipes, seal rings in the pipe connection should
be abandoned; do not use them again.
71
LIFAN AUTO
71-32 A/C System-Troubleshooting
Troubleshooting
System troubleshooting
Description
Measure pressure in high and low pressure sides of the cooling system by the manifold pressure gauge; judge type and
position of fault by measured pressure. Have the high and low pressure pipe connectors of the manifold pressure gauge
connect respectively to high and low pressure valve of the A/C pipes. When the compressor is in two states - stationary
and running; analyze the cooling system fault by reading value of the pressure gauge.
1. Inspection of compressor stationary state
(a). Have the high and low pressure pipe connectors of the
manifold pressure gauge connect respectively to high and
low pressure valve of the compressor.
(b). Have the compressor in stationary state; stop it for a long
time (shutdown time will exceed 10h).
△ Hint:
• Do not have refrigerant attach the skin; otherwise frostbite
will easily occur.
• Pipe connector part is a quick connector; when it is
connected, press the inflation valve until clatter is heard.
(c). Check the reading of voltmeter.

△ Hint:
High pressure value of the compressor should be the same as
Equilibrium pressure/MPa
the low pressure value; this value is called equilibrium pressure.

Equilibrium pressure is related with ambient temperature , as
shown in figure left.
Ambient temperature
Relationship between equilibrium pressure and ambient temperature
(d). Analysis of cooling system fault
Symptom Cause Measures
Equilibrium pressure is too Drain some refrigerant and keep the equilibrium pressure in
Excessive amount of refrigerant
high standard value
Fill with some refrigerant and keep the equilibrium pressure rise to
Equilibrium pressure is too low Insufficient amount of refrigerant
the standard value
No equilibrium pressure (i.e.,

pressure displayed in high Check the expansion valve, the fluid reservoir, the dryer and the
Blockage in the system
and low pressure gauge is not pipelines respectively
equal)
LIFAN AUTO
A/C System-Troubleshooting 71-33
2. Inspection of compressor running state

When compressor is in running condition, set the switch to "inner circulation" status. Temperature in air inlet
and outlet is 30~35°C. Blower control switch is located in "high speed" position and temperature control
switch is located in "coldest position". Control engine speed at 1500~2000r/min, and start air conditioner to
run compressor (but working time of compressor should not exceed 30min; otherwise pressure plate may be
damaged and serious accident may also be caused). Read value shown in pressure gauge.
(a). Reading in the manifold pressure gauge when the cooling

system is normal.
Reference value in high pressure side: 1.422 ~ 1.471
MPa
(b). Moisture appears in the cooling system.

△ Hint:
When moisture appears in the cooling system, A/C just can cool intermittently and finally fails to cool.
Symptoms existing in the 71

Probable causes Diagnosis Remedies
cooling system
• Moisture entering the • The dryer is oversaturated. • Replace the dryer.

cooling system is freezing
• When the system is running, • Moisture entering in the
in the expansion valve to • kept pumping to remove the
the low pressure end cooling system is freezing
cause temporary interruption moisture in the system.
sometimes becomes vacuum in the expansion valve to
of circulation; but after ice
and sometimes normal. hinder circulation of cooling • Add a proper amount of new
melts, the system works
normally. system. refrigerant.
LIFAN AUTO
(c). The air conditioning system can not provide sufficient cooling effect.
Symptoms existing in the Probable causes Diagnosis Remedies

cooling system
• Check by a leakage checking

device that the gas leaks;
• Pressure in high and low repair it when necessary.
pressure sides is low. • Insufficient refrigerant in the
system. • Add a proper amount of new
• Find bubbles in the • Gas leaks in some position of refrigerant.
inspection window. cooling system. • Refrigerant leaks.
• If pressure value is near to
• Cooling is not sufficient. 0 when connecting with
the instrument, keep the
system vacuum status after
inspection and repair.
(d). Poor circulation of refrigerant in the air conditioning system.

cooling system
• Pressure in high and low

pressure sides is low. • Dirt in the connector hinder
• Clogged receiver. • Replace the receiver.
• Pipe section from the part to flowing of refrigerant.
the receiver is frosting.
LIFAN AUTO
(e). Refrigerant in the air conditioning system does not circulate.

cooling system
• Check expansion valve and

EPR.
• Clear off dirt in the
• Wa t e r o r d i r t i n t h e expansion valve by air
• Vacuum in low pressure end
refrigerant hinder flowing of blowing; if this method
and very low pressure in
refrigerant. does not work, replace the
high pressure end.
• Refrigerant fails to circulate. expansion valve.
• Gas leaks in the thermal
• Frost or condense in the
pipe of the expansion valve • Replace the receiver.
pipe of front/rear end of
and hinders flowing of
expansion valve or receiver. • Exhaust air and add a proper
refrigerant.
amount of new refrigerant.
If gas leaks from the thermal
pipe, replace the expansion
valve.
(f). Excessive refrigerant in the A/C is added; or the condenser has poor radiation performance.
71
cooling system
• Clean condenser.
• Excessive refrigerant in the • Check running conditions of
• Pressure in high and low • As there are excessively
system the fan motor.
pressure sides is too high. much refrigerant, full cooling
effect can not be exerted. • Cooling performance of
• No bubbles are found by • If the condenser or the fan
condenser is not sufficient; motor are in normal state,
inspection window even • Cooling performance of
condenser radiation fin check the refrigerant amount
when the engine speed drops. condenser is not sufficient.
clogged or faulty fan motor. and fill it with a proper
amount of refrigerant.
LIFAN AUTO
(g). Air exists in the air condition system.

△ Hint:
If refrigerant is added even when no vacuum job is not conducted after removing the A/C cooling pipe, or if it is not
completely vacuum inside, it may cause insufficient cooling.

cooling system

pressure sides is too high. • Check if compressor oil is
• Air enters the air condition
• Feel by hands that the low • Air enters the air condition unclean or insufficient.
system
pressure pipe is heating. system • Exhaust air and add a proper
• Not completely vacuum.
• Find bubbles in the amount of new refrigerant.
inspection window.
(h). Expansion valve fault or incorrect installation.

cooling system
• Check installation of the

thermal pipe.
pressure sides is too high. • Excessive refrigerant amount
• Expansion valve exists fault, in low pressure pipe. • If the thermal pipe
• Frost in pipe on the low-
or thermal tube is improperly installation situation is
pressure end or lots of dew • Too open in expansion valve
installed. normal, check the expansion
appears.
valve; if damaged, replace it.
LIFAN AUTO
(i). Air conditioning compressor fault.

cooling system
• High pressure in low

• Compression fault.
pressure end. • Internal leakage in • Repair or replace the
compressor. • valve leaked or damaged; compressor.
• Low pressure in high
parts are loose and fall.
pressure end.
71
LIFAN AUTO

these parts.
1. Fuse (damaged) Replace fuse
2. A/C belt (too loose) Adjust A/C belt
3. Refrigerant (insufficient) Add refrigerant
4. Compressor (fault) Repair or replace the compressor.
5. Expansion valve (fault) Replace the expansion valve.

Cooling system does not
have cooling performance Replacing the condenser and the fluid reservoir dry tank
6. Condenser (blocked)
assembly
7. A/C pipe (blockage) Clean the A/C pipe
8. Operating mechanism assembly

Repair or replace the operating mechanism
(poor contact)
9. C o o l i n g s y s t e m ( i n s u ff i c i e n t
Check pipe or add refrigerant
pressure)
1. C o m p r e s s o r b e l t ( s l i p p e r y o r
Replace the compressor belt
degraded)
Heater and A/C system have 2. Compressor parts (loose) Tighten compressor loose parts
abnormal sound
3. Compressor bearing (damaged) Replace the compressor bearing
4. Blower (fault) Repair or replace the blower
1. Blower (damaged) Replace Blower
2. Blower relay (damaged) Replace the blower relay
3. Warm air ventilation channel

Connect the warm air ventilation channel
No warm air or insufficient (connector falls off)
warm air
4. Coolant (insufficient or clogged) Add coolant
5. Heat converter fin (deformed) Adjust fins by a tweezers or a fin comb
6. Heater pipe (blocking) Clean the heater pipeline
LIFAN AUTO
Read and clear DTCs

(DTC)
(a). Turn the ignition switch to ON.
(b). Connect LIFAN V30 diagnostic scanner to diagnostic port.
(c). Turn on the diagnosis tester, and enter into "Chongqing

LIFAN" diagnosis system.
Series selection
Chongqing Lifan
System configuration Help About Power off
(d). Select V5. 0 diagnostic procedure version, and click "OK".

71
Demo
OK
Cancel

LIFAN AUTO
(e). Select to enter "Air Conditioning System".

Anti-theft system
Vehicle body system
A/C System Return
(f). Select to enter "Air Conditioning Control System (Ruiyang)
A/C system LIFAN Dedicated\Chongqing Lifan\V5.0\A/C system
A/C control system (Ruiyang) Previous page
Next page
Print
Return
(g). Click to select "Read DTC".

△ Hint:
Function selection LIFAN Dedicated\Chongqing Lifan\V5.0\A/C system\A/C control system

If any previous DTC exists in the diagnostic scanner, firstly you
Clear fault code
Version info
Print
Return
LIFAN AUTO
(h). Read and record all displayed DTCs.
Fault code list

Evaporator temperature sensor cut-off
Evaporator temperature sensor short
Engine speed sensor fault
Mode air door actuator fault
Mode air door actuator fault
(i). If no DTC is found, select "OK" and return back.
Information
Fault code not found! OK
2. Clearing of DTCs
Function selection LIFAN Dedicated\Chongqing Lifan\V5.0\A/C system\A/C control system
Read fault code Previous page 71

Clear fault code
Version info
Print
Return
LIFAN AUTO

△ Hint:
Information If the fault code cannot be removed, it is an indication that the fault
has not been troubleshooted. You should remove the fault based on
Do you want to clear all the fault codes? OK
the fault code before trying to remove the fault code again.
Cancel
(c). Select "OK" to confirm that the trouble code has been
cleared.
Information
The fault code has been cleared! OK
LIFAN AUTO
Fault code (DTC) list

Attention:
Fault code (DTC) Fault code description Suspected Area
• Evaporator temperature sensor circuit

Evaporator temperature sensor has open-
B190013 • Evaporator temperature sensor
circuit.
• Air conditioner control unit
• Evaporator temperature sensor circuit

Evaporator temperature sensor has short-
B190011 • Evaporator temperature sensor
circuit.
• Indoor temperature sensor circuit

B190113 Indoor temperature sensor has open-circuit. • Indoor temperature sensor
• Indoor temperature sensor circuit

B190111 Indoor temperature sensor has short-circuit. • Indoor temperature sensor
• Outdoor temperature sensor circuit

B190213 Outdoor temperature sensor has open-circuit. • Outdoor temperature sensor
• Outdoor temperature sensor circuit

B190211 Outdoor temperature sensor has short-circuit. • Outdoor temperature sensor
• Solar sensor circuit

B190313 Solar sensor has open-circuit • Solar sensor
• Solar sensor circuit

B190311 Solar sensor has short-circuit. • Solar sensor
B190400 Speed sensor fault • Speed sensor
B190500 Coolant temperature sensor fault. • Water temperature sensor 71

B190600 Engine speed sensor fault. • Engine speed sensor
• Mode air door actuator circuit

B190700 Mode air gate actuator fault • Mode air door actuator
• Mode air door actuator circuit

B190800 Mixed air gate actuator fault • Mode air door actuator
LIFAN AUTO
• Blower circuit
B190900 Fan fault • Blower
• Speed adjusting mode
U190087 4D4 message receiving overtime • CAN bus
U190187 210 message receiving overtime • CAN bus
U190588 Bus closes • CAN bus
B190011 - Evaporator temperature sensor has short-circuit.

B190013 - Evaporator temperature sensor has open-circuit.
Check wire harness and connector

• Disconnect the battery negative electrode.
• Disconnect evaporator temperature sensor connector A03, air conditioner control unit
1 connector A05. To Step 2 To Step 4
• Use a digital multimeter resistance scale to check whether the resistance between No.1
terminal of A03 and No.11 terminal of A05, No.2terminal of A03 and No.3 terminal of
A05 is less than 2Ω.
Inspect evaporator temperature sensor

• Turn off air conditioner.
• Disconnect evaporator temperature sensor connector A03, and use a multimeter
resistance scale to check whether No.1 and No.2terminals of evaporator temperature
sensor are connected.
Replace air conditioner control unit.

3 To Step 6
• Refer to repair steps specified in Repair Manual for replacement of A/C control panel.

4 To Step 6
• Repair or replace faulty wire harness or connector.
Replace evaporator temperature sensor.

5 • Refer to repair procedures specified in repair manual to replace evaporator temperature To Step 6
sensor.
6 Check whether the trouble has been removed. The diagnosis is completed.
B190111 - Indoor temperature sensor has short-circuit.

B190113 - Indoor temperature sensor has open-circuit.

1 • Disconnect indoor temperature sensor connector I21, air conditioner control unit To Step 2 To Step 4
connector A05.
terminal of A05, No.2terminal of I21 and No.9 terminal of A05 is less than 2Ω.
LIFAN AUTO
Inspect indoor temperature sensor.

• Disconnect indoor temperature sensor connector I21, and use a multimeter resistance
scale to check whether No.1 and No.2terminals of indoor temperature sensor are
connected.

3 To Step 6

4 To Step 6
Replace indoor temperature sensor.

5 • Refer to repair procedures specified in repair manual to replace indoor temperature To Step 6
sensor.
B190211 - Outdoor temperature sensor has short-circuit.

B190213 - Outdoor temperature sensor has open-circuit.

• Disconnect outdoor temperature sensor connector U04, air conditioner control unit
1 connector A05. To Step 2 To Step 4
• Use a digital multimeter resistance scale to check whether the resistance between
No.2terminal of U04 and No.24 terminal of A05, No.1 terminal of U04 and No.10
terminal of A05 is less than 2Ω.
Inspect indoor temperature sensor.

• Disconnect outdoor temperature sensor connector U04, and use a multimeter resistance
scale to check whether No.1 and No.2terminals of indoor temperature sensor are
connected.

3 To Step 6

4 To Step 6
71
Replace outdoor temperature sensor.
5 • Refer to repair procedures specified in repair manual to replace outdoor temperature To Step 6
sensor.
LIFAN AUTO
B190700 - Mode air door actuator fault


• Disconnect mode motor connector A01, air conditioner control unit connector A05.
terminal of A01 and No.22terminal of A05, No.2terminal of A01 and No.21 terminal of
A05, No.3 terminal of A01 and No.7 terminal of A05, No.4 terminal of A01 and No.26
terminal of A05, No.5 terminal of A01 and No.1 terminal of A05 is less than 2Ω.
Check mode motor

• Disconnect mode motor connector A01.
• Inspect whether voltage between No.4 and No.5 terminals of mode motor is about 5V.
2 • Connect No.3 terminal of mode motor to oscilloscope. To Step 3 To Step 5
• Connect No.1 terminal and No.2terminal of mode motor to positive and negative poles
of battery (connecting time is shorter than 2s).
• Inspect feedback signal shown in oscilloscope.

3 To Step 6

4 To Step 6
Replace mode motor

5 To Step 6
• Refer to repair procedures specified in repair manual to replace mode motor.
B190800 - Mixed air door actuator fault


• Disconnect mixed air motor connector A04, air conditioner control unit connector
A05.
terminal of A04 and No.22terminal of A05, No.2terminal of A04 and No.21 terminal
of A05, No.3 terminal of A04 and No.7 terminal of A05, No.4 terminal A04 and No.26
terminal of A05, No.5 terminal of A04 and No.26 terminal of A05, No.5 terminal of A04
and No.1 terminal of A05 is shorter than 2Ω.
Inspect mixed air motor.

• Disconnect mixed air motor connector A04.
• Inspect whether voltage between No.4 and No.5 terminals of mixed air motor is about
5V.
• Connect No.3 terminal of mixed air motor to oscilloscope.
• Connect No.1 terminal and No.2terminal of mixed air motor to positive and negative
poles of battery (connecting time is shorter than 2s).
• Inspect feedback signal shown in oscilloscope.
LIFAN AUTO

3 To Step 6

4 To Step 6
Replace mixed air motor.

5 To Step 6
• Refer to repair procedures specified in repair manual to replace mixed air motor.
B190900 - Fan fault

Check the system

1 • Ensure that the power source operates normally. To Step 2
• Turn on windshield switch, and inspect whether blower works normally.
Inspect blower fuse.

2 • Open the central control box in the driving compartment. Go to step 7 Go to step 3
• Inspect whether blower fuse SB05 is burned out.
Inspect blower wire harness and connector.

• Disconnect blower connector A07.
• Disconnect speed adjusting mode connector A06.
3 • Use a multimeter resistance scale to check whether the resistance between No.2terminal Go to step 4 Go to step 8
of A07and No.1 terminal of A06 is less than 2Ω.
• Disconnect connector I10
• Use a multimeter resistance scale to check whether the resistance between No.1 terminal
of A07and No.2terminal of I1C is less than 2Ω.
Inspect speed adjusting mode wire harness and connector.

• Disconnect air conditioner control unit connector A05.
• Disconnect speed adjusting mode connector A06.
• Use a multimeter resistance scale to check whether the resistance between No.27
4 terminal of A05 and No.4 terminal of A06 is less than 2Ω. Go to step 5 Go to step 8
terminal of A05 and No.3 terminal of A06 is less than 2Ω.
• Use a multimeter resistance scale to check whether the resistance between No.2terminal
of A06 and grounding is less than 2Ω.
71
Check the blower
• Disconnect fan connector A07.
5 Go to step 6 Go to step 9
• Connect positive and negative poles to No.1 and No.2terminals of blower connector, and
inspect whether blower works normally.
Replace speed adjusting mode.

6 To Step 6
• Refer to repair steps specified in repair manual to replace speed adjusting mode.
LIFAN AUTO
Replace Fuse
7 • Before replacing the burnt fuse, firstly troubleshoot the circuit according to circuit To Step 10
diagram and then replace the fuse with one at rated ampere of 30A.

8 To Step 10
Replace blower
9 To Step 10
• Referring to the repair manual, replace the blower.
LIFAN AUTO
A/C System-Refrigerant 71-49
Refrigerant
Check
1. Check refrigerant filling amount (check it by inspection
window)
(a). Operate the A/C setting to meet inspection conditions.
Inspection conditions
• Engine speed: 1500r/min.
position.
vents.
• All doors are fully closed.
(b). Observe refrigerant flow rate by inspection window and

check refrigerant amount.
Normal Insufficient Empty or too more
(c). According to the following instructions, determine that refrigerant amount is proper. 71
△ Hint:
If liquid level is clear and no bubbles are found or just bubbles are noticed in 4 ~ 5s, it indicates that refrigerant is
sufficient; if a large number of bubbles exist, it indicates that refrigerant is insufficient and more refrigerants are
required.
LIFAN AUTO
71-50 A/C System-Refrigerant
Standards:
State of the inspection window

Refrigerant filling Pressure conditions in high
amount pressure side (about)
(About 1 min after the A/C switch is turned on)
Appropriate 1.8~2.5MPa
Excess ＞ 2.5MPa
Insufficient ＜ 1.2MPa
State description
Transparent: all cooling medium is transparent state under liquid condition.
Air bubble: if gas and liquid cooling medium are mixed, air bubbles will be produced.
White and impure: refrigerant oil and cooling medium are milky under separated condition.
Air bubble, white and impure: when gas cooling medium and separated refrigerant oil mixed, it has air bubbles and the
color is white and it is impure.
Attention:
• If it is found by inspection window that bubbles exist for a long time, it indicates that refrigerant in the
system is insufficient.
• If it is found by inspection window that there are no bubbles and the vent is not cold, it indicates that all
refrigerant in the system leaked`.
• If refrigerant immediately disappears and observing hole keeps clear when turning off air conditioner, it
indicates that refrigerant in system is overfilled.
• If bubbles in the hole firstly appear and then disappears when the A/C is turned off, it indicates that there
are proper amount of refrigerants in the system.
• If the inspection window is hazed, it indicates that it is too dirty inside the cooling system or the dryer is
damaged.
LIFAN AUTO
2. Inspect filling amount of refrigerant (by pressure

method).
△ Hint:
Measure pressure in the high and low pressure sides of the cooling
system by a pressure gauge to diagnose fault of cooling system.
(a). Close completely valves in the low pressure and high
pressure sides of the manifold pressure gauge.
(b). Connect one end of the filling hose to the manifold pressure
gauge; connect another end to the connection port of the
vehicle side.
△ Hint:
Do not have any objects connect the center of the manifold
pressure gauge.
Attention:
• Tighten filling hose only by hands in the process of
connection. Do not use any other tool.
• If seal parts connecting the filling hose are damaged,
replace them.
• Due to different connecting dimensions between low
pressure side and high pressure side, when connecting
hose, do not install it in reverse order.
• When connecting hose and repair valve on vehicle side,
connect quick coupler to repair valve and slide it until
"tick" sound is produced.
• Do not bend the pipe when connecting with
multifunction gauge.
(c). Operate the A/C setting to meet pressure measurement
71
conditions.
Conditions of pressure measurement:
• Engine speed: 1,500r/min.
position.
vents.
LIFAN AUTO
(d). Check pressure displayed in the manifold gauge when the

A/C is running.
△ Hint:
Pressure displayed in the multifunction gauge may lightly vary
with external air temperature.
Reference standard:
Reference value in high pressure side: 1.422 ~ 1.471
MPa
(e). Check if pressure is within specified range and then
determine refrigerant amount.
△ Hint:
If within specified range, it indicates that refrigerant filling
amount meets refrigerant. Otherwise it indicates that refrigerant is
insufficient or excessively much.
3. Check coolant for leakage
△ Hint:
Coolant leakage is the most common fault occurred in the use of A/C; the common inspection methods are by eyes,
soapy water, halogen light and fluorescent.
(a). Visual leakage inspection

Method: Check piping with the naked eye; if it is found that there is oil stain in somewhere in the system, you
may determine that this is leakage point.
Advantages and disadvantages: Visual inspection is easy without cost; but its big disadvantage is that this method
is only applicable to big leakage point suddenly breaking where colored liquid media flows out; otherwise it is
impossible to use this method. Because position with leakage is often small, many leakage points may become
invisible.
(b). Soap leakage inspection.
Method: Fill the system with pressure nitrogen of 1 ~ 2MPa, and then apply soapy water in various parts of the
system; points with bubbling are leakage points.
Advantages and disadvantages: length of the human arm is limited, and the range of vision is limited as well;
therefore it is impossible to detect leakage point in many conditions.
(c). Halogen lamp leakage inspection
Methods: Illuminate the leakage detection light and hold the air pipe by halogen light; when the pipe nozzle is
close to leakage of the system, the flame color become purple blue, it indicates lots of leakages occurred here.
Advantages and disadvantages: this method may produce open fire which is not only dangerous and will produce
poisonous gas when open fire encounters refrigerant. In addition, the method is uneasy to correctly locate leakage
point.
(d). Florescent leakage inspection
Methods: Add fluorescent to the system by a certain proportion. After the system runs 20min, wear a pair of
special glasses; shine the system outside by fluorescent. Yellow fluorescence indicates leakage.
advantages and disadvantages: accurate positioning; leakage can certainly directly seen with the eyes; the
inspection tool is easy to be carried; inspection cost is low.
LIFAN AUTO
Replace
1. Drain refrigerant
(a). Have the high and low filling rubber hose of the manifold
pressure gauge connect with the quick connector and then
mount the combination onto the A/C pipeline connector.
△ Hint:
Turn off the high and low pressure manual valve of the manifold
pressure gauge and then connect the pipeline. Place the drain hose
in the center of the manifold pressure gauge into a clean flask (or
onto a clean cloth); do not start the engine.
Attention:
Keep the working place well ventilated in recycling refrigerant;
do not have refrigerant close to open flame in order to avoid
producing toxic gas.
(b). Open the high-pressure manual valve slowly.

Attention:
Do not open the valve too much; slowly drain refrigerant and
observe the flask or rag in the intermediate drain hose outlet; if
refrigeration oil flows out together, reduce opening angle of the
high pressure manual valve.
(c). When pressure in the high pressure gauge drops to 340kPa,

slowly open the low-pressure manual valve; do not open it
too much.
71
Attention:
• Observe the flask in the intermediate drain hose; it
is ok if no refrigeration oil is in the flask or rag. Now
refrigerant flows out from both sides (high and low
pressure sides) of the system at the same time.
• Observe indication value of the manifold pressure
gauge; with pressure dropping in the system, properly
increase opening of high/low pressure manual valve;
when indication value in the pressure gauge in the high/
low pressure side drops to 0, the refrigerant draining
job is finished; now close the high/low pressure manual
valve of the manifold pressure gauge.
△ Hint:
In the process of draining, you should keep careful to prevent lots
of refrigeration oil from flowing out. Therefore, before adding
refrigerant, you should add an equal amount of new refrigerant oil
according to amount of oil flowed out from the flask.
LIFAN AUTO
2. Recycle refrigerant.
△ Hint:
If proper conditions are available, refrigerant can be recycled for
reuse. In doing so, you should prepare refrigerant recycling device.
Recycling steps are as follows:

• Connect filling hose in the middle of manifold pressure gauge to the entry of recover machine, and the other hose
on the recover machine is connected to the port of liquid reservoir. Open the manual valve of liquid reservoir and
switch on power supply of recover machine of refrigerant.
• Turn on the high and low pressure manual valve of the manifold pressure gauge.
• Run the recycling machine 15 ~ 20min.
Attention:
Refrigerant may produce toxic gas. So you should ensure good ventilation in the process of recycling; in addition,
as refrigerant is flammable, do not have it close to an open flame.
3. Remove the refrigerant recycling machine

• Close the fluid reservoir valve manual valve.
• Turn off the high and low pressure manual valve of the manifold pressure gauge.
• Turn off power supply of recycling machine.
• Remove the filling hose in the middle of the manifold pressure gauge from the recycling machine.
4. Make the cooling system vacuum

(a). Have the high/low pressure filling rubber hose of the
manifold pressure gauge mount on the connector of the
high/low pressure pipe connector in the A/C through the
quick connector; the filling rubber hose in the middle of the
manifold pressure gauge should connect with the vacuum
pump drawing connector.
LIFAN AUTO
(b). Before making the cooling system vacuum, open the high/
low pressure valve of the pressure gauge.
(c). Turn the vacuum pump to "ON" position; draw it for more
than 20-30 min; confirm that the gauge pressure reaches or
approaches to a value below -0.1MPa; turn off the high/low
pressure valve in the pressure gauge; and then finally stop
the vacuum pump.
△ Hint:
If a small amount of refrigerant oil flows out in draining refrigerant, you may close the high/low pressure valve of
manifold pressure gauge; remove the intermediate filling hose from the vacuum pump and place it in refrigerant oil and
then open the low pressure valve of the manifold pressure gauge; use vacuum pressure in the A/C to fill the cooling
system pipes with refrigerant oil flowed out. Draw vacuum in the cooling system again. Confirm that the gauge pressure
reaches or approaches to a value below -0.1MPa; turn off the high/low pressure valve in the pressure gauge; and then
stop the vacuum pump.
5. Air tightness check

• After the vacuum pump stops, pay attention to reading; measure pressure in pipeline after 5min; confirm
that reading does not change before next step. If the pressure rise (increasing speed is related with size of the
leakage), repair leakage part before drawing vacuum.
6. Refrigerant filling
(a). Confirm that no gas leakage occurs in the cooling system
pipeline and the connectors. Connect well the intermediate
hose with the refrigerant reservoir.
△ Hint:
If conditions allow, place the liquid reservoir onto the electronic
scale to know clearly filling amount of refrigerant.
71
LIFAN AUTO
(b). Confirm that 3 filling hoses on the manifold pressure gauge

are securely tightened. Open the manual valve in the liquid
reservoir to let refrigerant flow into the hoses. Now, the
high/low pressure valve of the manifold pressure gauge can
not be opened. Press the pressure gauge side for 1-2s by a
screwdriver; drain refrigerant in order to exhaust air in the
filling hose and the air pipe pressure gauge.
△ Hint:
If you add refrigerant from the high pressure pipe before starting
the engine, you can turn over the refrigerant reservoir or fill liquid
refrigerant in inverted manner.
Attention:
Do not have refrigerant splash over skin to avoid frosbite; you
should make protective measure before repair.
(c). Open the high-pressure valve in the pressure gauge and

add refrigerant from the high pressure side. At this time,
pay attention to the pressure gauge pointer; confirm the
high pressure gauge pointer rises steadily. If it fails to rise
steadily, check if the rubber pipes and the connections are
loose or the seal is broken; if any abnormality is found,
repair it.
(d). After the manifold pressure gauge pointer goes up and then
stops, turn the high pressure valve and start the engine.
(e). Turn the A/C and adjust the thermostat switch to "Max
Cold" position; open all doors and windows; switch to
"Internal Circulation" mode; adjust the engine speed to
"specified rotating speed".
(f). Place liquid reservoir (or pressure gas container) vertically

(because refrigerant must be gas state). Open low pressure
valve of manifold pressure gauge to continue to fill.
Never open the high pressure valve when the compressor
is running; otherwise refrigerant is flowing in reverse
direction, easily leading to breaking of the liquid reservoir.
LIFAN AUTO
(g). After adding a proper amount of refrigerant, turn off

the high and low pressure manual valve of the manifold
pressure gauge. Close the manual valve of the reservoir, and
remove connectors between the manifold pressure gauge
filling hose and the reservoir.
△ Hint:
Observe high and low pressure value of the pressure gauge and
check the refrigerant flowing states (transparent, bubble and turbid)
by the inspection window.
(h). You may judge the refrigerant filling amount by the inspection window or the manifold pressure gauge when the
following conditions are met:
• Engine speed: 1,500r/min.
• Adjust the temperature control switch to "Max Cold" position.
• Adjust the blower to maximum speed, and open all vents.
(i). After all procedures are completed, turn off the air conditioner and wait for it returning to balance pressure
condition. Turn on the air conditioner again according to Chapter 71 Electric Air Conditioner - Refrigerant,
Inspection. Judge refilling amount according to the said method.
△ Hint:
If refrigerant is not enough, add refrigerant. When adding refrigerant, pay full attention to state change of refrigerant
by the inspection window and the pointer change of the pressure gauge in the high pressure side; and then add a proper
amount of refrigerant.
7. Remove the quick connector of the filling pipe.

• Firstly close the low pressure valve in the pressure gauge after the refrigerant filling is finished, and then
close the switch (if available) on the quick connector. And remove the quick connector of the filling pipe
rapidly from the filling port; avoid gas leakage; fit well the charging valve cover.
71
8. Check refrigerant for leakage (see Chapter 71 Electric Air Conditioning - Refrigerant ,Inspection)
LIFAN AUTO
71-58 A/C System-HVAC assembly
HVAC assembly
Replace
1. Remove the HVAC assembly
(b). Drain engine coolant.
(c). As shown in figure, loosen the lock clips between the heater
pipe and the HVAC, and then pull out the heater water pipe.
(d). Drain refrigerant. (See Chapter 71 Power Air Conditioner –
Refrigerating Fluid, Replacement)
(e). Dismantle fixed bolts of pressure plate used to fix high and
low pressure pipe of air conditioner and HVAC assembly,
and unplug high and low pressure pipe.
(f). Dismantle dashboard assy. (See chapter 85, Dashboard and
Console - Dashboard - Replacement)
(g). Take out center ventilation transition pipe.
LIFAN AUTO
A/C System-HVAC assembly 71-59
(h). Dismantle fixed nuts of right ventilation pipe assembly, and

remove right ventilation pipe assembly.
(i). As shown in figure, disconnect all connectors connected

with HVAC assembly.
△ Hint:
When disconnecting connectors, pay attention to the connecting
positions of connectors.
(j). Disconnect drip pipe of air conditioner.
71
LIFAN AUTO
(k). Dismantle fixed bolts of HVAC assembly, and take out

HVAC assembly.
Attention:
When taking out HVAC assembly, it is necessary to unscrew
fixed bolts of dashboard horizontal beam.
2. Check and repair HVAC assembly

(b). Check and repair blower assembly
• When connecting positive and negative poles of battery
to No.1 and No.2terminal of blower, blower should
work normally.
△ Hint:
If blower doesn't work, it indicates that blower is damaged and to
be replaced.
• Dismantle fixed bolts of ECM bracket, and remove

ECM bracket and ECM.
Attention:
When taking out ECM, handle with care. Do not make it
crashed to avoid damage of ECM.
• Dismantle fixed screws of blower assembly, and remove
blower assembly.
• Install blower assembly and install fixed screws of
blower assembly and tighten them.
LIFAN AUTO
(b). Overhaul of speed adjusting resistance.

• Remove speed regulating resistor set screw, and take out
speed regulating resistor.
△ Hint:
Check the speed regulating resistor is damaged, if damaged, please
give the replace.
• Install speed adjusting resistance, and install fixed
screws of speed adjusting resistance and tighten them.
(c). Overhaul of inner circulation air gate motor, mode air gate
motor, mixed air gate motor.
△ Hint:
Overhaul methods of inner circulation air gate motor, mode air gate
motor, mixed air gate motor are the same. Now, take the overhaul
of mixed air gate motor as an example.
• Dismantle fixed screws of bellows, and remove bellows.
• Dismantle fixed screws of mixed air gate motor, and

remove mixed air gate motor.
△ Hint:
Inspect whether mixed air gate motor is damaged. If it is, replace
it. 71
• Install mixed air gate motor and fixed screws of fixed air
gate motor and tighten them.
LIFAN AUTO
(d). Overhaul of expansion valve.

• Remove the expansion valve set screw, and take out
expansion valve.
△ Hint:
Check the expansion valve is damaged, if damaged, please replace
it.
• Put the expansion valve into the correct position and
then mount and tighten set screws.
(e). Overhaul of evaporator.

• Remove the bellow assembly.
• Remove the bellow set screw, and take out the bellow.
• Remove the expansion valve assembly.
• Remove the bellow set screw, and take out the bellow.
• Remove the expansion valve assembly.
LIFAN AUTO
• Take out the HVAC assembly.

• Check if evaporator fins are damaged; if damaged,
repair or replace the HVAC assembly.
• Mount the evaporator assembly in reverse sequence
used in the removal.
(f). Overhaul of temperature switch.

• Remove the HVAC assembly.
• Remove the temperature switch from the evaporator.
• Mount the temperature switch onto the evaporator.
• Mount the HVAC assembly.
(g). Overhaul of heat exchanger.

• Dismantle fixed screws of heat exchanger pipe clamp,
and remove heat exchanger pipe clamp.
71
LIFAN AUTO
• Remove the heat exchanger assembly.
• Inspect whether heat exchanger fin is damaged. If it is,

please repair or replace heat exchanger assembly.
• Mount the heat exchanger assembly in reverse sequence
used in the removal.
3. Mount the HVAC assembly

△ Hint:
Mount the HVAC assembly in reverse sequence used in the removal.
LIFAN AUTO
A/C System-A/C compressor 71-65
A/C compressor
Check and repair
1. Dismantle air conditioner compressor assembly
(a).Drain refrigerant (See Chapter 71 power Air
Conditioner - Refrigerating Fluid, Replacement)
(b).Disconnect electromagnetic clutch wire harness
connector.
Attention:
Do not use hands to directly plug or unplug wire harness. Take
it out by pressing wire harness plug clamp.
(c). Dismantle fixed bolts of pressure plate of high and low

pressure pipe of compressor of air conditioner, and unplug
high and low pressure air pipe.
Attention:
High/low pressure pipes and inlet/outlet of the compressor shall
be covered to prevent dust and water in the air from going into
them.
71
(d). Use a offset ring spanner to exert force to tensioner in
clockwise, and remove drive belt.
LIFAN AUTO
71-66 A/C System-A/C compressor
(e). Dismantle fixed bolts of compressor of air conditioner, and

remove compressor of air conditioner.
2. Dismantle electromagnetic clutch

(a). Dismantle bolts of pressure plate of fixed electromagnetic
clutch.
△ Hint:
Fix the compressor on the vise and driving wheel with vise grip
pliers (wrap fixed driving wheel with a cloth), then dismantle fixed
bolt of electromagnetic clutch pressure plate.
(b). Dismantle driving wheel.

• Dismantle snap spring of fixed driving wheel by circlip
pliers.
• Remove driving wheel.
LIFAN AUTO
(c). Dismantle fixed snap ring of electromagnet by circlip pliers

and take out electromagnetic coil.
3. Install electromagnetic clutch

(a). Install electromagnet.
△ Hint:
Align installation location mark.
(b). Install electromagnetic coil in place and fasten it by snap

ring.
71
LIFAN AUTO
(c). Install driving wheel and snap ring in place by circlip pliers.
(d). Install pressure plate of electromagnetic clutch onto pulley

and fixed bolts and tighten them.
△ Hint:
Fix the compressor on the vise and driving wheel with vise grip
pliers (wrapping fixed driving wheel with cloth); install fixed bolts
of pressure plate for electromagnetic clutch.
4. Detect electromagnetic clutch clearance

(a). Switch on electromagnetic clutch and measure the clearance
of electromagnetic clutch by switching on/off.
△ Hint:
If the measured value is beyond standard range, remove pressure
plate and adjust belt pulley.
Attention:
Adjust less than three times.
LIFAN AUTO
5. Check refrigerant oil

△ Hint:
• Generally, it is not necessary to check the volume of refrigerant oil. If a great amount of refrigerant oil outflows
during the course of maintenance, it is necessary to fill refrigerating oil only when the compressor is installed.
Filling volume = outflow volume
• If it is replaced with a new compressor before installing, first discharge refrigerating fluid in air conditioner
refrigerating system, then pour out refrigerant oil of the new compressor according to the following standards.
The amount of refrigerant oil in new compressor-the amount of residual refrigerant oil = the amount of oil
in the new compressor to be discharged
Attention:
• When checking oil amount, pay attention to dismantling and installing.
• Because refrigerant oil may remain in the pipe of the vehicle, if a new compressor with some refrigerant
oil is installed, the system will have excessive oil, which affects the rate of heat exchange of refrigeration
pipe and causes poor refrigeration.
• If the compressor dismantled has little residual oil, it is necessary to check if refrigerant oil leaks.
• Confirm if correct refrigerant oil is used.
6. Install air conditioner compressor assembly

(a). Align air conditioner compressor with mounting position,
(d). Use a offset ring spanner to exert force to tensioner in

clockwise, and install drive belt. 71
LIFAN AUTO
(c). Use refrigerant oil to lubricate O-ring on high and low

pressure joints, and insert high and low pressure air pipe of
compressor into the mounting hole of compressor, and then
install fixed bolts of pressure plate and tighten them.
(d). Connect electromagnetic clutch connector.
7. Fill refrigerating fluid (See Chapter 71 power Air Conditioner – Refrigerating Fluid, Replacement)
LIFAN AUTO
A/C System-Condenser and drying tank assembly 71-71
Condenser and drying tank assembly

Check and repair
1. Vehicle-based inspection
(a). Check if condenser fin is very dirty. If it is dirty, banister
brush can be used for cleaning.
(b). Check if there is dust on the condenser. If there is,

compressed air can be used to remove dust from the
condenser.
(c). Inspect whether condenser fin is bent or deformed. If it 71

is deformed, use nipper to correct fin or use fin comb to
correct it.
LIFAN AUTO
71-72 A/C System-Condenser and drying tank assembly
(d). Check if the condenser leaks refrigerating fluid with a leak

detector. If it leaks, it is necessary to dismantle and weld it.
If it is impossible to weld, replace the condenser and drying
tank assembly.
△ Hint:
Preparation of leakage inspection of condenser: start the engine
and make the engine run at idle speed. Turn on air conditioner (A/C)
switch and adjust fan switch to high speed.
(e). Check if pipe joint leaks with a leak detector. If it does,

check if joint bolt has standard torque.
2. Dismantle condenser and drying tank assembly

(a). Discharge refrigerating fluid. (See Chapter 71 Power Air
Conditioner – Refrigerating Fluid, Replacement)
(b). Remove front bumper assembly. (see Chapter 81, Interior
and Exterior Trims - Front Bumper - Replacement)
(c). Dismantle fixed bolt between discharge pipe and the
condenser, and pull out discharge pipe.
LIFAN AUTO
(d). Dismantle fixed bolt of the condenser outlet pipe and the
condenser and pull out the condenser outlet pipe.
(e). Disconnect horn connector, and dismantle fixed bolt of horn

bracket, then remove the horn.
(f). Dismantle fixed bolt on upper end of condenser and

drying tank, and incline outwards a little then pull out the
condenser drying tank assembly upwards.
71
LIFAN AUTO
71-74 A/C System-Condenser and drying tank assembly
3. Install condenser and drying tank assembly

(a). Incline lower end of the condenser and drying tank a little
inwards and install lower end into fixed hole.
(b). Align upper end of the condenser with mounting hole and
install fixed bolt and fasten it.
(c). Install horn bracket onto front compartment beam of the

engine, and then fixed bolts and tighten them, next to
connect horn connector.
(d). Insert the condenser outlet pipe into the condenser interface
and install fixed bolt and then tighten it.
LIFAN AUTO
(e). Insert compressor discharge pipe into condenser connector

and install fixed bolts and then tighten them.
(f). Fill refrigerating fluid. (See Chapter 71 Power Air
Conditioner – Refrigerating Fuid, Replacement)
71
LIFAN AUTO
• Memo •
LIFAN AUTO
Safety protection device
Airbag......................................................................... 72-1
Preparation............................................................. 72-1
Precautions............................................................. 72-4
Distribution map..................................................... 72-6
Wiring diagram....................................................... 72-7
System description............................................... 72-10
On-Vehicle check................................................. 72-11
Pre-check.............................................................. 72-14
DTC list................................................................ 72-18
B149800 .............................................................. 72-22
B142100............................................................... 72-22
B142200............................................................... 72-22
B142300............................................................... 72-22
B142400............................................................... 72-23
B143100............................................................... 72-24
B143200 .............................................................. 72-24
B143300............................................................... 72-24
B143400............................................................... 72-24
Airbag ECU.............................................................. 72-25
Replace................................................................. 72-25
Driver airbag............................................................ 72-28
Replace................................................................. 72-28
Disposal................................................................ 72-31
Passenger airbag...................................................... 72-35
Replace................................................................. 72-35
Disposal................................................................ 72-38
Clock spring.............................................................. 72-39
Replace................................................................. 72-39
Seat belt..................................................................... 72-43 72
Repair specifications............................................ 72-44
Precautions........................................................... 72-44
Front seat belt........................................................... 72-47
Inspection............................................................. 72-47
Replace................................................................. 72-49
Rear seat belt............................................................ 72-53
Check.................................................................... 72-53
Replace................................................................. 72-53
LIFAN AUTO
Safety Protection Device-Airbag 72-1
Airbag
Preparation
1. Special tools
Professional tool of
1 Detonation airbag
airbag detonation
2 Diagnostic scanner Airbag Troubleshooting
72
LIFAN AUTO
72-2 Safety Protection Device-Airbag
For measuring voltage and

resistance
Dismantling of screws and

2 Screwdriver
prying of snap ring
Quick-action wrench
For tightening and removing
4 and short and long
bolts
extension rods
LIFAN AUTO
Airbag system
Working temperature -35~85℃
Working voltage 12 ±3V
Clock spring
Total number of coils for rotating body ≥ 6.3
Item N•m
Fixed bolt of airbag ECU 6~10
72
LIFAN AUTO
Precautions
Warning:
1. For safety airbag system, if correct steps are not followed, it may cause sudden folding of safety airbag
which can lead to serious accidents. At the same time, wrong operation for airbag may also cause
abnormal working.
2. Confirm that ignition switch is turned to OFF and the battery positive and negative cables are
disconnected for more than 90 seconds, and then conduct the operation (safety protection system is
provided with backup power. Therefore, if operation is conducted within 90s after the battery positive and
negative cables are disconnected, airbags may expand suddenly).
3. Do not expose airbag assembly in hot air or open flame.
Attention:
1. Because it is difficult to confirm the fault of airbag, diagnostic trouble code (DTC) is regarded as the most
important information source for troubleshooting. When troubleshooting is conducted for airbag, check
diagnostic trouble code (DTC) before disconnecting the battery.
2. Even if the collision is slight, airbag assembly does not expand; it is also necessary to check horn button
assembly and airbag electronic control unit (SRS ECU).
3. When repairing, it is necessary to impact safety airbag electric control unit (SRS ECU), so first disconnect safety
airbag electronic control unit (SRS ECU).
4. Do not use parts of airbag dismantled from another vehicle. If necessary, please use new parts.
5. Do not disassemble horn button assembly.
6. If the horn button assembly falls to the ground or the case has cracks, pits or other defects, it must be replaced.
7. Inspection of system circuit fault should be conducted by using high-resistance multimeter.
8. There is an information label on parts of airbag. Please follow the instructions on the label during the course of
maintenance.
9. After disconnecting the battery negative cable, electronic clock and audio system memory will be cleared. Before
maintenance, all necessary data shall be recorded. After maintenance, reset audio system and adjust electronic
clock. Do not try to use backup power on other vehicles to avoid data in system memory from losing. Backup
power will charge airbag, which will make airbag expand suddenly during the course of maintenance.
10. When maintaining airbag or other parts of the vehicle, please first encrypt airbag electronic control unit (SRSECU)
and then decrypt airbag electronic control unit (SRS ECU) after maintenance.
11. It is forbidden to disassemble or repair safety airbag module and safety airbag electronic control unit (SRS ECU)
assembly of driver and front passenger seats for the purpose of reuse or other cause.
12. If baking varnish operation may cause effect due to overheat (more than 93°C), it is necessary to take out safety
airbag electronic control unit (SRS ECU), safety airbag module and clock spring, etc.
13. The connector of airbag electronic control unit (SRS ECU) assembly, the connector between airbag electronic
control unit (SRS ECU) assembly and clock spring, the connector between clock spring and driver airbag
module, and the connector between airbag module of front passenger and airbag electronic control unit (SRS
ECU) assembly are provided with protection mechanism that prevents airbag from sudden expanding. When
repairing safety airbag system, requirements must be strictly followed, to avoid sudden fold of safety airbag and
damage of parts.
14. During the course of maintaining airbags, airbag modules shall be installed on vehicles after being taken out of
the container. If it is required to stop working, airbag modules shall be placed into the container. It is not allowed
to keep airbag modules unattended. When storing dismantled airbag modules, keep the airbag expanding and the
surface upwards.
15. After maintaining airbag, do not place airbag module in circuit immediately. First check the electricity, and then
connect airbag module after confirming everything is right .
LIFAN AUTO
16. When connecting airbag with power supply, nobody is allowed in the vehicle.
17. After maintaining airbag, first check if SRS warning lamp is normal.
18. Airbag has a certain service life (See Operator Manual). If it is beyond service life of airbag, the airbag and label
shall be replaced.
72
LIFAN AUTO
Distribution map
1 Driver front airbag module assembly 4 Central control box (fuse) in the cab
2 Instrument cluster (SRS warning indicator) 5 Clock spring
3 Passenger front airbag module assembly 6 Airbag electric control unit (ECU)
LIFAN AUTO
72
72-7
Airbag system (2-loop)

Driver compartment
central control box
Safety Protection Device-Airbag
LIFAN AUTO
IG1 PWR
Front passenger Front passenger
Main airbag (+) Main airbag (-) airbag (-) airbag (+)
Wiring diagram
Clock spring
Front passenger
Main airbag airbag
CAN system
Terminal definition
S03 to SRS ECU.
Terminal Terminal
No. No.
1 YGr Main airbag (+) 26 - -
2 YB Main airbag (-) 27 - -
3 YR Front passenger seat airbag (-) 28 - -
4 YW Front passenger seat airbag (+) 29 - -
5 - - 30 R IG1 PWR
6 B Grounding 31 - -
7 - - 32 - -
8 - - 33 - -
9 - - 34 - -
10 - - 35 - -
11 - - 36 - -
12 - - 37 - -
13 - - 38 - -
14 - - 39 - -
15 - - 40 - -
16 - - 41 - -
17 - - 42 - -
18 - - 43 - -
19 - - 44 - -
20 WB CAN_L 45 W CAN_H
21 - - 46 - -
22 - - 47 - -
23 - - 48 - -
24 - - 49 - -
25 - - 50 - -
LIFAN AUTO
S01 to clock spring (main airbag) SI1 connects with dashboard wire harness
Terminal Terminal
No. No.
1 YGr Main airbag (+) 1 W CAN_H
2 YB Main airbag (-) 2 WB CAN_L
3 R IG1 PWR
4 - -
S03 to front passenger seat safety airbag.
5 - -
6 - -
7 - -
8 - -
Terminal 9 - -
Color Function
No.
10 - -
1 YR Front passenger seat airbag (-)
2 YW Front passenger seat airbag (+)
3 - -
4 - -
72
LIFAN AUTO
System description
1. Working principles of airbag
When a head-on collision occurs, crash sensor will produce collision signal and airbag ECU will detect crash
signal to analyze it and determine whether it reaches to ignition requirements. Once it reaches requirements,
ignition pulse will be sent immediately to ignite the ignitrons in each airbag module. Then ignitron ignites gas
production drugs in each airbag module, which produces a great amount of gas. In an extremely short time,
airbag is inflated and swells to break through the cover and form a full airbag in order to protect the driver and
passengers from collision or reduce damage.
2. Working principles of airbag clock spring
Mounting case of clock spring is fixed on steering column. Upper part of clock spring turnplate is inserted into
steering wheel. Spiral type cable is installed between the turnplate and mounting case. When steering wheel
rotates left and right, clock spring turnplate will rotate with steering wheel to drive output end of the cable so that
spiral type cable is expanded or tightened up. In this way, it not only avoids wire harness from winding around
steering column, but also ensures wire harness continuity. In addition, electrical signal can be on at any time.
Therefore, clock spring is also wire harness bridge that the body provides power to related functional parts of
steering wheel.
3. System composition
LIFAN 720 model uses electronic double safety airbag system. Two airbags are equipped respectively in center
trimming cover of steering wheel and dashboard in front passenger seat. The airbag consists of driver airbag
module, front row passenger airbag module, airbag clock spring, airbag electronic control unit, airbag wire
harness and warning label.
LIFAN AUTO
On-Vehicle check
1. Inspect driver safety airbag module (no collision)
(a). Check the system with a diagnosis tester (See Chapter 72
Airbag – Troubleshooting, Pre-check).
(b). Conduct visual inspection to the surface, cutting opening
of gap, minor crack of driver safety airbag module installed
on the vehicle, to inspect whether they are damaged or have
obvious discolor.
2. Check driver airbag modules(collision occurs but airbag

does not expand)
obvious discolor.
(c). Check if airbag wire harness is scratched of the connector is
damaged or broken.
(d). Check if steering wheel is deformed.
(e). Check if the horn button touch piece is deformed or

damaged.
△ Hint:
72
If horn button is damaged, completely replace it. It unnecessary to
repair it.
LIFAN AUTO
Attention:
Driver safety airbag module and steering wheel should have no
interference, and there should have uniform clearance when a
new driver safety airbag module is installed on steering wheel.
Warning:
When installing driver airbag, correct installation procedures
shall be ensured.
3. Check driver airbag modules (collision occurs and

airbag expands)
(b). Remove airbag for the driver from the vehicle.
(c). Check carefully if clock spring and wire harness are
damaged.
4. Inspect passenger safety airbag module (no collision)

obvious discolor.
LIFAN AUTO
5. Inspect passenger safety airbag module (it is collided but

airbag doesn't fold)
obvious discolor.
(c). Check if airbag wire harness is scratched of the connector is
damaged or broken.
(d). Check if dashboard and reinforced rib of dashboard are
damaged.
Attention:
If dashboard and reinforced rib of dashboard is damaged,
please replace them immediately instead of maintaining.
6. Check passenger airbag modules (collision occurs and airbag expands) .

(a). Check the system with a diagnosis tester (See Chapter 72 Airbag – Troubleshooting, Pre-check).
(b). Remove dashboard with passenger safety airbag module assembly.
(c). Check carefully if parts and wire harness near airbag module of the passenger are damaged.
Attention:
If dashboard and reinforced rib of dashboard, airbag module wire harness and connector are damaged, please
replace them directly instead of maintaining.
7. Check airbag ECU(no collisions)

8. Check airbag ECU (collision occurs but airbag does not expand)
9. Check airbag ECU(collision occurs and airbag expands)

10. Check airbag wire harness and connector (no collisions) 72

11. Check airbag wire harness and connector (collision)

(b). Check if all wire harness of airbag is broken, cracked or segmented.
(c). Check if all wire harness connectors of airbag are damaged.
△ Hint:
SRS wire harness is a yellow wire harness which can differentiate from other wire harness.
LIFAN AUTO
72-14 Safety Protection Device-Troubleshooting
Troubleshooting
Pre-check
1. Self-diagnosis system check
(b). Check Airbag warning indicator of instrument cluster.
Standards:
5~6s after turning on of ignition switch, safety airbag
malfunction indicator lamp will flame out automatically.
If safety airbag malfunction indicator lamp constantly
lights up, it indicates that the system has circuit fault. It
is necessary to use diagnostic scanner to read fault code
(DTC) and repair it.
Attention:
When turning ignition switch to ON position, SRS ECU will
inspect electrical elements of the system.
2. Read diagnostic trouble code (DTC)

interface.

Lifan diagnosis system".
Series selection
Chongqing Lifan
System configuration Help About Power off
LIFAN AUTO
Safety Protection Device-Troubleshooting 72-15
"OK".
Demo
OK
Cancel
(d). Select and enter into “airbag”.

Anti-theft system
Vehicle body system
A/C System Return
(e). Select to enter "Safety Airbag System (TAKATACAN)".
Airbag system LIFAN Dedicated\Chongqing Lifan\V5.0\Airbag system
Airbag system (Changqing/Jinheng) Previous page

Airbag system (BOSCH AB10)
Airbag system (TAKATA K 4-loop) Next page 72

Airbag system (TAKATA K 6-loop)
Airbag system (TAKATA CAN) Print

Airbag system (East Joy Long)
Return
LIFAN AUTO

△ Hint:
Airbag system (TAKATA CAN) LIFAN Dedicated\Chongqing Lifan\V5.0\ If any previous DTC exists in the diagnostic scanner, firstly you
Read fault code
Previous page
Clear fault code
Next page
Print
Return
Read fault code

Power supply voltage is too high
Information
OK
LIFAN AUTO
3. Clear diagnostic trouble code (DTC)

Airbag system (TAKATA CAN) LIFAN Dedicated\Chongqing Lifan\V5.0\

Clear fault code
Next page
Print
Return

△ Hint:
Information If the fault code cannot be removed, it is an indication that the fault
has not been troubleshooted. You should remove the fault based on
OK the fault code before trying to remove the fault code again.
Cancel
72
LIFAN AUTO
DTC list
Attention:
Diagnostic trouble code Fault code description Suspected Area

(DTC)
B141200 Module internal fault —
B141300 Module reuse exceeds limit —
B141400 Impact data is recorded. —
B141800 Unwrite into VIN code —
• Battery
B149700 Power voltage is too high • Charging system
• System power supply
• Fuse
B149800 Power voltage is too low • System power supply
• Airbag ECU
B141700 Electric detonator has short-circuit. —
U002088 CAN communication is cut —
U014087 Lose communication with FBCM —
U015587 Lose communication with ICU —
• Driver airbag circuit

Driver front row airbag resistance is too
B142100 • Driver airbag assembly
high.
• Airbag ECU

Driver front row airbag resistance is too
low.
• Airbag ECU

Driver front row airbag grounding is short-
circuit.
• Airbag ECU

Driver front row airbag to power supply has
short-circuit.
• Airbag ECU
B142900 Driver seat belt resistance is too high. —
B142A00 Driver seat belt resistance is too low. —
B142B00 Driver seat belt grounding is short-circuit. —
Driver seat belt to power supply has short-

B142C00 —
circuit.
• Passenger safety airbag circuit

B143100 Passenger front airbag resistance is too high. • Passenger safety airbag assembly
• Airbag ECU
LIFAN AUTO

(DTC)

B143200 Passenger safety airbag resistance is too low. • Passenger safety airbag assembly
• Airbag ECU

B143300 Passenger safety airbag grounding is short-circuit. • Passenger safety airbag assembly
• Airbag ECU

Passenger safety airbag to power supply has short-
B143400 • Passenger safety airbag assembly
circuit.
• Airbag ECU
B143900 Passenger seat belt resistance is too high. —
B143A00 Passenger seat belt resistance is too low. —
B143B00 Passenger seat belt grounding has short-circuit. —
B143C00 Passenger seat belt to power supply has short-circuit. —
B144100 Driver side airbag resistance is too high. —
B144200 Driver side airbag resistance is too low. —
B144300 Driver side airbag grounding has short-circuit. —
B144400 Driver side airbag to power supply has short-circuit. —
B144500 Passenger side airbag resistance is too high. —
B144600 Passenger side airbag resistance is too low. —
B144700 Passenger side airbag grounding has short-circuit. —
Passenger side airbag to power supply has short-

B144800 —
circuit.
B14A100 Driver side air curtain resistance is too high. —
B14A200 Driver side air curtain resistance is too low. —
B14A300 Driver side air curtain grounding has short-circuit. —
Driver side air curtain to power supply has short-

B14A400 —
circuit.
B14A500 Passenger side air curtain resistance is too high. —
B14A600 Passenger side air curtain resistance is too low. —
B14A700 Passenger side air curtain grounding has short-circuit. —

72
Passenger side air curtain to power supply has short-
B14A800 —
circuit.
Driver front row side impact sensor - grounding

B147100 —
short-circuit
B147300 Driver front row side impact sensor - internal fault —
Driver front row side impact sensor - can't be

B147400 —
communicated
Driver front row side impact sensor - communication

B147500 —
error
Passenger front row side impact sensor - grounding

B148100 —
short-circuit
B148300 Passenger front row side impact sensor - internal fault —
LIFAN AUTO

(DTC)
Passenger front row side impact sensor -

B148400 —
can't be communicated
Passenger front row side impact sensor -

B148500 —
communication error
LIFAN AUTO

Attention:
If no DTC is displayed during inspection but the parts in the system can not work normally, check circuit
according to fault symptoms presented in the table below.
these parts.
1. Airbag warning indicator circuit (short

Repair or replace the harness or connector
circuit)
Airbag warning indicator is
usually on 2. Airbag ECU (damaged) Replace.
1. Airbag warning indicator circuit (open

circuit)
Airbag warning indicator is
not lit 2. Airbag ECU (damaged) Replace.
72
LIFAN AUTO
B149800 - Power voltage is too low

Check whether power line is open or short

• Turn off ignition switch and disconnect the battery negative electrode for more than 90s.
• Disconnect passenger compartment fuse box connector I1F.
1 • Disconnect SRS ECU connector S03. To Step 2 To Step 3

• Check whether the resistance between No.30 terminal of S03 and No.3 terminal of I1F is
less than 2Ω.
• Check whether the resistance between No.30 terminal of S03 and grounding is more than
1MΩ.
Check Fuse
• Confirm ignition switch is OFF and the battery negative electrode is disconnected for
more than 90s.
• Unplug fuse and visually inspect whether fuse FS25 is burned out.
Check Harness
3 To Step 6
Replace Fuse
4 • Before replacing the burnt fuse, firstly troubleshoot the circuit according to circuit To Step 6
Replace airbag ECU

5 To Step 6
• Refer to Maintenance Procedures in Maintenance Manual to replace airbag ECU.
B142100 - Driver front exhaust airbag resistance is too high.

B142200 - Driver front exhaust airbag resistance is too low.
B142300 - Driver front exhaust airbag grounding has short-circuit.
Check the clock spring.

• Turn off ignition switch and disconnect the battery negative electrode
for more than 90s.
• Dismantle horn button assembly and disconnect driver airbag assembly
connector.
• Disconnect clock spring connector S01.
• Check whether the resistance between clock spring connector S01 and
driver safety airbag assembly connector is less than 2Ω.
Check Harness
• Disconnect SRS ECU connector S03.
2 • Check whether the resistance between No.1 terminal of S03 and No.1 To Step 5 To Step 4
terminal of S01, No.2 terminal of S03 and No.2 terminal of S01 is less
than 2Ω.
• Check whether the resistance between No.1 and No.2terminals of S01
and grounding is more than 1MΩ.
LIFAN AUTO
Replacement of clock spring

3 • Refer to Maintenance Procedures in Maintenance Manual to replace To Step 6
clock spring.
Replace driver airbag

4 • Refer to maintenance procedures in maintenance manual to replace To Step 6
driver airbag.
Check harness
5 To Step 6
B142400 - Driver front exhaust airbag to power supply has short-circuit.

Check harness
• Dismantle horn button assembly and disconnect driver airbag assembly connector.

• Connect battery negative pole and turn ignition switch to ON position, and check
whether the voltage between No.1 and No.2terminals of clock spring connector and
grounding is 0V.

• Turn off ignition switch, and connect clock spring connector S01.
• Turn ignition switch to ON and check if the voltage between driver airbag connector and
the ground is 0V.
Check harness
3 To Step 6

4 To Step 6
• Refer to Maintenance Procedures in Maintenance Manual to replace clock spring.
Replace airbag ECU

5 To Step 6
72
LIFAN AUTO
B143100 - Passenger front airbag resistance is too high.

B143200 - Passenger front exhaust airbag resistance is too low.
B143300 - Passenger safety airbag grounding is short-circuit.
Check wire harness (airbag control module - passenger airbag)

• Turn off ignition switch and disconnect the battery negative electrode
for more than 90s.
• Disconnect passenger safety airbag connector S02.

• Check whether the resistance between No.3 terminal of S03 and No.1
terminal of S02, No.4 terminal of S03 and No.2terminal of S02is less
than 2Ω.
• Check if the resistance between 1/No.2 terminal of S02 and the ground
is more than 1MΩ?
Replace passenger airbag

2 • Refer to Maintenance Procedures in Maintenance Manual to replace To Step 4
passenger airbag.
Check Harness
3 To Step 4
B143400 - Passenger front airbag to power supply has short-circuit.

Check Harness
• Disconnect SRS ECU connector S03.
• Disconnect passenger safety airbag connector S02.
• Connect battery negative pole and turn ignition switch to ON position, and check
whether the voltage between No.1 and No.2terminals of passenger safety airbag
connector and grounding is 0V.
Replace passenger airbag

2 To Step 4
• Refer to Maintenance Procedures in Maintenance Manual to replace passenger airbag.
Replace airbag ECU

3 To Step 4
LIFAN AUTO
Safety Protection Device-Airbag ECU 72-25
Airbag ECU
Replace
1. Turn off ignition switch and disconnect the battery

negative cable
△ Hint:
After disconnecting the battery negative cable, wait for at least 90s
and conduct the following operations.
2. Dismantle console assembly (See Chapter 85 Dashboard
and Console - Console, Replacement)
3. Dismantle airbag ECU

(a). Disconnect airbag ECU connector.
Warning:
Before operating airbag, please read Chapter 72 Safety
Protection Device -Airbag, Precautions.
Attention:
Unplug ECU connector when ECU assembly is installed.
(b). Dismantle fixed bolts of airbag ECU.

(c). Remove airbag ECU. 72
LIFAN AUTO
72-26 Safety Protection Device-Airbag ECU
4. Install airbag ECU

(a). Place ECU on ECU mounting position on the floor.
△ Hint:
It is necessary to ensure that there is no foreign matter on the
mounting surface of ECU to ensure that ECU can be laid in level
condition. Keep ECU connector to the left to ensure the arrow
direction on ECU label is towards the vehicle front, and align three
mounting holes of ECU with mounting holes on ECU bracket.
Attention:
Handle airbag ECU with care to avoid airbag ECU from
falling off. If airbag ECU falls off, it is suggested to replace a
new ECU instead of installing damaged ECU on the vehicle.
(b). Install fixed bolts of airbag ECU.

Torque: 6~10N•m
LIFAN AUTO
Safety Protection Device-Airbag ECU 72-27
(c). Connect airbag ECU connector.

△ Hint:
Make sure all related connectors are fixed and all wire harness is
not damaged.
5. Install console assembly (See Chapter 85 Dashboard and

Console - Console, Replacement)
6. Connect cable to negative battery terminal
72
LIFAN AUTO
72-28 Safety Protection Device-Driver airbag
Driver airbag
Replace
negative cable
△ Hint:
2. Dismantle driver airbag module
Warning:
(a). Pry up driver airbag with a flat-blade screw to dismantle
hole plug.
Attention:
Wrap flat-blade screwdriver end with adhesive tape to avoid
damaging lower surface of steering wheel.
(b). Use screwdriver to pry snap ring on one side of passenger

safety airbag module.
(c). Open up driver airbag module.

△ Hint:
Press snap ring position on the top of passenger safety airbag
module; meanwhile push it forward, and then release you hands.
Snap ring will be released. Gradually release two snap rings on
the top of passenger safety airbag module, and then unfold driver
safety airbag module.
LIFAN AUTO
Safety Protection Device-Driver airbag 72-29
(d). Disconnect driver safety airbag module connector.

• Disconnect the airbag connector.
• Disconnect horn switch connector.
Attention:
Do not drag driver safety airbag module wire harness.
(e). Remove driver safety airbag module assembly and place it

safely.
Attention:
When placing airbag module with the face downwards, it is
very dangerous. If airbag expands, the module movement will
cause serious damage. Therefore, it is placed with the face
upwards.
3. Install airbag module for the driver

(a). Bring a new airbag module for the driver.
Attention:
If a new airbag module is handled improperly, it may expand
suddenly, which leads to serious damage. Therefore, when
handling the module, the module front shall face the body front 72
to reduce possible hurt.
LIFAN AUTO
(b). Connect driver safety airbag module connector.

• Connect the airbag connector.
• Connect horn switch connector.
(c). Install driver safety airbag module.

△ Hint:
Please exert hard force to snap ring position to ensure that safety
airbag is installed onto proper position. After installation, check
if airbag and steering wheel interface coincide. If they do not
coincide, it is necessary to reinstall it.
(d). Fold dismantling hole plug of driver safety airbag.

5. Check driver airbag module
6. Inspect safety airbag malfunction indicator lamp.
LIFAN AUTO
Disposal
△ Hint:
When one vehicle is discarded or driver airbag module is disposed, it is necessary to detonate driver airbag to avoid
the waste driver airbag from explosion in special circumstances. Please follow the steps below to conduct detonation
treatment. If the waste driver safety airbag can't be detonated, please contact Repair Center of LIFAN authorized dealer.
Warning:
• Do not discard driver airbag module that is not detonated.
• When detonating safety airbag, it will produce big explosive sound. It is recommended to conduct this
treatment outdoors or places where citizen living conditions are not affected.
• When detonating airbag, detonating tool specified by LIFAN shall be used. The operation shall be done in
a place far away from electrical interference.
• When detonating airbags, the operator shall keep10m from airbags.
• After the airbag is detonated, airbags will become hot. Do not touch it within 30min to avoid scalds.
• When handling detonated airbags, it is necessary to wear gloves and glasses.
• Do not spray water on the detonated safety airbag.
• It is necessary to wash hands after operation.
1. Preparation work
(a). Prepare special tools for detonating airbag.
(b). Prepare one battery as power supply for detonating airbag.
(c). Prepare one waste wheel with one steel rim and some waste
tires (without steel rims) or hard carton and heavy objects.
(d). Prepare some waste wire harness for vehicle maintenance.

△ Hint:
72
The diameter of bare wire harness shall be > 1.3mm, i.e., sectional
area of bare wire harness is larger than 1.25mm2.
Warning:
If wire harness for binding driver airbag is too thin or
unreliable, it may be broken when airbag expands. It is very
dangerous. Therefore, selected wire harness or equivalent shall
be reliable.
(e). Select a spacious and appropriate space.
LIFAN AUTO
2. Check the performance of special tool for detonating

airbag.
Red
(a). Connect special tool for detonating airbag to the battery.
△ Hint:
Black
Connect red clip of special tool for detonating airbag to the battery
positive electrode and black clip to the battery negative electrode.
Do not connect yellow wire. It is used to connect airbag module.
Yellow
(b). Press activating switch of special tools for detonating airbag

and check if switching diode light is lit.
Red Warning:
If diode light is not lit, it means special tool for detonating
Black
airbag may have a fault. Therefore, it cannot be used.
(c). Disconnect special tools for detonating airbag from the
battery.
Yellow
3. Fasten driver airbag module

(a). Connect driver airbag wire harness to driver airbag module.
LIFAN AUTO
(b). Fasten driver airbag on prepared wheel with wire harness.

△ Hint:
When driver airbag expands, it will damage the wheel. Therefore,
it requires waste wheels.
Warning:
• Make sure wire harness is reliable and fastened. If
airbag module expands and wire harness is broken,
airbag module will bounce, which is very dangerous.
• Make sure driver airbag surface is bound upwards.
If the metal surface is upwards, wire harness will be
broken when airbag expands. As a result, driver airbag
flies to the sky, which is very dangerous.
4. Connect special tools for denoting airbag.

(a). Connect driver airbag wire harness to yellow connector of
special tool for detonating airbag.
Red
△ Hint:
Black
In order to avoid damaging connector and wire harness of special
tool for detonating airbag, do not lock the secondary lock of double
interlocking. At the same time, make sure the line inside the tire is
a little bit loose. Double interlocking and loose wire harness can
Yellow ensure that the wire harness connector can be disconnected in time
to protect wire harness of special tool for detonating airbag when
airbag expands, although the vibration is very high.
(b). Move special tools for detonating airbag beyond 10m from
bound airbag.
5. Cover and handle bound airbag module

(a). Cover bound airbag module with hard carton or waste tire.
• Covering method of hard carton:
Use a hard carton that is larger than the wheel to cover
bound airbag module, and place heavy objects that are
larger than 190kg around the hard carton. 72
As shown in the figure below.
LIFAN AUTO
• Tire covering method:

Use at least 3 waste tires without steel ring to cover the
bound safety airbag module. As shown in the figure below.
6. Detonate airbag module

(a). Connect red and black clips of special tool of detonating
Red airbag to the battery positive and negative electrodes,
respectively.
Black (b). Check binding airbag when there is no person or animal
within 10m.
(c). Press detonation switch and detonate airbag.
Yellow
7. Dispose driver airbag module

(a). Remove driver airbag module from steel ring.
(b). Put driver safety airbag into plastic bag and seal the bag,
dispose driver safety airbag module as disposal of waste
parts.
Warning:
• After the airbag is detonated, airbags will become hot.
Do not touch it within 30min to avoid scalds.
• When handling detonated airbags, it is necessary to
wear gloves and glasses.
LIFAN AUTO
Passenger airbag
Replace

negative cable
△ Hint:
2. Dismantle glove box (See Chapter 85 Dashboard and
Dashboard Console - Glove Box, Replacement)
3. Disconnect front passenger airbag connector

Warning:
4. Remove dashboard assembly (See Chapter 85,
Dashboard and Console - Dashboard - replacement)
5. Dismantle passenger airbag module assembly

72
(a). Disconnect the tongue piece between airbag module of the
passenger and dashboard slightly.
Warning:
It is forbidden to disassemble airbag module of front
passengers.
LIFAN AUTO
(b). Remove passenger airbag module assembly and place it

safely.
Attention:
When placing airbag module with the face downwards, it is
very dangerous. If airbag expands, the module movement will
cause serious damage. Therefore, it is placed with the face
upwards.
6. Install airbag module assembly for the passenger

(a). Fetch a new airbag module for the passenger.
Attention:
If a new airbag module is handled improperly, it may expand
suddenly, which leads to serious damage. Therefore, when
handling the module, the module front shall face the body front
to reduce possible hurt.
(b). Install the new passenger airbag onto dashboard.

Attention:
After installation, carefully inspect whether it is installed
properly.
7. Install dashboard assembly (see chapter 85,Dashboard
and Console - Dashboard - Replacement)
LIFAN AUTO
8. Connect front passenger airbag connector

Attention:
Do not pull airbag wire harness forcedly.
9. Install glove box (See Chapter 85 Dashboard and

10. Connect Cable to Negative Battery Terminal
11. Inspect passenger safety airbag module.
72
LIFAN AUTO
Disposal
△ Hint:
When a vehicle is discarded or passenger airbag module is disposed, it is necessary to denote waste passenger airbag
to avoid it from detonating in special conditions. Please follow the instructions in accordance with the following
procedures. If the waste passenger airbag cannot be detonated, please contact with service station authorized by LIFAN.
Warning:
• Never discard passenger airbag module that is not detonated.
• When detonating safety airbag, it will produce big explosive sound. It is recommended to conduct this
treatment outdoors or places where citizen living conditions are not affected.
• When detonating airbags, detonating tool specified by LIFAN shall be used. The operation shall be done in
a place far away from electrical interference.
• When detonating airbags, the operator shall keep10m from airbags.
• After the airbag is detonated, airbags will become hot. Do not touch it within 30min to avoid scalds.
• When handling detonated airbags, it is necessary to wear gloves and glasses.
△ Hint:
Disposal method of passenger airbag is the same as that of
driver airbag (See Chapter 72 Airbag - Airbag of the Driver,
Disposal).
LIFAN AUTO
Safety Protection Device-Clock spring 72-39
Clock spring
Replace
negative cable
△ Hint:
2. Wheels shall face forwards
3. Dismantle driver airbag module (See Chapter 72 Airbag
- Airbag of the Driver, Replacement)
Warning:
4. Dismantle steering wheel (See Chapter 62 Steering

5. Dismantle steering column shield (See Chapter 62

Steering Mechanism - combination lever, Replacement) 72
LIFAN AUTO
72-40 Safety Protection Device-Clock spring
6. Dismantle clock spring

(a). Unfold clock spring jack catch
△ Hint:
If clock spring is required to be used continuously, it is required to
make a mark on clock spring or fasten it with adhesive tape.
(b). Remove clock spring, and disconnect clock spring

connector.
Attention:
Do not pull airbag wire harness forcedly.
7. Install clock spring

(a). Check if front wheel is right ahead.
(b). Connect clock spring connector.
LIFAN AUTO
Safety Protection Device-Clock spring 72-41
(c). Install the catch of clock spring and fix clock spring.
8. Align clock spring

(a). Turn ignition switch to OFF.
(b). Disconnect the battery negative cable.
(c). Rotate clock spring counterclockwise until it is difficult to
rotate it.
△ Hint:
Do not exert excessive force.
(d). Then rotate the clock by three turns clockwise and align
with marks.
△ Hint:
Rotate clock spring around the center left and right by three turns.
72
LIFAN AUTO
72-42 Safety Protection Device-Clock spring
9. Install steering column shield (See Chapter 62 Steering

Mechanism -combination lever, Replacement)
10. Install steering wheel (See Chapter 62 Steering

11. Install driver airbag module(See Chapter 72 Airbag -

Airbag of the Driver, Replacement)
13. Inspect passenger safety airbag module.
LIFAN AUTO
Safety Protection Device-Seat Belt 72-43
Seat belt
Preparation

resistance
Dismantling of screws and

2 Screwdriver
prying of snap ring
Quick-action wrench
bolts
extension rods
72
LIFAN AUTO
72-44 Safety Protection Device-Seat Belt
Item N•m
Fixed bolts and screws of front seat belt retractor Upper: 10 Lower: 65~85
Lower fixed plate bolt of front seat belt 65~85
Upper fixed plate nuts of front seat belt 65~85
Fixed bolts of front row seat belt buckle 65~85
Fixed bolts of rear row seat belt retractor assembly 65~85
Lower fixed plate bolt of rear seat belt 65~85
Fixed bolts of rear seat belt buckle and waistband 65~85
Precautions
1. If seat belt is damaged, split or belt buckle function is abnormal, it is necessary to replace it immediately.
2. If any collision occurs and seat belt bears a certain impact force, even if seat belt is not damaged, it is also
necessary to replace it immediately.
3. Do not insert any foreign object into seat belt buckle or modify or remove seat belt.
4. When a seat belt is dirty, use neutral detergent to wash it. Do not use corrosive, dye or dry cleaning agent.
Otherwise, they will affect seat belt strength seriously.
5. If seat belt is damaged, cracked or deformed due to chemical action and sunlight, it is necessary to replace seat
belt.
6. If metal connection part of seat belt is bent, deformed or corrosive, the seat belt shall be replaced.
7. Performance requirements of retractor : at mounting angle, it shall be retracted freely and automatically.
8. Performance requirements of regulating part: regulating part shall be regulated easily. After adjustment, the braid
cannot be loose by itself and is safe and reliable.
9. Performance requirement of seat belt buckle: insert lock plate and you must feel obvious opening condition
during opening of buckle. Buckle should not be opened by itself, and assembly can't be fail.
LIFAN AUTO
Safety Protection Device-Seat Belt 72-45
Components diagram
1 Seat belt height adjuster 6 Front left seat belt retractor assembly
2 Front right seat belt retractor assembly 7 Rear row double buckle assembly
3 Front row seat belt buckle assembly 8 Rear row seat belt retractor assembly
4 Rear row double buckle assembly 9 Rear row buckle and retractor assembly 72
5 Rear row buckle and waistband assembly
LIFAN AUTO
Troubleshooting
these parts.
Seat belt cannot be pulled

Seat belt retractor assembly (damaged) Replace.
out.
Seat belt cannot

Seat belt retractor assembly (damaged) Replace.
retract automatically
It is difficult to fasten the

Seat belt buckle (damaged) Replace.
seat belt buckle
It is difficult to unfasten the

Seat belt buckle (damaged) Replace.
seat belt buckle
Seat belt cannot be locked

immediately after being Seat belt retractor assembly (damaged) Replace.
pulled to specified length
1. Fuse (blown) Replace.

Driver seat belt indicator is
lit 3. d r i v e r s e a t b e l t b u c k l e ( i n t e r n a l l y
Replace.
damaged)
4. Wire harness (open circuit or short circuit) Repair or replace the harness or connector
LIFAN AUTO
Safety Protection Device-Front seat belt 72-47
Front seat belt

Inspection
1. Check seat belt retractor
(a). Pull out the seat belt in constant force; the seat belt should
be pulled out rather easily.
Attention:
If it cannot be pulled out easily, please replace seat belt.
(b). If you quickly pull the seat belt, the seat belt should be
locked up and can not extend.
Attention:
If it cannot be locked immediately, replace seat belt
immediately.
2. Check seat belt buckle

(a). Insert the seat belt into buckle. 72
△ Hint:
Buckle can be installed or dismantled easily and reliably. The
surface shall be smooth without sharp edge. If the seat belt cannot
be inserted into the buckle, it is necessary to replace the buckle and
check it again.
LIFAN AUTO
72-48 Safety Protection Device-Front seat belt
(b). Pull seat belt forcedly, and seat belt shall be locked.
Attention:
If the seat belt escapes from buckle, it is necessary to replace
seat belt buckle.
(c). Press the buckle button; the seat belt should be easily taken
out.
Attention:
If not so, it is recommended to immediately replace the seat
belt to eliminate potential hazard.
3. Check driver seat belt buckle

(a). Check the connectivity of driver seat belt buckle.
Standards:
Terminal No. Seat Belt Specification
1-2 Fixed No continuity
1-2 Releasing Breakover
If it does not conform to the requirements, please replace driver

seat belt buckle.
LIFAN AUTO
Replace.
1. Remove seat belt retractor assembly
(a). Dismantle B-pillar trim (See Chapter 81 Interiors and
Exteriors – B-pillar Panel, Replacement).
(b). Dismantle lower fixed plate of front seat belt.

△ Hint:
Push lower fixed plate shield of front seat belt aside and move it
up, and dismantle fixed plate bolts and remove lower fixed plate of
front seat belt.
(c). Dismantle upper A pillar trim (See Chapter 81 Vehicle Trim

- B-pillar Trim Panel, Replacement)
72
LIFAN AUTO
(d). Dismantle fixed plate nut of front seat belt, and remove
upper fixed plate of front seat belt.
(e). Dismantle fixed bolts and screws of front seat belt retractor
assembly.
(f). Remove front seat belt retractor assembly.
2. Install front seat belt retractor assembly

(a). Install front seat belt retractor assembly and fixed bolts and
screws of retractor.
Upper screw torque: 10N•m
Lower bolt torque: 65~85N•m
LIFAN AUTO
(b). Install upper fixed plate of front seat belt and fixed plate
nuts and tighten them.
(c). Install upper B-pillar trim (See Chapter 81 Vehicle Trim -

B-pillar Trim Panel, Replacement)
(d). Install lower B-pillar trim (See Chapter 81Vehicle Trim -

B-pillar Trim Panel, Replacement)
72
LIFAN AUTO
(e). Install fixed plate of front seat belt and fixed bolts and
tighten them.
△ Hint:
After installing seat belt, check if fixed bolts are fixed and check
seat belt for performance to avoid personal hurt in an emergency.
3. Check front seat belt retractor assembly (See Chapter
72 Supplementary Restraint Device – Front Seat belt,
Detection)
4. Dismantle front seat belt buckle

(a). Disconnect front seat belt buckle connector.
(b). Dismantle fixed bolt of front seat belt buckle.
(c). Remove front seat belt buckle.
5. Install front seat belt buckle
(a). Install front seat belt buckle.
(b). Install fixed bolt of front seat belt buckle and tighten it.
(c). Disconnect front seat belt buckle connector.
LIFAN AUTO
Safety Protection Device-Rear seat belt 72-53
Rear seat belt

Check
△ Hint:
Inspection method of rear seat belt retractor and buckle is the same as that of front seat belt retractor and buckle. Please
join in inspection steps of front seat belt.
Replace
1. Dismantle rear doorsill trim panel assembly (See

Chapter 81 Interiors and Exteriors- Rear doorsill trim
panel, Replacement)
2. Dismantle rear seat assembly (See Chapter 84 Seat –

Rear Seat, Replacement)
72
LIFAN AUTO
72-54 Safety Protection Device-Rear seat belt
3. Dismantle C-pillar panel assembly (See Chapter 81 Seat

– C-Pillar Panel, Replacement)
4. Dismantle rear shelf panel.
5. Dismantle rear seat belt retractor assembly

(a). Dismantle lower fixed plate bolts of rear seat belt.
LIFAN AUTO
(b). Dismantle fixed bolt of rear seat belt retractor assembly.

(c). Remove rear seat belt retractor assembly.
6. Dismantle rear seat belt buckle and waistband assembly.

(a). Dismantle fixed bolt of rear seat belt buckle and waistband
assembly.
(b). Remove rear seat belt buckle and waistband assembly.
7. Install rear seat belt retractor assembly

(a). Install fixed bolts of rear seat belt retractor
(b). Install rear shelf panel.
72
LIFAN AUTO
72-56 Safety Protection Device-Rear seat belt
(c). Install fixed plate bolts of lower rear seat belt and tighten
them.
8. Install rear seat belt buckle and waistband assembly

(a). Install rear seat belt buckle and waistband assembly.
(b). Install fixed bolts of rear seat belt buckle and waistband
assembly and tighten them.
9. Install C-pillar panel assembly (See Chapter 81 Seat -

C-pillar Panel, Replacement)
LIFAN AUTO
10. Install rear seat assembly (See Chapter 84 Seat - Rear

Seat, Replacement)
11. Install rear doorsill trim panel assembly (See Chapter

81 Interiors and Exteriors- Rear Doorsill Trim Panel,
Replacement)
72
LIFAN AUTO
• Memo •
LIFAN AUTO
Remote control central lock system
Remote control central lock system.......................... 73-1

Preparation............................................................. 73-1
Precautions............................................................. 73-3
Wiring diagram....................................................... 73-5
On-Vehicle check................................................. 73-12
All center control locks don't work. .................... 73-14
Only front left door central lock is invalid........... 73-15
Only front right door central lock is invalid........ 73-16
Only rear left door central lock is invalid............ 73-16
Only rear right door central lock is invalid.......... 73-17
Front left door lockout mechanism........................ 73-18
Check.................................................................... 73-18
Replace................................................................. 73-18
Front right door lockout mechanism..................... 73-19
Check.................................................................... 73-19
Replace................................................................. 73-19
Right left door locking device................................. 73-20
Check.................................................................... 73-20
Replace................................................................. 73-20
Rear right door locking device................................ 73-21
Check.................................................................... 73-21
Replace................................................................. 73-21
Rear trunk lid locking device.................................. 73-22
Check.................................................................... 73-22
Replace................................................................. 73-22
73
LIFAN AUTO
Remote control central lock system-Remote control central lock system 73-1
Remote control central lock system

Preparation

and resistance
For removing screws and

2 Screwdriver
prising panels.
73
LIFAN AUTO
73-2 Remote control central lock system-Remote control central lock system
Front left door locking device resistance ≤ 2Ω
Rear right door locking device resistance ≤ 2Ω
Right left door locking device resistance ≤ 2Ω
Rear right door locking device resistance ≤ 2Ω
Rear compartment door stopper resistance ≤ 2Ω
Item N•m
Fixed bolts of locking device 5~7
Fixed screws of lock body protection sleeve 5~7
Door lock body retaining screw 10~12
Fixed bolts of door lock body bracket 10~12
Fixed screws of door outer handle base 5~7
Fixed screws of door lock cylinder 10~12
LIFAN AUTO
Precautions
1. Switch off power supply.

(a). Before dismantling or installing any electrical device, or when a tool or device contacts exposed electrical
terminal easily, first disconnect the battery negative cable to prevent personal hurt or vehicle damage.
Attention:
Before disconnecting the battery negative cable, please do not leave the key in the vehicle to avoid the vehicle
door from being locked.
(b). If there are no special notes, ignition switch must be turned off.
2. Disconnecting negative cable of battery can zero clear one-day milemeter and timer on instrument cluster.
Attention:
Total mileage will not be zeroed.
3. Disconnecting negative cable of battery may lose the stored setting.
Attention:
After connecting the battery cathode cable again, it is required to set the sound system again. (Refer to “Operating
Manual of Audio System”)
73
LIFAN AUTO
Components diagram
1 Centre plate center control switches assy. 5 Rear right door lock assembly
2 Front vehicle body controller components 6 Rear left door lock assembly
3 Right door lock assembly 7 Front left door lock assembly
4 Trunk lock assembly
LIFAN AUTO
73
73-5
F/L door control system

Driver compartment
central control box
Remote control central lock system-Remote control central lock system
F/L door lamp
LIFAN AUTO
Interior dimming lamp CAN system
Battery power supply Battery power supply Step lamp control Background light
power
F/L door control unit
Glass lift Glass lower
Child lock
switch
F/L door window
Front left Front right Rear left Rear right
regulator switch
Wiring diagram
F/L door
Down Up window regulator motor
F/L door control system (continued)
F/L door control unit

Key unlocking Key lockout Unlock Lockout Door open reminder singal
LIFAN AUTO
OFF ON F/L central lock motor
73-6
73
73-7
F/R door control system

Driver compartment
central control box
F/R door lamp Interior dimming lamp CAN system
LIFAN AUTO
Battery power supply Battery power supply Door lamp control Background light
power
F/R door control unit
Unlock Lockout Glass lift Glass lower
F/R door window
regulator switch
F/R central lock F/R door window
motor regulator motor
OFF ON
R/L door control system
Driver compartment
central control box
LIFAN AUTO
Battery power supply Battery power supply Background light
power
R/L door control unit
R/L door window
regulator switch
R/L central lock R/L door window
OFF ON
73-8
73
73-9
R/R door control system

Driver compartment
central control box
LIFAN AUTO
power
R/R door control unit
R/R door window
regulator switch
R/R central lock R/R door window
OFF ON lower lift
Terminal definition D05 to Front left door control unit.
D04 to Front left door control unit.

No.
1 - -
Terminal Color Function 2 - -
No.
3 - -
1 - -
4 - -
2 - -
5 OW Unlocking
3 - -
6 OR Locking
4 - -
7 B Grounding
5 - -
8 RV Battery power supply
6 - -
9 WB Glass descending
7 - -
10 WR Glass lifting
8 - -
9 RW Battery power supply
10 B Grounding M04 to Rear left door control unit

11 G LIN
12 V Background lighting lamp (+)
13 OBr Key unlock
14 OV Key lock
15 OG Door unlocked signal Terminal Color Function

No.
16 GB Step lamp control
1 - -
2 - -
D07 to Front left door central lock
3 - -
4 - -
5 WR Glass lifting
Terminal Color Function 7 R Battery power supply
No.
8 B Grounding
1 OBr Key unlock
9 OR Locking
2 OV Key lock
10 OW Unlocking
3 OG Door unlocked switch
4 B Grounding
5 OW Unlocking
6 OR Locking
LIFAN AUTO
M01 to Rear left door central control lock. N01 to Rear right door central control lock.
Terminal Terminal
No. No.
1 OW Unlocking 1 OW Unlocking
2 OR Locking 2 OR Locking
3 - - 3 - -
4 - - 4 - -
N04 to Rear right door control unit K04 to Front right door control
Terminal Terminal
No. No.
1 - - 1 - -
2 - - 2 - -
3 - - 3 - -
4 - - 4 - -
5 WR Glass lifting 5 WR Glass dropping
6 WB Glass descending 6 WB Glass lifting
7 R Battery power supply 7 RV Battery power supply
8 B Grounding 8 B Grounding
9 OR Locking 9 OR Locking
10 OW Unlocking 10 OW Unlocking
K01 to Front right door central lock

73

No.
1 OW Lock (+)
2 OR Unlock (+)
3 - -
4 - -
LIFAN AUTO
On-Vehicle check
△ Hint:
Refer to LIFAN 720 car User's Manual to inspect the function of door control system.
1 Manual door unlock key 3 Manual rear compartment unlock key
2 Manual door lock key
△ Hint:
• Under lock condition, when pressing unlock switch, only Front left door is unlocked; when pressing unlock
switch again, the other three doors are unlocked.
• Under lock condition, when pressing unlock switch, all door are locked.
• When pressing trunk lock switch, trunk lock is unlocked.
LIFAN AUTO
Remote control central lock system-Troubleshooting 73-13
Troubleshooting
these parts.
2. Circuits (open-circuit of short circuit

Repair or replace wire harness or connector.
-circuit )
All center control locks don't
work.
3. Central control door lock (open-circuit or
Replace.
short-circuit)
4. CAN bus (open-circuit or short-circuit) Inspect CAN communication system

-circuit )
Only Front left door central
lock is invalid 2. Front left door lock motor (damaged) Replace.
3. Front left door control unit (damaged) Replace.

-circuit )
Only Front right door
central lock is invalid 2. Front left door lock motor (damaged) Replace.

-circuit )
Only Right left door central

-circuit )
Only rear right door central
73
LIFAN AUTO
73-14 Remote control central lock system-Troubleshooting
All center control locks don't work.

Check system
• Ensure that the power supply operates normally.
1 To Step 2
• Press unlock or lock switch on central control panel, and inspect whether all door locks
work normally.
Check fuse
2 • Open the central control box in the driving compartment. To Step 9 To Step 3
• Inspect whether instrument cluster fuse FS15, FS16 are burned out.
Check power supply for broken circuit

• Disconnect Front left door control unit connector D04 and D05, Front right door control
unit connector K04 and K05, Rear left door control unit connector M04 and M05, Front
right door control unit connector N04 and N05.
3 • Disconnect passenger compartment fuse box connector I1D, I1E, I1F. To Step 4 To Step 8
of I1F, and No.9 terminals of D04, K05, M05, N05 is less than 2Ω.
of I1F, No.16 and No.15 terminals of I1E, No.6 terminal of I1D an No.7 terminals of
K04, M04, N04, is less than 2Ω.
Check for power supply short circuit to ground

unit connector K04 and K05, Rear left door control unit connector M04 and M05, Front
4 right door control unit connector N04 and N05. To Step 5 To Step 8
• Connect negative terminal of battery.
• Use a digital multimeter voltage scale to check whether the voltage between No.9 of
D04, No.8 terminal of D05, No.9 terminals of K05, M05, N05, and No.7 terminals of
K05, M05, N05 battery voltage.
Check grounding circuit for broken circuit

5 unit connector K04 and K05, Rear left door control unit connector M04 and M05, Front To Step 6 To Step 8
right door control unit connector N04 and N05.
of D04, and No.7 terminal of D05, No.8 terminals of K04, M04, N04, No.10 terminal of
K04, M04, N04 is less than 2Ω.
LIFAN AUTO
Inspect CAN circuit

• Disconnect Front left door control unit connector D04, Front right door control unit
connector K05, Rear left door control unit connector M05, Front right door control unit
connector N05.
• Disconnect FBCM connector I18.
terminal of I18 and No.11 terminals of D04, K05, M05, N05 is less than 2Ω.
Replace central control door lock switch.

7 To Step 10
• Refer to repair procedures specified in repair manual to replace central control panel.
Check harness
8 To Step 10
Replace fuse
9 • Before replacing the burnt fuse, firstly troubleshoot the circuit according to Wiring To Step 10
diagram and then replace the fuse with one at rated ampere of 10A and 20A.
Only front left door central lock is invalid

Inspect central control door lock open-circuit

1 • Disconnect Front left door lock motor connector D07, Front left door control unit To Step 2 To Step 5
connector D05.
and No.6 terminals of D07, No.5 and No.6 terminals is less than 2Ω.

2 • Disconnect Front left door lock motor connector D07. To Step 3 To Step 5
and No.6 terminals of D07 and grounding is more than 1MΩ.
Inspect front left door lock motor.

3 • Disconnect Front left door lock motor connector D07. To Step 4 To Step 5
• When connecting positive and negative poles of battery to No.5 and No.6 terminals of
Front left door lock motor, whether door lock motor works normally.
Replace front left door control unit.

4 To Step 6
• Refer to repair procedures specified in repair manual to replace Front left door control
unit.
73
Check harness
5 To Step 6
LIFAN AUTO
73-16 Remote control central lock system-Troubleshooting
Only front right door central lock is invalid


1 • Disconnect Front right door lock motor connector K01, Front right door control unit To Step 2 To Step 5
connector K04.
• Use a digital multimeter resistance scale to check whether the resistance between
No.1and No.2terminals of connector K01, and No.10 and No.9 terminals is less than 2Ω.

2 • Disconnect Front right door lock motor connector K01. To Step 3 To Step 5
• Use a digital multimeter scale to check whether resistance between No.1 and
No.2terminals of K01 and grounding is more than 1MΩ.
Inspect front right door lock motor.

3 • Disconnect Front right door lock motor connector K01. To Step 4 To Step 5
• When connecting positive and negative poles of battery to No.1 and No.2terminals of
Front right door lock motor, check whether door lock motor works normally.
Replace front right door control unit.

4 • Refer to repair procedures specified in repair manual to replace Front right door control To Step 6
unit.
Check harness
5 To Step 6
Only rear left door central lock is invalid


1 • Disconnect Rear left door lock motor connector M01, Rear left door control unit To Step 2 To Step 5
connector M04.
and No.2terminals of M01 and No.10 and No.9 terminals is less than 2Ω.

2 • Disconnect Rear left door lock motor connector M01. To Step 3 To Step 5
• Use a digital multimeter resistance scale to check whether No.1 and No.2terminals of
connector and grounding is more than 1MΩ.
Inspect Rear left door lock motor.

3 • Disconnect Rear left door lock motor connector M01. To Step 4 To Step 5
Rear left door lock motor, check whether door lock motor works normally.
LIFAN AUTO
Replace rear left door control unit.

4 • Refer to repair procedures specified in repair manual to replace Rear left door control To Step 6
unit.
Check harness
5 To Step 6
Only rear right door central lock is invalid


1 • Disconnect Rear right door lock motor connector N01, Rear right door control unit To Step 2 To Step 5
connector N04.
terminal of connector N01, No.10 and No.9 terminals of N04 is less than 2Ω.

2 • Disconnect Rear right door lock motor connector N01. To Step 3 To Step 5
and No.2terminals of connector N01 and grounding is more than 1MΩ.
Inspect rear right door lock motor.

3 • Disconnect Rear right door lock motor connector K01. To Step 4 To Step 5
Rear right door lock motor, whether door lock motor works normally.
Replace rear right door lock unit.

4 • Refer to repair procedures specified in repair manual to replace Rear right door control To Step 6
unit.
Check harness
5 To Step 6
73
LIFAN AUTO
73-18 Remote control central lock system-Front left vdoor lockout mechanism
Front left door lockout mechanism

Check
1. Check front left door locking device
(a). Connect No.6 terminal of Front left door lock stopper
connector D07 to positive pole of battery, and connect No.5
Lockout terminal to negative pole of battery.
Unlock
Phenomenon: lock
(b). Connect No.5 terminal of Front left door lock stopper
connector D07 to positive pole of battery, and connect No.6
terminal to negative pole of battery.
Phenomenon: unlock
(c). Keep Front left door lock in unlock condition, and use a
digital multimeter resistance scale to check the resistance
between No.1 and No.4 terminals of front door lock stopper
Lockout connector D07.
Resistance: ≤2Ω
Unlock
(d). Keep Front left door lock in lock condition, and use a digital
multimeter to check the resistance between No.2and No.4
terminals of front door lock stopper connector D07.
Resistance: ≤2Ω
If it does not conform to the requirements, replace front left
door lock assembly.
Replace
△ Hint:
See Chapter 82 Door and Door lock -Front Door Lock, Replacement.
LIFAN AUTO
Remote control central lock system-Front right door lockout mechanism 73-19
Front right door lockout mechanism

Check
1. Check front right door locking device
(a). Connect No.1 terminal of Front right door lock stopper
connector K01 and positive pole of battery, and connect
Lockout No.2terminal to negative pole of battery.
Unlock Phenomenon: unlock
(b). Connect No.2terminal of Front right door lock stopper
connector K01 and positive pole of battery, and connect
No.1 terminal to negative pole of battery.
Phenomenon: lock
If it does not conform to the requirements, replace front
right door lock assembly.
Replace
△ Hint:
See Chapter 82 Door and Door lock -Front Door Lock, Replacement.
73
LIFAN AUTO
73-20 Remote control central lock system-Right left door locking device
Right left door locking device

Check
1. Check right left door locking device
(a). Connect No.1 terminal of rear left door lock stopper
connector M01 and positive pole of battery, and connect
Lockout
No.2terminal to negative pole of battery.

(b). Connect No.2terminal of rear left door lock stopper
connector M01 and positive pole of battery, and connect
Phenomenon: lock
If it does not conform to the requirements, replace right left
door lock assembly.
Replace
△ Hint:
See Chapter 82 Door and Door Lock- Rear Door Lock, Replacement.
LIFAN AUTO
Remote control central lock system-Rear right door locking device 73-21
Rear right door locking device

Check
1. Check rear right door locking device
(a). Connect No.1 terminal of rear right door lock stopper
Lockout
connector N01 and positive pole of battery, and connect
(b). Connect No.2terminal of rear right door lock stopper
connector N01 and positive pole of battery, and connect
Phenomenon: lock
If it does not conform to the requirements, replace rear right
door lock assembly.
Replace
△ Hint:
See Chapter 82 Door and Door Lock- Rear Door Lock, Replacement.
73
LIFAN AUTO
73-22 Remote control central lock system-Rear right door locking device
Rear trunk lid locking device

Check
1. Check rear trunk lid locking device
(a). Connect No.2terminal of rear trunk door lock stopper
connector L03 and positive pole of battery, and connect
Phenomenon: unlock
(b). Connect No.3 terminal of rear trunk door lock stopper
connector L03 and positive pole of battery, and connect
Phenomenon: lock
If above requirements are not met, replace rear compartment
door lock assembly.
Replace
△ Hint:
See Chapter 82 Door and Door Lock – Rear Trunk Lid Lock, Replacement.
LIFAN AUTO
Audio system
Audio system.............................................................. 74-1

Preparation............................................................. 74-1
Precautions............................................................. 74-2
Wiring diagram....................................................... 74-4
On-Vehicle check................................................... 74-7
The system does not work...................................... 74-9
Play CD with poor tone quality.............................. 74-9
Play radio with poor tone quality......................... 74-10
Volume of sound is small in all modes................. 74-11
Speaker is mute (all speakers are mute)............... 74-11
Loudspeaker is mute(individual loudspeaker is
mute )..............................................................74-12
Unable to receive radio broadcast........................ 74-12
CD cannot be inserted or pop up after inserting... 74-13
CD cannot be taken out........................................ 74-13
CD skipping......................................................... 74-13
Display doesn't show or show incorrectly............ 74-14
Radio-cassette........................................................... 74-15
Check and repair................................................... 74-15
Alt speaker horn....................................................... 74-20
Check.................................................................... 74-20
Replace................................................................. 74-21
Front speaker............................................................ 74-23
Inspection............................................................. 74-23
Replace................................................................. 74-24
Rear-mounted loudspeaker..................................... 74-26
Check.................................................................... 74-26
Replace................................................................. 74-26
Antenna..................................................................... 74-28
Inspection............................................................. 74-28
Replace................................................................. 74-29 74
LIFAN AUTO
Audio System-Audio system 74-1
Audio system
Preparation

resistance

2 Screwdriver
prising panels.
FM
Tuning 87.5 - 108.0MHz
Sensitivity ＜ 10dBµV
Stereo resolution ≥ 25dB 74

AM
Tuning 522 - 1620kHz
Sensitivity 30dBµV
CD part
Distortion ＜ 0.5%
Signal/ noise ratio (S/N) ＞ 65dB
Audio section
LIFAN AUTO
74-2 Audio System-Audio system
Power supply 12V
Speaker impedance 4Ω
Output power 4X35W
Audio response CD 20Hz~20kHz
Item N•m
Fixed screws of middle air outlet panel 5~6
Radio retaining screw 5~6
Connecting screws of radio-cassette player and control panel 5~6
Fixed bolts of antenna amplifier 6~10
Fixed bolts of front speaker 6~10
fixed bolts of rear-mounted loudspeaker 6~10
Precautions
1. The data of AM/FM stations stored in the radio will be erased when the cable is disconnected from the
negative battery terminal. If necessary, record these data before disconnecting the cable from the negative
battery terminal. Set the stations after connecting the cable to the negative battery terminal.
2. While dismantling and installing antenna assembly, it is necessary to ensure firm grounding connection.
△ Hint:
If antenna grounding is not fixed, broadcasting noise will occur. Even if a new antenna is used, the problem still exists.
3. While dismantling and installing radio-cassette player, it is necessary to take out CD from radio-cassette
player, and then conduct operation.
△ Hint:
If CD is stuck in radio and tape player and cannot be taken out, do not take it out forcedly and then drive your vehicle to
LIFAN service station.
4. Do not touch speaker tapered cone.
LIFAN AUTO
Components diagram
1 Left alt speaker 5 Front left speaker
2 Comprehensive display 6 Radio

74
3 Right alt speaker 7 Right left loudspeaker
4 Front right speaker 8 Rear right loudspeaker
LIFAN AUTO
Audio mainframe power supply, signal, grounding
Driver compartment
central control box
Audio System-Audio system
Aerial amplifier
LIFAN AUTO
Aerial signal ACC power Battery power supply
Audio control unit
Background light power Steering wheel switch (+) Steering wheel switch (-)
Wiring diagram Clock spring
Interior dimming lamp
74-4
74
74-5
Audio mainframe speaker control

Audio control unit
Rear right Rear right Front right Front right Front left Front left Rear left Rear left
speaker (+) speaker (-) speaker (+) speaker (-) speaker (+) speaker (-) speaker (+) speaker (-)
LIFAN AUTO
Audio System-Audio system
Rear right Front right door F/R Alt speaker F/L Alt speaker Front left door Rear left
speaker speaker speaker speaker
74-6 Audio System-Audio system
Terminal definition I35 to audio
I34 to audio

No.
No. 1 GV Steering wheel switch (+)
1 V Rear right loudspeaker (+) 2 GW Steering wheel switch (-)
2 VB Rear right loudspeaker (-) 3 RW Ignition switch power supply
3 O Front right speaker (+) 4 V Power supply for background lighting
4 OB Front right speaker (-) 5 RV Battery power supply
5 W Front left speaker (+) 6 B Grounding
6 WB Front left speaker (-) 7 W CAN-H
7 Y Right left loudspeaker (+) 8 WB CAN-L
8 YB Right left loudspeaker (-)
D03 to Front left door speaker

D02to Front left alt speaker

No.
1 WB Front left alt speaker (-) No.
2 W Front left alt speaker (+) 1 W Front left door speaker (+)
2 WB Front left door speaker (-)

K07 to Front right alt speaker
K08 to Front right door speaker.

No.
1 OB Front right alt speaker (-)
2 O Front right alt speaker (+) Terminal Color Function

No.
B05 to Rear left speaker 1 O Front right door speaker (+)
2 OB Front right door speaker (-)

No.
B08 to Rear right speaker
1 Y Right left loudspeaker (+)
2 YB Right left loudspeaker (-)
I33 to audio receiving antenna

No.
1 V Rear right loudspeaker (+)
Terminal 2 VB Rear right loudspeaker (-)

Color Function
No.
1 RW Antenna amplifier (+)
LIFAN AUTO
On-Vehicle check
△ Hint:
Refer to LIFAN 720 Car User's Manual to inspect onboard CD panel function; meanwhile inspect whether horn speaker
vocalizes normally. Preliminarily judge fault cause and eliminate possibility of misoperation.
1 Mode switching key 10 CD out key
2 Radio mode switching key 11 Volume key
3 Balance set key 12 Numeric key 1

74
4 Back key 13 Numeric key 2
5 Forward key 14 Numeric key 3
6 Scan key 15 Numeric key 4
7 Menu key 16 Numeric key 5
8 Navigation key 17 Numeric key 6
9 Silence key
LIFAN AUTO
74-8 Audio System-Troubleshooting
Troubleshooting
these parts.
1. R a d i o a n d t a p e p l a y e r p o w e r a n d
grounding circuit (open circuit or short Repair or replace the harness or connector
The system does not work circuit)
2. Radio and tape player (damaged) Replace.
1. CD (damaged) Replace.
Check if wire harness joint is fixed and make

2. Wire harness (loose)
Play CD with poor tone troubleshooting if necessary
quality
3. Loudspeaker (installation problem) Check and install the speaker again
1. Antenna (bad reception) Replace the environment or antenna assembly
Check if wire harness joint is fixed and make

2. Wire harness (loose)
Play radio with poor tone troubleshooting if necessary
quality
3. Loudspeaker (installation problem) Check and install the speaker again
1. Loudspeaker circuit (poor contact) Repair or replace the harness or connector

Volume of sound is small in
all modes
1. R a d i o a n d t a p e p l a y e r p o w e r a n d
grounding circuit (open circuit or short Repair or replace the harness or connector
Loudspeaker is mute (all
circuit)
loudspeakers are mute)
1. Loudspeaker circuit (open circuit or short

Loudspeaker is Repair or replace the harness or connector
circuit)
mute(individual loudspeaker
is mute )
2. Loudspeaker (damaged) Replace.
1. Antenna assembly (receiving problem) Replace the environment or antenna assembly

Unable to receive radio
broadcast
1. CD (can't identify or damaged) Replace CD

CD cannot be inserted or
pop up after inserting.
1. CD (use unknown CD) Replace CD

CD cannot be taken out
1. CD (damaged) Replace CD
CD skipping
1. Display wire harness (open-circuit or

Inspection or replacement
Display doesn't show or short-circuit)
show incorrectly.
2. Comprehensive display (damaged) Replace.
LIFAN AUTO
Audio System-Troubleshooting 74-9
The system does not work

Check system
1 To Step 2
• Turn the ignition switch to ACC.
• Turn on radio and tape player to check if the system starts.
Check fuse
2 • Remove the glove compartment from the left lower panel of the instrument console. To Step 7 To Step 3
• Check if audio fuse F22 and F23 are blown.

• Dismantle radio and tape player assembly and check if radio and tape player wire
harness is fastened.
3 • Disconnect radio-cassette player connector I35. To Step 4 To Step 6
• Use a multimeter voltage scale to inspect whether the voltage between No.3 and No.5
terminals of I35 and grounding is battery voltage.
Check open circuit of grounding wire

• Disconnect radio-cassette player connector I35.
terminals of I35 and grounding is less than 2Ω.
Replace radio and tape player

5 • Refer to maintenance procedure in Maintenance Manual, and replace radio and tape To Step 8
player.
Check harness
6 To Step 8
Replace fuse
7 • Before replacing blown fuse, first make troubleshooting for circuit according to Wiring To Step 8
diagram. Then replace the fuses with rated ampere 10A and 15A.
Play CD with poor tone quality

Check audio setting

1 • Turn on the audio system. To Step 2
• Set all modes of audio system to initial value and check if the sound is normal
Check CD 74
2 • Take out CD and check if there is an obvious scratch on the CD (It is suggested to use a To Step 3
new CD for diagnosis)
Check tone quality of the system

3 • Compared it with another vehicle of the same type and with normal audio and check To Step 4 To Step 7
whether there are differences between them.
LIFAN AUTO
Check system wire harness

• Dismantle radio and tape player and check if radio and tape player connector is inserted
or wire harness is loose.
4 • Dismantle front door panel, and inspect whether four connectors on two speakers are To Step 7 To Step 5
connected well or wire harness is loose.
• Dismantle rear shelf panel, and inspect whether rear speaker connector is connected well
Check speaker
5 • While checking system harness, check whether there are too much dust and foreign To Step 6 To Step 7
matters and if it is installed properly.
Check radio and tape player

• Dismantle radio and tape player assembly.
6 To Step 7
• Replace the same type of radio and tape player provided by LIFAN.
• Turn on audio system and check if the system works?
Play radio with poor tone quality

Check audio setting

• Turn on the audio system.
1 To Step 2
• Set all modes of audio system to initial value, readjust sound frequency, and check if
sound is normal.
Check antenna assembly

• Dismantle radio and tape player.
• Disconnect antenna amplifier power supply connector I33.
• Use a digital multimeter voltage scale to check whether the voltage of No.1 terminal of
2 I33 is battery voltage. To Step 3 To Step 7
• Use a digital multimeter resistance scale to check whether antenna amplifier wire harness
and grounding are connected.
• Unplug antenna plug, and use a digital multimeter resistance scale to check whether
surface of plug and grounding are connected.
Check tone quality of the system

3 • Compared it with another vehicle of the same type and with normal audio and check To Step 4 To Step 7
whether there are differences between them.
Check system wire harness

• Dismantle radio and tape player and check if radio and tape player connector is inserted
4 • Dismantle front door panel, and inspect whether four connectors on two speakers are To Step 7 To Step 5
connected well or wire harness is loose.
Check speaker
5 • While checking system harness, check whether there are too much dust and foreign To Step 6 To Step 7
matters and if it is installed properly.
Check radio-cassette player

• Dismantle radio-cassette player assembly.
6 To Step 7
LIFAN AUTO
Volume of sound is small in all modes

Check audio system

1 • Turn on the audio system. To Step 2
• Turn up the volume to check whether the sound is normal.
Check CD
• Replace one CD and turn up the volume to check if the sound is normal.
Check loudspeaker circuit

• Dismantle radio and tape player, and check if radio and tape player connector is inserted
3 • Dismantle front door panel, and inspect whether four speaker connectors are connected To Step 5 To Step 4
well or wire harness is loose.

• Dismantle radio and tape player assembly.
4 To Step 5
Speaker is mute (all speakers are mute)

Check system
1 To Step 2
• Turn on radio-cassette player to check if the system starts.
Check fuse
• Check if audio fuse F22 is blown.

3 • Disconnect radio-cassette player connector I35. To Step 4 To Step 5
• Use a multimeter voltage scale to check whether the voltage between No.3 terminal of
I35 and grounding is battery voltage.
74
Replace radio and tape player
4 • Refer to maintenance procedure in Maintenance Manual, and replace radio and tape To Step 7
player.
Check harness
5 To Step 7
Replace fuse
LIFAN AUTO
Loudspeaker is mute(individual loudspeaker is mute )

Check system
1 • Make sure audio system connection is normal and turn ignition switch lock to ACC. To Step 2
• Turn on audio power supply and check if the loudspeaker sounds.
Check silent loudspeaker circuit

• Dismantle front door inner panel or rear shelf.
2 • Disconnect silent loudspeaker connector. To Step 3 To Step 4
• Check if power supply terminal voltage of the loudspeaker is 4~8V with the voltage
position of a multimeter.
Check mute loudspeaker

• Check if there is connectivity between No.2 terminals of loudspeaker wire harness with
3 the resistance position of a multimeter. To Step 4
• Connect No.2 terminal of the loudspeaker to the battery positive and negative electrodes
and then check if the loudspeaker sounds.
Unable to receive radio broadcast

Check system
• Move the vehicle to a place where you can receive radio broadcast.
1 • Make sure audio system connection is normal and turn ignition switch lock to ACC. To Step 2
• Start channel searching function of radio-cassette player, and inspect whether it can
receive radio broadcasting.
Check optional parts

2 Check if the vehicle is installed with any optional part which prevents antenna from To Step 6 To Step 3
receiving.
Check radio and tape player power circuit

• Disconnect radio and tape player connector.
• Use a multimeter voltage scale to check whether the voltage of No.5 terminal of I35 is
10~14V.
• Use a multimeter resistance to check whether No.6 terminal of I35 and grounding are
connected.
Check antenna assembly

• Disconnect antenna amplifier power supply connector I33.
• Use a digital multimeter voltage scale to check whether the voltage between No.1
4 terminal of connector I33 and grounding is 10~14V. To Step 5 To Step 6
• Use a digital multimeter resistance scale to check whether antenna amplifier wire harness
and grounding are connected.
• Unplug antenna plug, and use a digital multimeter resistance scale to check whether
surface of plug and grounding are connected.

• Pull out radio antenna plug.
5 • When radio and tape player is connected, turn ignition switch lock to ACC and turn on To Step 6
radio and tape player to go into AM mode.
• Lay a screwdriver, fin steel wire or other metal parts into the antenna insert hole of radio-
cassette player to inspect whether obvious noise is produced from speaker.
LIFAN AUTO
CD cannot be inserted or pop up after inserting.

Check the quality of inserted CD

1 • Check if the CD is audio CD. To Step 2
• Inspect whether CD has deformation, crack, discolor, sticking or other conditions.
Check inserting methods of CD

• Check if CD turns upside down when inserting it.
Check CD Replace radio

3 • Wipe off CD from inside to outside with a soft cloth and insert it again to check if it is To Step 4 and tape
normal. player
CD cannot be taken out

Check operation conditions

1 • Confirm if audio system is opened. To Step 2
• Press CD tray-in key for above 2S to check if CD pops up normally.
Recheck
Replace radio
2 • Confirm if audio system is opened. To Step 3 and tape
player
• Replace with a new CD and check if it pops up.
CD skipping
Check CD
1 • Check if there is dirt on CD surface. If there is dirt, please wipe it off. To Step 2
• Check if CD is deformed or cracked.
Replace CD and test it

• Replace it with another CD to check if CD has skipping.

Replace radio
3 and tape To Step 4
• Reinstall radio and tape player to check if radio and tape player is installed in its own player
place.
74
LIFAN AUTO
Display doesn't show or show incorrectly.

Inspect display fuse.

1 • Remove the glove compartment from the left lower panel of the instrument console. To Step 2
• Inspect whether audio equipment fuse F22is burned out.
Check harness
• Dismantle air outlet panel of dashboard.
• Inspect whether display wire harness connector is connected well and whether wire
harness is loose.
Check wire harness

3 • Replace wire harness between comprehensive display and radio- cassette player. To Step 5 To Step 4
• Turn on audio system again, and inspect whether display condition is normal.
Inspect display.
4 • Replace with new display or send the display to professional technician for inspection. To Step 5
• Turn on audio system again, and inspect whether display condition is normal.
LIFAN AUTO
Audio System-Radio-cassette 74-15
Radio-cassette
Check and repair
2. Dismantle middle air vent panel.
(a). Remove middle air outlet panel screws.
(b). Pry up middle air outlet panel with a flat-blade screwdriver.

Attention:
Wrap adhesive tape around the shaft of screwdriver, to avoid
damage to the instrument console panel.
(c). Disconnect connector.

△ Hint:
Shake the connector and check it for looseness and its terminals for
disconnection.
(d). Remove middle air vent panel.
74
LIFAN AUTO
74-16 Audio System-Radio-cassette
3. Remove radio body

(a). Dismantle fixed screws of radio-cassette player.
△ Hint:
Radio -cassette player and central control switches assy share the
same screw.
(b). Take out central control switches assy with radio -cassette
player assembly.
(c). Rotate radio-cassette player assembly.
(d). Disconnect central control switches assy connector.
LIFAN AUTO
(e). Disconnect connector, data connector and antenna

connector.
△ Hint:
The radio fuse is installed on the side of connector. If necessary,
Check the fuse.
(f). Take out radio -cassette player with central control switches
assy assembly.
(g). Disassemble radio -cassette player with central control

switches assy assembly.
Attention:
Radio and tape player body is detected only by professionals.
Laypeople shall not dismantle it at random.
△ Hint:
Replace suspicious radio and tape player with normal radio and
tape player to determine if the radio and tape player body is
damaged.
4. Mount the radio-cassette body

(a). Assemble radio -cassette player with central control
switches assy assembly.
Torque: 5 ~ 6N•m
(b). Connect radio-cassette player connector, data connector,
antenna connector, and lay radio-cassette player.
Attention:
Connect the connector. If you hear a clear “click”,it means it is 74
connected in place.
LIFAN AUTO
74-18 Audio System-Radio-cassette
(c). Insert central control switches assy connector.
(d). Install fixed screws of radio-cassette player.

Torque: 5 ~ 6N•m
△ Hint:
If the screw connection is insecure, replace it with a larger screw
or a clip.
5. Install middle air vent panel

(a). Connect connector.
LIFAN AUTO
(b). Install middle air vent panel.
(c). Install fixed screws of middle air vent panel.

Torque: 5 ~ 6N•m

7. Debug radio-cassette player, adjust radio settings.
8. Check the audio entertainment system is working normally.
74
LIFAN AUTO
74-20 Audio System-Alt speaker horn
Alt speaker horn

Check
1. Components inspection
(a). Use a digital multimeter 200Ω resistance scale to check the
resistance between two terminals of alt speaker horn wire
harness.
Resistance: 4Ω
(b). Or connect two terminals of alt speaker horn to positive and

negative poles of battery.
Phenomenon: horn rings
Attention:
Do not connect two electrodes of the horn with the battery for
a long time.
If it does not conform to the above conditions, replace the
component.
LIFAN AUTO
Audio System-Alt speaker horn 74-21
Replace
2. Dismantle front door inner panel assembly
3. Dismantle alt speaker horn
(a). Disconnect alt speaker horn connector.
(b). Pry alt speaker horn snap-fits.

Attention:
Buckle is easy to stay at vehicle body. It is necessary to
dismantle snap-fits. Do not leave buckle inside vehicle body.
(c). Remove alt speaker horn.
74
LIFAN AUTO
74-22 Audio System-Alt speaker horn
4. Install alt speaker horn

(a). Install alt speaker horn.
Attention:
Replace with a new snap-fit.
(b). Connect alt speaker horn connector.

Attention:
Connect the connector. If you hear a clear “click”,it means it is
connected in place.
5. Install front door inner protective panel (See Chapter 81 Vehicle Trim - Front Door Protective Panel,
Replacement).
7. Open audio system, and test whether alt speaker horn is normal.
LIFAN AUTO
Audio System-Front speaker 74-23
Front speaker
Inspection
1. Components inspection
(a). Use a digital multimeter 200Ω resistance scale to check
the resistance between two terminals of front speaker wire
harness.
Resistance: 4Ω
(b). Connect 2 terminals of front speaker to positive and

negative poles of battery.
Sign: Buzz
Attention:
Do not connect two electrodes of the horn with the battery for
a long time.
If it does not conform to the above conditions, replace the
component.
74
LIFAN AUTO
74-24 Audio System-Front speaker
Replace

2. Dismantle front door inner panel assembly
3. Dismantle front speaker.
(a). Disconnect front speaker connector.
(b). Dismantle front speaker fixed bolts.
(c). Remove front speaker.

Attention:
Avoid touching the speaker cone.
LIFAN AUTO
Audio System-Front speaker 74-25
4. Install front speaker.

(a). Install fixed bolts of front speaker and tighten them.
Torque: 6 ~ 10N•m
(b). Connect front speaker connector.

Attention:
connected in place.
5. Install front door inner panel assembly

7. Turn on audio system, and test whether front speaker is normal.
74
LIFAN AUTO
74-26 Audio System-Rear-mounted loudspeaker
Rear-mounted loudspeaker
Check
△ Hint:
Inspection of rear speaker is the same as that of front speaker. Refer to inspection of front speaker.
Replace
2. Dismantle shelf panel trim assembly.
3. Dismantle rear-mounted loudspeaker body
(a). Disconnect rear-mounted loudspeaker connector.
(b). Dismantle fixed bolts of rear-mounted loudspeaker.
LIFAN AUTO
Audio System-Rear-mounted loudspeaker 74-27
(c). Remove rear-mounted loudspeaker.
4. Install rear-mounted loudspeaker body

(a). Install fixed bolts of rear-mounted loudspeaker body and
tighten them.
Torque: 6 ~ 10N•m
(b). Connect rear-mounted loudspeaker connector.

Attention:
connected in place.
74
5. Install shelf panel trim assembly (See Chapter 81 Vehicle Trim - Shelf Panel Trim Assembly, Replacement)
7. Turn on audio system, and test whether rear speaker is normal.
LIFAN AUTO
Antenna
Inspection
1. Inspection of antenna amplifier.
(a). Disconnect antenna amplifier connector, and test power
supply voltage of amplifier.
Voltage value:10~14V
(b). Use a digital multimeter 200Ω resistance scale to check

the resistance between antenna amplifier wire harness and
grounding.
Resistance: Continuity
△ Hint:
If the above requirements are not met, directly replace antenna
assembly.
2. Antenna inspection
(a). Pull out the antenna and measure resistance between the
antenna and the ground using a digital multimeter switched
to "200Ω" position.
△ Hint:
If the above requirements are not met, dismantle right C-Pillar
trimming plate, and inspect whether the antenna and vehicle body
are connected well. If it is, replace antenna assembly.
LIFAN AUTO
Audio System-Rear-mounted loudspeaker 74-29
Replace
2. Dismantle radio-cassette player body
3. Remove the antenna assembly
(a). Disconnect connector.
(b). Dismantle right A-pillar trim panel (See Chapter 81 Interiors
and Exteriors- A-pillar Trim Panel, Replacement).
(c). Dismantle right C-Pillar trimming plate (See Chapter 81
Vehicle Trim - C-Pillar Trim Panel, Replacement).
(d). Dismantle fixed bolts of antenna amplifier, and disconnect

antenna connector.
(e). Dismantle right roof trimming plate (See Chapter 81
Vehicle - Roof, Replacement).
(f). Dismantle dashboard (See Chapter 85 Console and Control
Table - Dashboard, Replacement).
(g). Remove antenna assembly.
Attention:
Do not jerk the antenna. Take it out orderly.
4. Install antenna assembly

(a). Install the antenna orderly.
△ Hint:
Straight antenna and clamp antenna with wire clamp.
(b). Install dashboard (See Chapter 85 Console and Control Table -Dashboard, Replacement).
(c). Install roof trimming plate (See Chapter 81 Vehicle Trim - Roof, Replacement). 74
LIFAN AUTO
(d). Install fixed bolts of antenna amplifier, and connect antenna

connector. Torque: 6 ~ 10N•m
(e). Connect antenna amplifier connector, and insert antenna

connector.
5. Install radio-cassette player body

6. Connect the battery negative cable and turn on audio system to test if it is normal
7. Improve installation.
(a). Install right C-Pillar trimming plate (See Chapter 81 Vehicle Trim - C-Pillar Trim Panel, Replacement).
(b). Install right A-pillar trimming plate (See Chapter 81 Vehicle Trim - A-pillar Trim Panel, Replacement).
LIFAN AUTO
Driver information system
Driver information system........................................ 75-1

Preparation............................................................. 75-1
Description............................................................. 75-3
Wiring diagram....................................................... 75-7
Basic check........................................................... 75-11
DTC list................................................................ 75-15
B190016 - Power supply voltage of instrument cluster
is too low.............................................................. 75-17
B190017 - Power supply voltage of instrument cluster
is too high............................................................. 75-17
None instrument operates..................................... 75-17
Instrument background lighting lamp des not come
on....................................................................75-18
Fuel gauge malfunction........................................ 75-19
Parking brake indicator lamp does not come on or stay
on.......................................................................... 75-20
Oil pressure warning lamp cannot be illuminated /
stays on................................................................. 75-20
Brake system fault warning lamp cannot be
illuminated / stays on............................................ 75-21
Fasten-front-passenger-seat-belt warning lamp cannot
be illuminated/stays on......................................... 75-22
Passenger seat belt indicator doesn't light up/
constantly lights up.............................................. 75-23
Instrument assembly................................................ 75-25
Replace................................................................. 75-25
Central display......................................................... 75-28
Replace................................................................. 75-28
75
LIFAN AUTO
Driver Information System-Driver information system 75-1
Driver information system

Preparation
1. Special tool
1 Diagnostic scanner Instrument cluster diagnosis

resistance

2 Short screwdriver
panels.
75
LIFAN AUTO
75-2 Driver Information System-Driver information system
Item N•m
Instrument cluster fixed screw 5~6
Fixed screw of instrument cover 5~6
Fixed screw of central display 5~6
LIFAN AUTO
Description
S/N Symbol Name Description
When turning the ignition switch to the ON position, with the

vehicle self-checking, this indicator lamp will be lit and then go out
1 Engine fault indicator lamp
automatically. If it stays on, it is an indication that there is a trouble
in the electronic engine control.
When turning the ignition switch to the ON position, with the

Fault indicator lamp of vehicle self-checking, this indicator lamp will be lit and then go out
2
engine OBD system automatically. If the indicator lamp stays on, it is an indication that
there is a trouble in the engine emission control system.
75
When the ignition switch is turned to the ON position, with the
vehicle self-checking, this warning lamp will be lit. When the engine
Low oil pressure warning
3 starts, the warning lamp will go out. If this lamp constantly lights
lamp
up, it indicates that the engine oil pressure is lower than the specified
value.
When turning on the left turn signal lamp, the green arrow on
dashboard will flicker together with the left-side turn signal lamp.
Left turn signal indicator
4 When switching on the alarm switch, the left and right arrows on
lamp
dashboard will flicker together with all turn signal lamps. After
switching off the turn or alarm switch, all will go out.
LIFAN AUTO
This indicator lamp is used to indicate the working conditions of

Indicator lamp of front fog front fog lamps. When front fog lamps illuminate, this indicator lamp
5
lamps will be lit. After switching off the fog lamps, this indicator lamp will
go out.
This indicator lamp is used to indicate the working conditions of low-

beam headlights. This indicator lamp will be lit when the low-beam
6 Low beam indicator lamp headlights illuminate in order to prompt that the low-beam lights are
in the ON state. When turning off the low-beam headlight switch,
this indicator lamp will go out.
This indicator is used to indicate the working conditions of high-

beam headlights. This indicator lamp will be lit when the high-beam
7 High beam indicator lamp headlights illuminate in order to prompt that the high-beam lights
are in the ON state. When the high-beam headlight switch is turned
off, this indicator lamp will go out.
This indicator lamp is used to indicate the states of clearance lamps.

When clearance lamps illuminate, this indicator lamp will be lit to
8 Clearance indicator lamp
prompt that clearance lamps are in the ON state. When turning off
clearance lamps, this indicator lamp will go out.
This lamp will flame out after the engine is started. If battery
Battery charging indicator
9 charging indicator constantly lights up, it indicates that the battery or
lamp
recharging system has faults.
When turning on the right turn signal lamp, the green arrow on
dashboard will flicker together with the right-side turn signal lamp.
Right turn signal indicator
10 When switching on the alarm switch, the left and right arrows on
lamp
dashboard will flicker together with all turn signal lamps. After
switching off the turn or alarm switch, all will go out.
11 PEPS Smart key leaving reminding function (optional).
This indicator lamp is used to indicate the state of the parking brake.
Normally, it is in the OFF state. When the parking brake is raised up,
Parking brake indicator
12 the indicator lamp will be lit automatically. When the parking brake
lamp
is released, the indicator lamp will go out automatically. Otherwise, it
is necessary to repair it.
Turn the ignition switch to ON. When the indicator lamp illuminates,
it is an indication that the rear windshield defroster starts to work. If
Rear windshield defroster the defroster switch is pressed down, the defroster will stop working
13
indicator lamp and the indicator lamp will be turned off. When the defroster working
continuously for 15minutes, the system will turn off automatically
and the indicator lamp will go out.
After the door is opened, this indicator lamp will be lit. After all
doors are closed, the indicator lamp will go out.
Indicator lamp for door When turning the ignition switch to the ON position and shifting
14
unclosed and reversing radar the gearshift lever to reverse position, and the distance between the
vehicle tail and the barrier less than 1. 5m, this indicator lamp
will be lit and a hint sound will be produced.
15 Immobilizer warning lamp Used to guard against theft and warn.
In the process of driving, when the vehicle speed exceeds 120km/

Overspeed warning lamp h, this warning lamp will be lit to remind the driver of the vehicle
16
(optional) overspeeding. When the vehicle speed is less than 120km/h, the
warning lamp will go out automatically.
LIFAN AUTO
When pressing down the trunk switch, this indicator lamp will be
Warning lamp for trunk lid
17 lit to prompt the driver that the trunk lid is unclosed. If the trunk lid
unclosed
closed, the indicator lamp will go out.
This indicator lamp is used to indicate the ABS working conditions.

When turning the ignition switch to the ON position, with the vehicle
ABS(Anti-block Braking
18 self-checking, the ABS indicator lamp will be lit for several seconds
System) fault indicator lamp
and then go out . If the indicator lamp stays on, it is an indication that
the ABS failed.
This indicator lamp is used to indicate the working conditions of rear

Indicator lamp of rear fog fog lamps. When rear fog lamps illuminate, this indicator lamp will
19
lamps be lit. After switching off the fog lamps, this indicator lamp will go
out.
This indicator lamp is used to indicate whether the driver's seat belt is
on lock condition. If this lamp lights up accompanying with prompt
20 Driver's seat belt indicator.
tone, it indicates that the seat belt isn't buckled. When seat belt is
buckled tightly and timely, this lamp will flame out automatically.
This indicator lamp is used to indicate whether the front passenger's

seat belt is on lock condition. If this lamp lights up accompanying
Front passenger seat belt
21 with prompt tone, it indicates that the seat belt isn't buckled. When
indicator.
seat belt is buckled tightly and timely, this lamp will flame out
automatically.
This indicator lamp is used to indicate the airbag working conditions.

When turning the ignition switch to the ON position, with the vehicle
22 Airbag warning lamp
self-checking, the indicator lamp will be lit for several seconds and
then go out. If it stays on, it is an indication that the airbag failed.
This indicator lamp is used to indicate the engine coolant

temperature. When turning the ignition switch to the ON position,
Water-temperature warning with the vehicle self-checking, the indicator lamp will be lit for
23
lamp several seconds and then go out. If it stays on, it is an indication that
the coolant temperature exceeds the specified value. Be sure to stop
driving.
When ignition switch is placed to "ON" position, this indicator lamp

Brake system fault warning will lights up for 3s-4s and then automatically flames out. If this lamp
24
lamp constantly lights up or doesn't light up, it indicates that the brake
system has faults.
This indicator lamp is used to indicate the quantity of fuel in the

tank. When turning the ignition switch to the ON position, with the
25 Fuel warning lamp vehicle self-checking, the indicator lamp will be lit little and then go
out. If this lamp lights up after starting, it indicates that oil volume is
insufficient.
75
LIFAN AUTO
Components diagram
1 Instrument cluster 2 Central display
LIFAN AUTO
75
75-7
Instrument cluster power supply, ground, data line

Driver compartment
central control box
Driver Information System-Driver information system
LIFAN AUTO
Battery power supply IG1 PWR
Combination instrument
Wiring diagram
CAN system
Instrument cluster audible warning and alarm
Vehicle signal Parking brake Oil pressure Fuel level signal Unfastened driver seat Unfastened passenger Brake fluid
switch signal switch signal belt signal seat belt signal level signal
LIFAN AUTO
Occupant probe
Left seat belt
switch
Right seat belt Brake fluid
switch level sensor
Fuel sensor
Hand brake Oil pressure
switch alarm switch
75-8
75
75-9
Instrument cluster illumination, indication

Illumination
LIFAN AUTO
Charging indicator signal
Background light power
Interior dimming lamp Charging system
Terminal definition
Terminal Terminal
Terminal definition Terminal definition
No. No.
1 Battery power supply 17 Ignition switch power supply
2 Grounding 18 Grounding
3 Vehicle signal 19 -
4 Manual brake warning 20 Charging indication
5 CAN_H 21 -
6 CAN_L 22 Fuel level signal
7 Main seat belt unbuckled signal 23 Passenger's seat belt unbuckled signal
8 - 24 -
9 - 25 Brake fluid level warning
10 Engine oil pressure warning 26 CAN_L
11 Background lighting lamp 27 CAN_H
12 - 28 -
13 - 29 -
14 - 30 -
15 - 31 -
16 - 32 -
LIFAN AUTO
Driver Information System-Troubleshooting 75-11
Troubleshooting
Basic check
When conducting basic inspection, engine must reach to the specified working temperature. When conducting road test,
this test must be carried out by more than two persons.
Step No. Inspection item Recommended action
Inspect the battery. YES Go to step 2
1 • Battery voltage should not be lower than 12V.

NO Recharge or replace battery.
Inspect tachometer. YES Go to step 3

• Connect diagnostic scanner, and select engine
rotation speed.
• Respectively observe the readings of tachometer
when it is in 750, 1000, 2000, 3000, 4000, 5000,
6000r/min.
2
• The corresponding allowed tolerance should be NO
within ±75,±100, ±200, ±150, ±200, ±250, ±300r/
min.
• The needle should have no runout condition when it
is at constant speed or acceleration speed.
Inspect speedometer. YES Go to step 4

• Connect diagnostic scanner, and select vehicle
speed.
• Respectively observe the readings of speedometer
when vehicle speed is in 20,40,60,80,100,120,140,1
60,180km/h.
3 • The corresponding allowed tolerance should be
within ±3, ±5, ±5, ±5, ±5, ±6, ±7, ±8, ±9km/h NO To fault symptom table
• The needle should have no runout condition when it
is at constant speed or acceleration speed.
Attention: excessive abrasion of tire and excessive air
inflation or insufficient air inflation may cause error.
Inspect engine oil pressure indicator YES Go to step 5

• Engine oil pressure indicator should light up.
4
• After the start of engine, engine oil pressure NO To fault symptom table
indicator should flame out.
Inspect fuel gauge YES Go to step 6

5
• Fuel gauge should indicate current fuel volume. NO To fault symptom table
75
Inspect recharging indicator YES Inspection is completed.
• Recharging indicator should light up.
6
• After the start of engine, recharging indicator should NO To fault symptom table
flame out.
LIFAN AUTO
75-12 Driver Information System-Troubleshooting
Read and clear DTCs

(DTC)
interface.

Series selection
Series selection
Chongqing Lifan
System
configuration
(c). Select the diagnostic program V5. 0 version, and then

click "OK".
Demo
OK
Cancel

LIFAN AUTO
(d). Select and enter "instrument system"

Anti-theft system
Vehicle body system
A/C System Return
(e). Select and enter "instrument control system (HIRAIN

ICM)".
Instrument system LIFAN Dedicated\Chongqing Lifan\V5.0\Instrument system\
Instrument system (HIRAIN ICM) Previous page
Next page
Print
Return

△ Hint:
Instrument system (HIRAIN ICM) LIFAN Dedicated\Chongqing Lifan\V5.0\ If any previous DTC exists in the diagnostic scanner, firstly you
Clear fault code
Next page
Print
Return
75
LIFAN AUTO
Information
OK
2. Clearing of DTCs
Instrument control system (HIRAIN ICM) LIFAN Dedicated\Chongqing Lifan\V5.0\

Clear fault code
Next page
Print
Return
Information
OK
Cancel
LIFAN AUTO
DTC list
Attention:

(DTC)
• Power supply of the system
Power supply voltage of instrument cluster • Fuse

B190016
is too low. • Power supply circuit of instrument cluster
• Instrument cluster
Power supply voltage of instrument cluster • Power supply of the system

B190017
is too high. • Combination instrument
U000288 High speed CAN bus offline • High speed CAN bus
U002088 Low speed CAN bus offline • Low speed CAN bus
U220D00 Internet signal fault • CAN bus
U010087 Lose communication with ECM • CAN bus
U012187 Lose communication with ABS • CAN bus
U015187 Lose communication with SDM • CAN bus
U014087 Lose communication with FBCM • CAN bus
U014187 Lose communication with RBCM • CAN bus
U021587 Lose communication with PEPS • CAN bus
U016487 Lose communication with ATC • CAN bus
75
LIFAN AUTO

these parts.

None instrument operates Repair or replace the harness or connector
-circuit )

Instrument background Repair or replace the harness or connector
-circuit )
lighting lamp des not come
on.

-circuit )
Fuel gauge malfunction
2. Fuel level sensor (damaged) Replace.

-circuit )
Parking brake indicator lamp
does not come on or stay on 2. Manual brake switch (damaged) Replace.

-circuit )
Oil pressure warning lamp
cannot be illuminated / stays
2. Oil pressure warning switch (damaged) Replace.
on.

-circuit )
Brake system fault warning
lamp cannot be illuminated
2. Brake fluid level sensor (damaged) Replace.
/ stays on.

-circuit )
Driver Seat Belt Warning
Lamp Does Not Come on or
2. Driver's seat belt switch (damaged) Replace.
Stay on

-circuit )
Passenger's seat belt
2. Passenger's seat belt switch (damaged) Replace.
indicator doesn't light up or
constantly lights up.
3. Passenger's detector (damaged) Replace.
Liquid crystal display

abnormality.
LIFAN AUTO
B190016 - Power supply voltage of instrument cluster is too low.

B190017 - Power supply voltage of instrument cluster is too high.
Step Diagnosis YES NO

• Use a digital multimeter voltage scale to inspect whether battery voltage is about 12V.
Check fuse
• Inspect whether instrument cluster fuse FS34 and FS35 are burned out.

• Turn the ignition switch to OFF.
• Disconnect instrument cluster connector I14.
• Disconnect passenger compartment fuse box connectors of I1E and I1F.
• Use a digital multimeter resistance scale to inspect whether the wire harnesses between
No.1 terminal of I14 and No.5 terminal of I1E, No.17 terminal of I14 and No.4 terminal
of I1F are connected well.

4 • Use a digital multimeter voltage scale to inspect whether voltage between No.1 terminal To Step 5 To Step 6
of I14 and grounding is battery voltage.
• Ignition switch: ON
• Use a digital multimeter voltage scale to inspect whether voltage between No.17 terminal
and grounding is battery voltage.

Manual.
Check harness
6 To Step 9
Replace fuse
Replace the battery

8 To Step 9
• For replacement of battery, refer to repair procedures specified in Maintenance Manual.
None instrument operates

75
Check system
1 • Ensure that the power supply operates normally. To Step 2
Turn the ignition switch to ON. Check whether the instrument cluster can work normally.
Check fuse
• Inspect whether instrument cluster fuse FS34 and FS35 are burned out.
LIFAN AUTO

• Disconnect passenger compartment fuse box connectors of I1E and I1F.
• Use a digital multimeter resistance scale to inspect whether the wire harnesses between
No.1 terminal of I14 and No.5 terminal of I1E, No.17 terminal of I14 and No.4 terminal
of I1F are connected well.

4 • Use a digital multimeter voltage scale to inspect whether voltage between No.1 terminal To Step 5 To Step 7
and grounding is battery voltage.

5 • Disconnect instrument cluster connector I14. To Step 6 To Step 7
• Using a digital multimeter in Ohm range, check whether continuity exists between the
terminal 2 and 18 of terminal block D01 and the ground.

6 To Step 9
To replace the instrument cluster, refer to the maintenance procedures in the Repair Manual.
Check harness
7 To Step 9
Replace fuse
Instrument background lighting lamp des not come on.

Check system
1 To Step 2
• Turn on the clearance lamp, to check whether the instrument cluster background lighting
lamp works normally.
Check power circuit for broken or short circuit

• Turn ignition switch to "OFF".
• Turn on the clearance lamp.
LIFAN AUTO

Manual.
Check harness
4 To Step 5
Fuel gauge malfunction

Check whether signal circuit is broken

• Ignition switch: OFF
1 • Disconnect fuel sensor connector B10 and instrument cluster connector I14. To Step 2 To Step 7
• Use a digital multimeter resistance scale to check whether resistance between

No.2terminal of connector B10 and No.22terminal of I14 is lower than 2Ω.
Check whether short circuit occurs between signal circuit to ground

2 • Disconnect fuel sensor connector B10. To Step 3 To Step 7
• Use a digital multimeter resistance scale to check whether resistance between

No.2terminal of connector B10 and grounding is more than 1MΩ.

• Disconnect fuel sensor connector B10.
• Use a digital multimeter resistance scale to check whether resistance between No.3
terminal of connector B10 and grounding is lower than 2Ω.
Inspection of fuel sensor

4 • Disconnect fuel sensor connector B10. To Step 5 To Step 6

• Disconnect fuel sensor, and use a digital multimeter resistance scale to respectively
check whether resistance are respectively 95Ω, 32. 5Ω, 7Ω when the simulation fuel
level is in empty, 1/2volume and full volume.

Manual.
Replacement of electric fuel pump

6 • To replace the electric fuel pump, refer to the maintenance procedures in the Repair To Step 8
Manual.
Check harness
7 To Step 8
75
LIFAN AUTO
Parking brake indicator lamp does not come on or stay on

Check system
• Check whether the parking brake indicator lamp does not come on or stay on.

2 • Disconnect manual brake switch connector I23. To Step 3 To Step 6
• Using a digital multimeter in Ohm range, check whether the resistance between the
terminal 1 of terminal block I23 and the ground is higher than 1MΩ.

3 • Disconnect manual brake switch connector I23 and instrument cluster connector I14. To Step 4 To Step 6
• Use a digital multimeter resistance scale to inspect whether the resistance between No.1
terminal of I23 and No.4 of I14 is lower than 2Ω.
Check hand brake switch

• Release the parking brake.
4 terminal of manual brake switch and grounding is more than 1MΩ. To Step 5 To Step 7
• Apply the parking brake.
terminal of manual brake switch and grounding is lower than 2Ω.

Manual.
Check harness
6 To Step 8
Replace hand brake switch

7 To Step 8
• Referring to the service manual, replace the parking brake switch.
Oil pressure warning lamp cannot be illuminated / stays on.

Check system
• Check whether the oil pressure warning lamp stays on or cannot be illuminated.

2 • Disconnect engine oil pressure warning switch connector E22. To Step 3 To Step 6
terminal of U16 and grounding is more than 1MΩ.
LIFAN AUTO

3 • Disconnect engine oil pressure warning switch connector E22and instrument cluster To Step 4 To Step 6
connector I14.
terminal of E22and No.10 terminal of I14 is lower than 2Ω.
Inspection of oil pressure warning switch

• When the engine oil pressure is low, check whether the resistance between the Terminal
1 of oil pressure warning switch and ground is less than 2Ω by switching the digital
4 multimeter to the resistance function. To Step 5 To Step 7
• When the engine oil pressure is normal, check whether the resistance between the
Terminal 1 of oil pressure warning switch and ground is more than 1MΩ by switching
the digital multimeter to the resistance function.

5 To Step 8
To replace the instrument cluster, refer to the maintenance procedures in the Repair Manual.
Check harness
6 To Step 8
Replace the oil pressure alarm switch.

7 • To replace the oil pressure warning switch, refer to the maintenance procedures in the To Step 8
Repair Manual.
Brake system fault warning lamp cannot be illuminated / stays on.

Check system
• Check whether the brake fault warning lamp stays on or be illuminated.

2 • Disconnect brake fluid level sensor connector U16. To Step 3 To Step 7

3 • Disconnect brake fluid level sensor connector U16 and instrument cluster connector To Step 4 To Step 7
I14.
terminal of U16 and No.25 terminal of I14 is lower than 2Ω.

4 • Disconnect brake fluid level sensor connector U16. To Step 5 To Step 7 75
• Use a digital multimeter resistance scale to inspect whether the resistance between
No.2terminal of U16 and grounding is lower than 2Ω.
LIFAN AUTO
Inspection of brake fluid level sensor

• When the brake fluid level is low (below the MIN mark), check whether the resistance
between the Terminal 1 and Terminal 2 of brake fluid level sensor is less than 2Ω by
5 switching the digital multimeter to the resistance function. To Step 6 To Step 7
• When the brake fluid level is at normal position (between the MIN and MAX marks),
check whether the resistance between the Terminal 1 and Terminal 2 of brake fluid level
sensor is more than 1MΩ by switching the digital multimeter to the resistance function.

Manual.
Check harness
7 To Step 9
Replacement of brake fluid level sensor

8 • To replace the brake fluid level sensor, refer to the maintenance procedures in the Repair To Step 9
Manual.
Fasten-front-passenger-seat-belt warning lamp cannot be illuminated/stays

on.
Check system
• Check whether the fasten-driver-seat-belt warning lamp stays or cannot be illuminated.

2 • Disconnect driver's seat belt switch connector I28. To Step 3 To Step 7

3 • Disconnect driver's seat belt switch connector I28 and instrument cluster connector To Step 4 To Step 7
I14.
terminal of I28 and No.7 terminal of I14 is lower than 2Ω.

4 • Disconnect driver's seat belt switch connector I28. To Step 5 To Step 7
No.2terminal of I28 and grounding is lower than 2Ω.
LIFAN AUTO
Check driver seat belt switch

• Fasten the seat belt.
• Check whether the resistance between the Terminal 1 and Terminal 2 of driver seat belt
5 switch is more than 1MΩ by switching the digital multimeter to the resistance function. To Step 6 To Step 7
• Unfasten the seat belt.
• Check whether the resistance between the Terminal 1 and Terminal 2 of driver seat belt
switch is less than 2Ω by switching the digital multimeter to the resistance function.

Manual.
Check harness
7 To Step 9
Replace driver seat belt switch

8 To Step 9
• Referring to the service manual, replace the driver seat belt switch.
Passenger seat belt indicator doesn't light up/ constantly lights up

Check system
• Whether passenger seat belt indicator constantly lights up or doesn't light up.

2 • Disconnect passenger seat belt switch connector I24 and passenger detector connector To Step 3 To Step 8
I25.
terminal of I24, No.1 terminal of I25 and grounding is more than 1MΩ.

• Disconnect passenger seat belt switch connector I24, passenger detector connector I25,
3 and instrument cluster connector I14. To Step 4 To Step 8
terminal of I25 and No.23 terminal of I14, No.2terminal of I25 and No.1 terminal of I14
is lower than 2Ω.

4 • Disconnect passenger seat belt switch connector I24. To Step 5 To Step 8
75
LIFAN AUTO
Inspect passenger seat belt switch

• Buckle the passenger seat belt.
5 terminal and No.2terminal of passenger seat belt switch is more than 1MΩ. To Step 6 To Step 9
• Disconnect passenger seat belt.
between No.1 terminal and No.2terminal of passenger seat belt switch is lower than 2Ω.
Inspect passenger detector

• A passenger with weight of about 65kg sits down on the passenger seat.
6 between No.1 terminal and No.2terminal of passenger detector is lower than 2Ω. To Step 7 To Step 10
• No person sits down on the passenger seat.
between No.1 terminal and No.2terminal of passenger detector is more than 1MΩ.

Manual.
Check harness
8 To Step 11
Replace passenger seat belt switch

9 • For replacement of passenger seat belt switch, refer to repair steps specified in To Step 11
maintenance manual.
Replace passenger detector

10 • For replacement of passenger detector, refer to repair steps specified in maintenance To Step 11
manual.
LIFAN AUTO
Driver Information System-Instrument assembly 75-25
Instrument assembly
Replace
2. Lower steering wheel
(a). Press the steering wheel adjuster downwards.
(b). Lower the steering wheel to the lowest position.
3. Dismantle dashboard cover

(a). Remove two fixed screws of lower dashboard covers with a
short screwdriver.
(b). Pry up dashboard cover with a flat-blade screwdriver.
Attention:
(c). Remove dashboard cover.
4. Remove the instrument

(a). Remove the two instrument fixed screws with a cross
screwdriver.
△ Hint:
Steering wheel may affect normal working condition of flat-blade
screwdriver. To facilitate operation, the angle of steering wheel can
be slightly adjusted. Do not excessively rotate steering wheel.
75
LIFAN AUTO
75-26 Driver Information System-Instrument assembly
(b). Take out instrument assembly.

△ Hint:
There is a positioning tone besides 2fixed screws, and it is
necessary to horizontally take out instrument assembly.
(c). Rotate the instrument to right side to expose instrument

connector.
(d). Disconnect instrument connector.
(e). Take out instrument assembly.
5. Install instrument assembly

(a). Connect the instrument connector.
Attention:
When connecting the connector to the loudspeaker, you should
hear clear clicks. They indicate that the connection is well
done.
LIFAN AUTO
Driver Information System-Instrument assembly 75-27
(b). Mount the instrument assembly.

△ Hint:
Insert below the console the harness at rear end of instrument
console. Insert the instrument alignment tab into the hole.
(c). Install the instrument fixed screws.
Torque: 5 ~ 6N•m
(d). Close the instrument cover.

Attention:
Please strike the protective cover on the instrument protective
cover snap-fit position.
(e). Install fixed bolts of instrument protective cover.
Torque: 5 ~ 6N•m
6. Adjustment of steering wheel

7. Connect Cable to Negative Battery Terminal
8. Turn on the ignition lock to test whether instrument is in normal condition.
75
LIFAN AUTO
75-28 Driver Information System-Central display
Central display
Replace

2. Dismantle middle air vent panel.

Attention:
(c). Disconnect connector.

△ Hint:
Shake the connector and check it for looseness and its terminals for
disconnection.
(d). Remove middle air vent panel.
LIFAN AUTO
Driver Information System-Central display 75-29
3. Dismantle central display.

(a). Use cross screwdriver to dismantle fixed screws of display
body.
(b). Remove central display.
4. Install central display

(a). Install central display onto the middle air vent panel.
(b). Install fixed screws of central display and tighten them.
Torque: 5 ~ 6N•m
5. Install middle air vent panel

(a). Connect connector.
75
LIFAN AUTO
75-30 Driver Information System-Central display
(b). Install middle air vent panel.
(c). Install fixed screws of middle air vent panel.

Torque: 5 ~ 6N•m

7. Open audio system or air conditioning system.
8. Inspect whether central display is normal.
LIFAN AUTO
Reversing radar system
Reversing radar system............................................. 76-1

Precautions............................................................. 76-3
System description..................................................... 76-5
Wiring diagram....................................................... 76-6
On-vehicle check.................................................... 76-8
The system won't work completely...................... 76-11
The self-checking system is abnormal................. 76-12
The system will work without shifting to reverse
position................................................................. 76-13
When shifting to reverse position, the system will not
work (but the reversing lamp is normal)........................
76-14
The display indicates and buzzes abnormally...... 76-15
Reversing switch....................................................... 76-16
Inspection............................................................. 76-16
Replace................................................................. 76-16
Reverse radar sensor............................................... 76-18
Inspection............................................................. 76-18
Replace...................................................................... 76-19
76
LIFAN AUTO
Reversing Radar System-Reversing radar system 76-1
Reversing radar system

Preparation

resistance
Removing screws and

2 Screwdriver mounting bracket of Reverse
radar sensor
76
LIFAN AUTO
76-2 Reversing Radar System-Reversing radar system
Measuring distance 0.3~1.5m
Rating voltage of reverse radar sensor 12V
Working voltage of reverse radar sensor 9 - 16V
Item N•m
Reversing switch 44~49
LIFAN AUTO
Precautions
1. The detecting function may be abnormal under the following conditions.

(a). Reverse radar sensor is covered by mud or snow or other impurities. The detecting function can be restored after
the sensor being cleaned.
(b). Reverse radar sensor is frozen. The detecting function can be restored after the sensor temperature rise.
(c). Reverse radar sensor is shielded.
(d). If fault indication occurs in chilly weather, the Reverse radar sensor cannot detect barriers.
2. The detecting range can be affected under the following conditions.

(a). Reverse radar sensor covered by mud or snow or other impurities.
(b). Vehicles in extremely hot or cold areas.
3. Faulty detecting can occur under the following conditions.

(a). Driving on bumpy or unpaved roads or through high grass.
(b). Sounds from another vehicle horn, motorcycle engine or large vehicle air brake or ultrasonic waves from another
vehicle's sonar transmitted near the vehicle.
(c). Heavy rain or water dropped or spattered on the sensor.
(d). Excessive vehicle tilt.
(e). Vehicle equipped with other protection bar or radio antenna.
(f). Reverse radar sensor covered by mud or snow or other impurities.
(g). Vehicle moving toward high curbs or corners of outshoots.
4. The reverse radar sensor cannot detect some objects.

(a). Slight objects, such as lines or ropes.
(b). Materials absorbing ultrasonics, such as cotton or snow.
(c). Objects with sharp edges.
(d). short circuit and small objects.
(e). Highly-suspended objects.
5. Other cautions
(a). The reverse radar sensor cannot detect the objects right under the bumper. (The reverse radar sensor can detect
low objects or slight bars but lose tracking of such objects.)
(b). The reverse radar sensor may be unable to detect extremely close barriers.
(c). The fallen or violently-crashed reverse radar sensor may be unable to detect barriers.
76
LIFAN AUTO
Components diagram
1 Reversing switch 4 RBCM bracket
Instrument cluster (reversing clearance buzzer

2 5 Reverse radar sensor
and multi-functional display)
3 RBCM (reversing radar controller) 6 Mounting bracket of reverse radar sensor
LIFAN AUTO
System description
1. Overview
LIFAN 720 series reversing radar system is a kind of vehicle monitoring system on the basis of simulation of bat
flying detection principle. It emits and receives signal through two ultrasonic reversing radar sensors installed
on the rear of the vehicle, and feedback information to controller (RBCM) which calculates distance of barrier
by comparing signal returning time and then produces sound, indicator warning according to different distance,
to remind the driver of distance between barrier and vehicle and improve convenience and safety of vehicle
reversing.
2. Component function
Parts Function
Reverse radar sensor Detect the distance between vehicle and barrier.
Interval buzzer Inform the driver in sound form according to the distance of barrier.
1. Indicate position of barrier and rough distance between vehicle and

barrier.
Multi-function display screen
2. Inform the driver of whether ultrasonic sensor has fault, whether it
is frozen or stained.
1. Judge the rough distance between vehicle and barrier according to

the signal received from ultrasonic sensor and send the information
Reversing radar controller (RBCM) to comprehensive display.
2. Ring the interval buzzer.
Reversing switch Send the reversing signal to reversing radar controller (RBCM).
3. Self-inspection function of reversing radar controller

(b). Gear on reversing gear, and reversing radar controller (RBCM) will conduct self-inspection.
• If reversing radar function is normal, the reversing indicator and buzzer will work normally, and it is
necessary to run for 0.8±0.2s.
• If the reversing radar functions abnormally, it is an indication that the reversing indicator lamp and buzzer
operate abnormally.
4. Detecting range of reversing radar

(a). When detecting distance S>1. 5m, three sections don't light up.
(b). When detecting distance 1m<S≤1. 5m, the most inner layer lights up. (Sound: the interval is 1s)
(c). When detecting distance 0.5m<S≤1m, the middle layer and most inner layer light up. (Sound: the interval is 0.5s)
(d). When detecting distance S<0.5m, three layers light up. (Sound: continuous ring) test height: about 528mm
76
LIFAN AUTO
Reverse radar
Sensor (+) Signal Sensor (-) Signal
Reversing Radar System-Reversing radar system
LIFAN AUTO
Wiring diagram
Left reverse radar probe Right reverse radar probe
76-6
Terminal definition VH1 to Rear vehicle body harness
V01 to Left reverse radar probe
Terminal
Color Function No.
No.
1 GV Left reversing radar probe signal
1 GBl Left reversing radar probe (+)
2 GO Right reversing radar probe signal
2 GV Left reversing radar probe signal
3 GBl Power supply of reversing radar probe
3 GB Left reversing radar probe (-)
4 GB Grounding of reversing radar probe
5 GrBr Trunk antenna (+)

V02 to Trunk low-frequency magnetic field aerial
6 Gr Trunk antenna (-)

No.
1 GrBr Antenna (+)
2 Gr Antenna (-)
V03 to Right reverse radar probe

No.
1 GBl Right reversing radar probe (+)
2 GO Right reversing radar probe signal
3 GB Right reversing radar probe (-)
76
LIFAN AUTO
On-vehicle check
1. Advanced inspection
(a). Turn the ignition switch to ON. Shift the shift-lever to
reverse position and apply the parking brake to ensure the
vehicle safety.
(b). Move a column with a diameter of 60mm around the sensor
to measure the detecting range of the reverse radar sensor.
(c). When detecting a barrier, the detecting indicator lamps and

buzzers will work as follows:
• When detecting distance S>1.5m, three sections don't
light up.
• When detecting distance 1m<S≤1.5m, the most inner

layer lights up. (Sound: the interval is 1s)
LIFAN AUTO
• When detecting distance 0.5m<S≤1m, middle layer and

the most inner layer light up. (Sound: the interval is 0.5s)
• When detecting distance S<0.5m, three layers light up.

(Hint sound: continuous sound)
2. Inspection of self-inspection function of reversing radar

(a). Inspect self-inspection function of reversing indicator and buzzer: turn ignition switch to ON position. After 0.4s
and gear shifting rod is on reversing position, inspect the working condition of reversing indicator and buzzer. It
is necessary to run for 0.8±0.2s, at this moment, the system is in working condition of normal inspection.
(b). If reversing indicator doesn't lights up or buzzer doesn't ring according to the specification, it indicates that the
wiring is in breaking condition.
76
LIFAN AUTO
76-10 Reversing Radar System-Troubleshooting
Troubleshooting
these parts.
1. Fuse (blown) Replace
2. Reversing switch (damaged) Replace
The system won't work 3. RBCM (damaged) Replace

completely.
4. Multi-function display (damaged) Replace
5. Wire harness (power supply is open-circuit

or short-circuit)
1. Reverse radar sensor (damaged) Replace
2. Harness (short circuit or open circuit of

sensor circuits)
The self-checking system is
abnormal.
3. RBCM (damaged) Replace
4. C A N s y s t e m ( a b n o r m a l w o r k i n g
Use diagnostic scanner to diagnose system fault.
condition)

The system will work
without shifting to reverse 2. Reversing switch (damaged) Replace
position.
When shifting to reverse 2. RBCM (damaged) Replace

position, the system will not
work (but the reversing lamp 3. Wire harness (open circuit or short circuit) Repair or replace the harness or connector
is normal).
condition)
1. Instrument cluster (damaged) Replace

The indication of display
or the buzz of buzzer is 3. RBCM (damaged) Replace
abnormal (but the reversing
lamp is normal). 4. Wire harness (open circuit or short circuit) Repair or replace the harness or connector
condition)
LIFAN AUTO
Reversing Radar System-Troubleshooting 76-11
The system won't work completely.

Inspect RBCM fuse.

• Inspect whether RBCM fuse FS13 is burned out.
Inspect reversing switch.

Hint:
Shift to reverse position to check whether the reversing lamp will be illuminated. Indirectly
judge the damage condition of reversing switch.
• Disconnect reversing switch connector.
• Shifting to reverse position, measure the two terminals of the reversing lamp switch for
connectivity by switching the digital multimeter to the resistance function.
• Without shifting to reverse position, measure the two terminals of the reversing lamp
switch for connectivity by switching the digital multimeter to the resistance function.
Inspect multi-function display and interval buzzer

3 • Open one door of the four vehicle doors. To Step 4 To Step 6
• Check whether the multi-function display can indicate the door opening.
• Inspect whether interval buzzer (door speaker) rings.
Inspect RBCM.
• Shift to R Position.
4 • Disconnect RBCM connector H01. To Step 5 To Step 6

terminal of RBCM and grounding is 10~14V.
• Use a digital multimeter resistance scale to check whether No.17 terminal of RBCM and
grounding is connected.
Eliminate communication fault between wire harness and CAN system.

• Use diagnostic scanner to read the communication condition of reversing radar of CAN
5 system and judge whether it is normal. To Step 6
• Check the harnesses for short circuit s or opens according to the electrical wiring
diagrams.
6 Eliminate detected fault and test if the fault is eliminated. Diagnosis is over.
76
LIFAN AUTO
The self-checking system is abnormal.

Inspect CAN system communication fault.

1 • Use diagnostic scanner to read the communication condition of reversing radar of CAN To Step 2 To Step 5
system and judge whether it is normal.
Inspect RBCM.

Check the reverse radar sensor.

• Remove the rear bumper.
• Disconnect the connector of the reverse radar sensor. Use a slight brass wire to fetch out
the terminals in order to perform measurement with the digital multimeter. Connect the
connector of the reverse radar sensor.
• Measure whether there is a signal voltage <1.5V between the Terminal 2 of the reverse
radar sensor signal line and ground by switching the digital multimeter to the voltage
3 function. To Step 4 To Step 5
• Measure whether there is a voltage of 10~14V between the Terminal 1 of the reverse
radar sensor power line and ground by switching the digital multimeter to the voltage
function.
• Measure whether there is connectivity between the Terminal 3 of the reversing radar
sensor grounding line and ground by switching the digital multimeter to the resistance
function.
Hint:
To avoid measurement error, it is recommended to replace the reverse radar sensor with a
new one of the same type of the same vehicle model for comparison.
Troubleshoot the harness faults.

4 To Step 5
Check the harnesses for short circuit s or opens according to the electrical wiring diagrams.
LIFAN AUTO
The system will work without shifting to reverse position.

Inspect reversing switch.

Hint:
Shift to reverse position to check whether the reversing lamp will be illuminated. Indirectly
judge the damage condition of reversing switch.
• Disconnect reversing switch connector.
• Shifting to reverse position, measure the two terminals of the reversing lamp switch for
connectivity by switching the digital multimeter to the resistance function.
• Without shifting to reverse position, measure the two terminals of the reversing lamp
switch for connectivity by switching the digital multimeter to the resistance function.
Inspect RBCM.


3 function. To Step 4
function.
function.
Hint:
To avoid measurement error, it is recommended to replace the Reverse radar sensor with a
76
LIFAN AUTO
When shifting to reverse position, the system will not work (but the
reversing lamp is normal).

Inspect RBCM.


• Disconnect the connector of the Reverse radar sensor. Use a slight brass wire to fetch out
function.
function.
Hint:

4 • Check the harnesses for short circuit s or opens according to the electrical wiring To Step 5
diagrams.
LIFAN AUTO
The display indicates and buzzes abnormally.

Inspect multi-function display and interval buzzer

1 • Open one door of the four vehicle doors. To Step 2 To Step 6
• Check whether the multi-function display can indicate the door opening.
• Inspect whether interval buzzer (door speaker) rings.

Inspect RBCM.


function.
function.
Hint:

5 • Check the harnesses for short circuits or opens according to the electrical wiring To Step 6
diagrams.
76
LIFAN AUTO
76-16 Reversing Radar System-Reversing switch
Reversing switch
Inspection
△ Hint:
• The reversing switch also controls the reversing lamp. To avoid repetition, before checking the reversing switch,
be sure to check whether the reversing lamp won't work, and then, check the reversing switch.
• When checking, repairing or removing the reversing switch, be sure to check the reversing switch harness for
looseness. If there is , tighten the harness connector before testing the reversing switch.
1. Inspect the reverse switch

(b). Disconnect reversing switch connector.
(c). Measure the reversing switch with the digital multimeter.
Standards:
Condition Measure the pins Resistance value
Shift to reverse
1-2 <2Ω
position.
Withdraw from reverse

1-2 ≥ 1ΜΩ
position.
(d). If it is inconsistent with the requirements, replace the

reversing switch.
Replace
1. Removal of reversing switch

(a). Disconnect the battery cathode cable.
(b). Disconnect reversing switch connector.
LIFAN AUTO
Reversing Radar System-Reversing switch 76-17
(c). Dismantle reversing switch.
2. Installation of reversing switch

(a). Install the reversing switch and tighten it.
(b). Connect reversing switch connector.

Attention :
connected in place.
(c). Connect the battery negative cable.
76
LIFAN AUTO
76-18 Reversing Radar System-Reverse radar sensor
Reverse radar sensor

Inspection
△ Hint:
For the inspection of the reverse radar sensor, in general, use the substitution method to perform indirect testing. The
following methods are seldom used in practice but for reference under special conditions.
1. Inspection of reverse radar sensor

(a). Connect the battery positive and negative cables to
the Terminal 1 and Terminal 3 of the reversing radar
respectively.
(b). Measure the Terminal 2 of the reverse radar sensor by
switching the digital multimeter to the voltage function
to ensure the voltage of the Terminal 2 is about 0.02V, or
measure the Terminal 2 of the reverse radar sensor with
an oscillograph to ensure the Terminal 2 has a square wave
signal.
(c). If there is no output voltage or signal, it is an indication that
the reverse radar sensor is damaged.
LIFAN AUTO
Reversing Radar System-Reverse radar sensor 76-19
Replace
1. Remove the rear bumper
(a). Dismantle rear bumper (See Chapter 88, Vehicle Trim -
Rear bumper, Replacement)
2. Removal of reverse radar sensor

(a). Disconnect the connector of the reverse radar sensor.
(b). Poke the mounting bracket of the reversing radar.
76
LIFAN AUTO
76-20 Reversing Radar System-Reverse radar sensor
(c). Remove the reverse radar sensor from inner to outer.
3. Installation of reverse radar sensor

(a). Install the reverse radar sensor from outer to inner.
(b). Insert the mounting bracket of the reversing radar.

△ Hint:
After fixed the mounting bracket, shake the revering radar gently
to check it for firm installation and check whether the reverse radar
sensor joints with the rear bumper in place.
LIFAN AUTO
Reversing Radar System-Reverse radar sensor 76-21
(c). Connect the connector of the reverse radar sensor.

Attention :
connected in place.
4. Install rear bumper

(b). Install rear bumper (See Chapter 88, Vehicle Trim - Rear
Bumper, Replacement)
76
LIFAN AUTO
• Memo •
LIFAN AUTO
Lighting system
Lighting system.......................................................... 77-1 Replace................................................................. 77-50

Preparation............................................................. 77-1 Tail lamp................................................................... 77-57
Repair specifications.............................................. 77-2 Replace................................................................. 77-58
Precautions............................................................. 77-3 Front fog lamp.......................................................... 77-63
Component diagram (front lamps)......................... 77-4 Inspection............................................................. 77-63
Wiring diagram....................................................... 77-6 Adjustment........................................................... 77-63
On-vehicle check.................................................. 77-21 Replace................................................................. 77-64
Troubleshooting........................................................ 77-23 Side turn signal lamp............................................... 77-68
Diagnostic steps.................................................... 77-23 Inspection............................................................. 77-68
Read and clear DTCs............................................ 77-23 Replace................................................................. 77-68
Fault code (DTC) list............................................ 77-27 Step lamp.................................................................. 77-70
Problem symptoms table...................................... 77-29 Inspection............................................................. 77-70
B102011............................................................... 77-30 Replace................................................................. 77-70
B102015............................................................... 77-30 Front ceiling light..................................................... 77-73
B102111............................................................... 77-31 Inspection............................................................. 77-73
B102115............................................................... 77-31 Replace................................................................. 77-73
B102211............................................................... 77-32 Rear ceiling light...................................................... 77-77
B112011............................................................... 77-33 Inspection............................................................. 77-77
B112015............................................................... 77-33 Replace................................................................. 77-77
B112111................................................................ 77-33 High-mounted brake lamp...................................... 77-80
B112115............................................................... 77-33 Inspection............................................................. 77-80
B112211............................................................... 77-34 Replace................................................................. 77-80
B112311............................................................... 77-35 Trunk light................................................................ 77-81
B112611............................................................... 77-35 Inspection............................................................. 77-81
Neither high beam lamp comes on....................... 77-36 Replace................................................................. 77-81
High beam on one side is not lit........................... 77-37 License plate lamp.................................................... 77-83
Neither low beam lamp comes on........................ 77-38 Inspection............................................................. 77-83
Dipped headlight on one side is not lit................. 77-39 Replace................................................................. 77-83
Interior dimming lamp is not lit........................... 77-39
Interior lamps do not light.................................... 77-40
Front ceiling lamp is lit but rear ceiling lamp is not
lit.....................................................................77-41
Front ceiling lamp is not lit but rear ceiling lamp is
lit.....................................................................77-41
Trunk light do not lighting................................... 77-42
Width lamp and license plate lamp are not lit...... 77-43
Front fog lamp and rear fog lamp are not lit........ 77-43
Front fog lamp is lit but rear fog lamp is not lit... 77-44 77
Front fog lamp on one side is not lit..................... 77-45
Brake lamp does not come on.............................. 77-46
Left brake lamp is lit but right brake lamp is not
lit............................................................... 77-46
Front headlamp....................................................... 77-48
Adjustment........................................................... 77-48
Inspection............................................................. 77-49
LIFAN AUTO
Lighting System-Lighting system 77-1
Lighting system
Preparation
1. Special tool
Lighting system fault

1 Scan Tool
diagnosis

and resistance

2 Screwdriver
panels.
77
LIFAN AUTO
77-2 Lighting System-Lighting system
Headlamp (high-beam) 60W white
Headlamp (low-beam) 55W white
Headlamp (width lamp) 5W white
Front headlamp (turn signal lamp) 21W amber
Side turn signal lamp LED amber
Front fog lamp 55W white
Rear fog lamp 21W red
Rear headlamp (brake lamp) 21W red
Rear headlamp (turn signal lamp) LED red
Rear headlamp (width lamp) LED red
Rear headlamp (reversing lamp) 21W white
Rear license plate lamp LED white
High-mounted brake lamp LED red
Interior combination ceiling lamp 10W white
Item N•m
Headlamp assembly fixed bolt 20~25
Tail lamp assembly fixed nut 8~10
Front fog lamp assembly fixed nuts 8~10
Front ceiling light fixed screw 4~5
High-mounted brake lamp fixed screw 4~5
LIFAN AUTO
Precautions
1. Precaution for use of battery

(a). When using the battery during checking, do not let the tester probe for the positive battery terminal come too
close to that for the negative battery terminal. Otherwise short circuit could occur.
2. Precautions for replacement of headlamp

(a). The halogen lamp could burst due to high temperature. Even a thin oil film on its surface can cause damage.
(b). Be careful to operate halogen lamps. Because very high pressure exists inside the bulb, falling, collision or
damage of bulbs may cause explosion or crash.
(c). When replacing the bulb, if the bulb is away from the vehicle for a long time, the lamp cover may be
contaminated by dust and moisture.
(d). Replace with a bulb of the same power.
(e). Always mount the light holder securely after replacing the bulb. Gaps around the light holder may cause fuzzy
light cap and water ingress into the light chamber.
77
LIFAN AUTO
Component diagram (front lamps)
1 Fixed nuts of left/right front fog lamp 8 Bulb
2 Bulb 9 Left/right front step lamp
3 Front left/right fog lamp 10 Bulb
4 Front left/right headlamp fixed bolts 11 Left/right side turn signal lamp
5 Front left/right headlamp 12 Front ceiling light
6 Front left/right headlamp fixed bolts 13 Bulb
7 Bulb
LIFAN AUTO
Component diagram (rear lamps)
1 Rear ceiling light 7 Left/right reflex reflector
2 Bulb 8 License plate lamp
3 Fixed nuts of left/right rear headlamp 9 Bulb
4 Bulb 10 Trunk light
5 Bulb 11 High-mounted brake lamp
6 Rear left/right headlamp
77
LIFAN AUTO
Wiring diagram
Next page
Left high beam
Left low beam
Headlamp system
Left dimming motor
Left front headlamp
Right high-beam
headlamp
Right low-beam
headlamp
Next page
central control box

Engine compartment
Right dimming
motor
Right front headlamp
LIFAN AUTO
77
77-7
Headlamp system (continued)

Previous page Previous page
Driver compartment
central control box
High beam lamp Low beam lamp
Lighting System-Lighting system
control control
LIFAN AUTO
Dimmer switch
Headlamp adjusting switch
Combination lever
Low
beam
High
Overtaking beam
Headlamp
Clearance
Combination lever lamp
Next page
LIFAN AUTO
Light control switch Back light control
Background light
adjusting switch
77-8
77
77-9
Interior dimming lamp (continued)

Previous page
Audio control unit Instrument Power rearview Cigarette Headlamp Warning lamp
cluster mirror switch lighter adjusting switch switch
LIFAN AUTO
Rear left door Rear right door Front left door Rear right door A/C control unit
control unit control unit control unit control unit
Interior lamp
Driver compartment
central control box
Front ceiling light

Rear ceiling light
LIFAN AUTO
77-10
Next page
77
77-11
Interior lamp (continued)

Previous page
CAN system
RBCM power supply,
ground, data line
Step lamp control
Trunk lamp
　
Front right door control Front left door control Rear right door control Rear left door control
LIFAN AUTO
Trunk switch
Front right door Front left door Rear right door Rear left door
control switch control switch control switch controll switch Trunk switch
Width lamp
Combination lever
Headlamp
Clearance lamp
LIFAN AUTO
Light control switch Front width beam
Front right width

Front left width
Left front headlamp Right front headlamp
lamp
lamp
77-12
Next page
77
Width lamp (continued)
77-13
Previous page
CAN system
LIFAN AUTO
Left license Right license
plate lamp plate light
Rear right width lamp

Left rear width lamp
Left rear Rear right width
headlamp lamp
License plate Width lamp
lamp
Fog lamp
Engine compartment
central control box
Rear fog
lamp
Combination
lever
Front fog lamp
LIFAN AUTO
Fog lamp Front fog
switch lamp control Front left fog Front right
lamp fog lamp
77-14
Next page
77
77-15
Fog lamp (continued)

Previous page
CAN system
LIFAN AUTO
Rear right fog lamp
Rear left fog lamp
Left rear headlamp Right rear headlamp
Rear fog lamp
Brake lamp
Driver compartment CAN system
central control box
Instrument control unit
LIFAN AUTO
Brake lamp switch
High-mounted
Brake lamp control brake lamp control
ABS power supply,
ground, data line
Main brake Auxiliary
brake
77-16
Next page
77
77-17
Brake lamp (continued)

Previous page Previous page
LIFAN AUTO
Right brake lamp
Left brake lamp
Left rear Right rear headlamp

headlamp
High-mount brake lamp
Turn signal lamp, hazard warning flasher
Rear left steering lamp Rear right steering lamp
Left turning Right turning
Combination
lever
LIFAN AUTO
Steering switch
Rear right steering

Rear left steering
Left rear headlamp Right rear
headlamp
lamp
lamp
CAN system
77-18
77
77-19
Steering lamp, Danger warning lamp (continued)

Warning lamp switch Left turn signal lamp Right turn signal lamp
Interior dimming
lamp
LIFAN AUTO
Warning lamp
switch
Left side turn Left turn Right turn Right side turn
signal lamp signal lamp signal lamp signal lamp
Reverse light
CAN system
Reverse light switch
LIFAN AUTO
Right reverse light
Reverse light control
Left reverse light

Left rear Right rear
Reverse light headlamp headlamp
switch
77-20
On-vehicle check
1. Checking function
(a). Stop the vehicle in a safe place and use parking brake.
Attention :
When checking the lighting system, make sure that the battery
voltage is not less than 12V.
(c). Turn on all lamp switches of the lighting system in turn, and
check all lamps of the lighting system.
Phenomenon: Lamps will illuminate or go out due to
switch control.
△ Hint:
For detailed procedures of using switches and turning on/off lamps,
please refer to Service Manual for LIFAN 720.
(d). Disconnect combination lever connector I05:

Check the resistance between No.8 and No.6 terminals of
I05 with the resistance position of a digital multimeter.
When lamp switch is turned to Overtaking, Low Beam and
High Beam, the resistance shall increase progressively.
Otherwise, replace the combination lever. Check No.7
and No.6 terminals of I05 with the resistance position of
a digital multimeter. When lamp switch turns to AUTO,
Headlamp, Clearance Lamp, the resistance shall increase
progressively. Otherwise, replace the combination lever.
Check No.13 and No.6 terminals of I05 with the resistance
position of a digital multimeter. When lamp switch turns to
Rear Fog Lamp, Front Fog Lamp, OFF, the resistance shall
increase progressively. Otherwise, replace the combination
lever.
Check No.12 and No.6 terminal of I05 with the resistance
position of a digital multimeter. When lamp switch turns
to Right Turn, OFF, Left Turn, the resistance shall increase
progressively. Otherwise, replace the combination lever.
2. Inspection of fuse and relay of engine compartment

central control box
(b). Open the central control box cover of the engine
compartment.
(c). Check the corresponding fuses and relays of the lighting
system.
Phenomenon: Fuses have good connectivity and relays
work normally. 77
△ Hint:
Central control box of engine compartment includes related fuses
of lighting system: front fog lamp fuse, high beam fuse, dipped
headlight fuse, front fog lamp relay, high beam relay and dipped
headlight relay.
Attention :
According to actual configuration, some vehicles may have
different fuse positions. Please refer to the identification on the
back of fuse box.
LIFAN AUTO
3. Inspection of fuses in driving compartment central

control box
(a). Remove the glove box on the left lower panel of the
instrument console .
(b). Check the corresponding fuses of the lighting system.
Phenomenon: Fuses have good connectivity.
△ Hint:
Body has related fuse of lighting system: turn signal lamp fuse, tail
lamp fuse (two), ceiling lamp fuse, step lamp fuse.
LIFAN AUTO
Lighting System-Troubleshooting 77-23
Troubleshooting
Diagnostic steps
1. Read the DTC

2. Record the DTC, and then clear the DTC
3. Verify and simulate the fault: turn on corresponding lamp switch to simulate fault state and read DTC
again.
4. Vehicle-based inspection
5. Make troubleshooting according to DTC list, and then go to Step 7.
6. Eliminate fault according to fault symptom; and then go to step 7
7. Confirm troubleshooting and the system restores working.
8. The diagnosis ends
Read and clear DTCs

(DTC)
interface.
77
LIFAN AUTO
77-24 Lighting System-Troubleshooting

Series selection
Chongqing LIFAN
System
configuration
"OK".
Demo
OK
Cancel
ABS, airbag and anti-theft system of LIFAN.

(d). Select and enter into “Body System”.
Chongqing LIFAN Dedicated\Chongqing LIFAN\V5.0\

Anti-theft system
Vehicle body system
A/C System Return
LIFAN AUTO
(e). Select “Body Control System (HIRAIN FBCM)”.

△ Hint:
Vehicle body system LIFAN Dedicated\Chongqing LIFAN\V5.0\Vehicle body system

Reading DTC and clearing method for “Body Control System
(HIRAIN RBCM)” are the same as “Body Control System
Vehicle body system (HIRAIN FBCM) Previous page
Vehicle body system (HIRAIN RBCM)
(HIRAIN FBCM)”.
Next page
Print
Return

△ Hint:
Front body control system (HIRAIN FBCM) LIFAN Dedicated\Chongqing LIFAN\V5.0\

Read fault code
Previous page
Clear fault code

ECU reset Next page
Print
Return
Information
OK
Cancel
77
LIFAN AUTO
2. Clearing of DTCs
Front body control system (HIRAIN FBCM) LIFAN Dedicated\Chongqing LIFAN\V5.0\
Read fault code

Previous page
Clear fault code
ECU reset Next page
Print
Return
Information
OK
Cancel
LIFAN AUTO

Attention :
Diagnostic trouble code Fault code description Suspected area

(DTC)
FBCM
• Front left turn signal lamp circuit

B102011 Front left turn signal lamp with short circuit • Front left turn signal lamp
• FBCM

B102015 Front left turn signal lamp with open circuit • Front left turn signal lamp
• FBCM
• Front right turn signal lamp circuit

Front right turn signal lamp with short
B102111 • Front right turn signal lamp
circuit
• FBCM

Front right turn signal lamp with open
B102115 • Front right turn signal lamp
circuit
• FBCM
• Width lamp circuit

B102211 Front width lamp with short circuit • Front width lamp
• FBCM
RBCM
• Rear left turn signal lamp circuit

B112011 Rear left turn signal lamp with short circuit • Rear left turn signal lamp
• RBCM
• Rear left turn signal lamp circuit

B112015 Rear left turn signal lamp with open circuit • Rear left turn signal lamp
• RBCM
• Rear right turn signal lamp circuit

B112111 Rear right turn signal lamp with short circuit • Rear right turn signal lamp
• RBCM
• Rear right turn signal lamp circuit

B112115 Rear right turn signal lamp with open circuit • Rear right turn signal lamp
• RBCM
• License plate lamp circuit

B112211 License plate lamp with short circuit • License plate lamp
• RBCM
77
• High-mounted brake lamp circuit
B112311 High-mounted brake lamp with short circuit • High-mounted brake lamp
• RBCM
LIFAN AUTO

(DTC)
• Reversing lamp circuit

B112611 Reversing lamp with short circuit • Reverse light
• RBCM
B111079 Brake lamp switch with logical error • Brake lamp switch
LIFAN AUTO

Using the table below will help to find causes of the problem. In proper sequence check each component; replace it
when necessary.
Malfunction Suspected area Recommended action

phenomenon
1. Fuse (broken) Replace
2. Relay (damaged) Replace
3. Wire harness (open circuit or short circuit) Repair or replace the harness or connector.
Neither high beam
lamp comes on
4. Combination lever (damaged) Replace
5. Bulb (damaged) Replace
6. FBCM (damaged) Replace
Only high beam on
one side is lit
Neither low beam
lamp comes on
4. combination lever (damaged) Replace
Only dipped 1. Wire harness (open circuit or short circuit) Repair or replace the harness or connector.
headlight on one side
is lit 2. Bulb (damaged) Replace
1. Combination lever (damaged) Replace
Interior dimming
lamps are not lit
3. Regulating switch of backlight (damaged) Replace
Interior lamps are not
lit
4. Ceiling lamp control switch (damaged) Replace

Front ceiling lamp
2. R e a r c e i l i n g l a m p c o n t r o l s w i t c h
is lit but rear ceiling Replace
(damaged)
lamp is not lit
1. Bulb (damaged) Replace 77

Front ceiling lamp is
2. F r o n t c e i l i n g l a m p c o n t r o l s w i t c h
not lit but rear ceiling Replace
(damaged)
lamp is lit
LIFAN AUTO
Malfunction Suspected area Recommended action

phenomenon

Trunk light do not
lighting
3. Trunk switch (damaged) Replace
Wi d t h l a m p a n d 2. Wire harness (open circuit or short circuit) Repair or replace the harness or connector.
license plate lamp
are not lit 3. combination lever (damaged) Replace

Front fog lamp and
rear fog lamp 3. Wire harness (open circuit or short circuit) Repair or replace the harness or connector.
are not lit
4. combination lever (damaged) Replace
1. Rear fog lamp (damaged) Replace
Front fog lamp is lit 2. Wire harness (open circuit or short circuit) Repair or replace the harness or connector.
but rear fog lamp is
not lit 3. combination lever (damaged) Replace
Only front fog lamp
on one side is lit
Brake lamps are not
lit
3. Brake lamp switch (damaged) Replace
Left brake lamp is lit 1. Wire harness (open circuit or short circuit) Repair or replace the harness or connector.
but right brake lamp
is not lit 2. Right brake lamp (damaged) Replace
B102011 - Front left turn signal lamp with short circuit

B102015 - Front left turn signal lamp with open circuit
Check system
• Ensure that the power source operates normally.
1 To Step 2
• Turn lamp switch to left turn position and check if the left turn signal lamp works
normally.
Check front left turn signal lamp

• Refer to the procedures in maintenance manual to check if front left turn signal lamp
bulb and left turn signal lamp LED are damaged.
LIFAN AUTO
Check wire harness and connector (FBCM - front left turn signal lamp )
3 • Disconnect front left turn signal lamp connector U12, left turn signal lamp connector To Step 4 To Step 7
U14, FBCM connector I20.
• Check if the resistance between No.14 terminal of I20 and No.1 of U12, No.1 terminal
of U14 is less than 2Ω with the resistance position of a digital multimeter.
Check wire harness and connector (front left turn signal lamp - grounding)
U14.
• Check if the resistance between No.2 of U12, No.2 terminal of U14 and the grounding is
less than 2Ω with the resistance position of a digital multimeter.
Replace FBCM
5 To Step 8
• Refer to maintenance procedure in maintenance manual to replace FBCM.
Replace Bulb
6 • Refer to maintenance procedure in maintenance manual to replace turn signal lamp bulb To Step 8
or left turn signal lamp assembly.

7 To Step 8
B102111 - Front right turn signal lamp short circuit

B102115 - Front right turn signal lamp open circuit
Check system
• Turn lamp switch to right turn position, check if right turn signal lamp works normally.
Check front right turn signal lamp

• Refer to the procedures in maintenance manual to check if front right turn signal lamp
bulb and right turn signal lamp LED are damaged.
Check wire harness and connector (FBCM - front right turn signal lamp )
3 • Disconnect front right turn signal lamp connector U23, right turn signal lamp connector To Step 4 To Step 7
U21 and FBCM connector I20.
• Check if the resistance between1No.5 terminal of I20 and No.1 of U23, No.1 terminal of
U21 is less than 2Ω with the resistance position of a digital multimeter.
Check wire harness and connector (front left turn signal lamp - grounding)
77
U21.
• Check the resistance between No.2 of U23, No.2 terminal of U21 and grounding is less
than 2Ω with the resistance position of a digital multimeter.
LIFAN AUTO
Replace FBCM
5 To Step 8
Replace bulb
6 • Refer to maintenance procedure in maintenance manual to replace turn signal lamp bulb To Step 8
or right turn signal lamp assembly.

7 To Step 8
B102211 - Front width lamp with short circuit

Check system
• Turn lamp switch to small lamp position, check if front width lamp works normally.
Check front width lamp

• Refer to the procedures in maintenance manual to check if front width lamp bulb is
damaged.
Check wire harness and connector (FBCM - front width lamp )

3 • Disconnect front left headlamp connector U11, front right headlamp connector U24, To Step 4 To Step 7
FBCM connector I20.
• Check if the resistance between No.2 terminal of I20 and No.6 of U11, No.6 terminal of
U24 is less than 2Ω with the resistance position of a digital multimeter.
Check wire harness and connector (front width lamp - grounding)

4 • Disconnect front left headlamp connector U11 and front right headlamp connector To Step 5 To Step 7
U24.
• Check if the resistance between No.3 of U11, No.3 terminal of U24 and the grounding is
Replace FBCM
5 To Step 8
Replace bulb
6 To Step 8
• Refer to maintenance procedure in maintenance manual to replace front width lamp bulb.

7 To Step 8
LIFAN AUTO
B112011 - Rear left turn signal lamp short circuit

B112015 - Rear left turn signal lamp open circuit
Check system
1 To Step 2
• Turn lamp switch to left turn position and check if the left turn signal lamp works
normally.
Check rear left turn signal lamp

• Refer to the procedures in maintenance manual to check if rear left turn signal lamp bulb
is damaged.
Check wire harness and connector (RBCM - rear left turn signal lamp)
3 • Disconnect rear left headlamp connector H03, RBCM connector H02. To Step 4 To Step 7
• Check if the resistance between No.5 terminal of H02 and No.1 terminal of H03 is less
Check wire harness and connector (rear left turn signal lamp - grounding)
4 • Disconnect rear left headlamp connector H03. To Step 5 To Step 7
• Check if the resistance between No.2 terminal of H03 and the grounding is less than 2Ω
with the resistance position of a digital multimeter.
Replace RBCM
5 To Step 8
• Refer to maintenance procedure in maintenance manual to replace RBCM.
Replace Bulb
6 To Step 8
• Refer to maintenance procedure in maintenance manual to replace turn signal lamp bulb.

7 To Step 8
B112111 - Rear right turn signal lamp short circuit

B112115 - Rear right turn signal lamp open circuit
Check system
• Turn lamp switch to right turn position, check if right turn signal lamp works normally.
77
Check rear right turn signal lamp
• Refer to the procedures in maintenance manual to check if rear right turn signal lamp
bulb is damaged.
LIFAN AUTO
Check wire harness and connector (RBCM - rear right turn signal lamp )
3 • Disconnect right tail lamp connector H05, RBCM connector H02. To Step 4 To Step 7
• Check if the resistance between No.4 terminal of H02 and No.1 terminal of H05 is less
Check wire harness and connector (rear right turn signal lamp - grounding)
4 • Disconnect rear right headlamp connector H05. To Step 5 To Step 7
• Check if the resistance between No.2 terminal of H05 and the grounding is less than 2Ω
Replace RBCM
5 To Step 8
Replace bulb
6 To Step 8
• Refer to maintenance procedure in maintenance manual to replace turn signal lamp bulb.

7 To Step 8
B112211 - License plate lamp with short circuit

Check system
• Turn lamp switch to small lamp position, and check if license plate lamp works normally.
Check license plate lamp

• Refer to the procedures in maintenance manual to check if license plate lamp is
damaged.
Check wire harness and connector (RBCM - license plate lamp)

3 • Disconnect left license plate lamp connector L01, right license plate lamp connector To Step 4 To Step 7
L02, RBCM connector H02.
• Check if the resistance between 1No.1 terminal of H02 and No.2 of L01, No.2 terminal
of L02 is less than 2Ω with the resistance position of a digital multimeter.
Check wire harness and connector (license plate lamp - grounding)

4 • Disconnect left license plate lamp connector L01, right license plate lamp connector To Step 5 To Step 7
L02.
• Check if the resistance between No.1 of L01, No.1 terminal of L02 and the grounding is
Replace RBCM
5 To Step 8
Replace license plate lamp

6 To Step 8
• Refer to maintenance procedure in maintenance manual to replace license plate lamp.
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7 To Step 8
B112311 - High-mounted brake lamp with short circuit

Check system
• Step on brake pedal, and check if high-mounted brake lamp works normally.
Check high-mounted brake lamp

• Refer to the procedures in maintenance manual to check if high-mounted brake lamp is
damaged.
Check wire harness and connector (RBCM - high-mounted brake lamp )

3 • Disconnect high-mounted brake lamp connector B06, RBCM connector H02. To Step 4 To Step 7
• Check if the resistance between No.9 terminal of H02and No.2 of terminal B06 is less
Check wire harness and connector (high-mounted brake lamp - grounding)

4 • Disconnect high-mounted brake lamp connector B06. To Step 5 To Step 7
• Check if the resistance between No.1 of B06 and the grounding is less than 2Ω with the
resistance position of a digital multimeter.
Replace RBCM
5 To Step 8
Replace high-mounted brake lamp

6 • Refer to maintenance procedure in maintenance manual to replace high-mounted brake To Step 8
lamp.
Check the harness and connector

7 To Step 8
B112611 - Reversing lamp with short circuit

Check system
1
To Step 2 77
• When the transmission is put into “Reverse Gear”, check if reversing lamp work
normally.
Check reversing lamp

• Refer to the procedures in maintenance manual to check if reversing lamp bulb is
damaged.
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Check wire harness and connector (RBCM - reversing lamp)

3 • Disconnect the left headlamp connector H03, the right headlamp connector H05, RBCM To Step 4 To Step 7
connector H02.
• Check if the resistance between No.12 terminal of H02 and No.6 terminal of H03, No.6
terminal of H05 is less than 2Ω with the resistance position of a digital multimeter.
Check wire harness and connector (reversing lamp - grounding)

4 • Disconnect left headlamp connector H03, right headlamp connector H05. To Step 5 To Step 7
• Check if there is the resistance between No.2 of H03, No.2 of H05 and the grounding is
Replace RBCM
5 To Step 8
Replace reversing lamp

6 To Step 8
• Refer to maintenance procedure in maintenance manual to replace reversing lamp bulb.

7 To Step 8
Neither high beam lamp comes on

Check system
1 To Step 2
• Set the light control switch at the High Beam Lamp position, to check whether the high
beam lamp operates normally.
Check fuse
• Turn ignition switch to OFF.
• Open the central control box in the driving compartment.
• Take out high beam fuse FS07, check if the fuse is blown.
Check relay
• In normal state, check if there is continuity between No.1 and No.2 pins of RL05 with a
3 multimeter. To Step 4 To Step 8
• Apply the voltage on No.1 and No.2 pins of RL05, check if there is continuity between
No.3 and No.5 pins of RL05 with a multimeter.
Check harness for broken circuit

• Turn ignition switch to ON
• Turn lamp switch to “High Beam” position to check if there is about 12V voltage
4 between 1No.6 pin of I20 and the grounding with the voltage position of a digital To Step 5 To Step 7
multimeter.
• Check if there is about 12V voltage between No.2 pin of U11 and the grounding with the
voltage position of a digital multimeter.
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5 • Check if there is continuity between No.3 pin of U11 and the grounding with a digital To Step 6 To Step 7
multimeter.
• Check if there is continuity between No.5 pin of I20 and No.6 pin of I05, No.7 pin of I20
and No.8 pin of I05 with the resistance position of a digital multimeter.
Check combination lever

6 • Refer to check method of lamp switch in Check on the Vehicle to check if combination To Step 9 To Step 10
lever is in good state.
Check harness
7 To Step 11
Replacement of fuse or relay

• Before replacing the burnt fuse, firstly troubleshoot the circuit according to wiring
8 To Step 11
• Replace the relay with the corresponding specifications.
Replace bulb
9 To Step 11
• Refer to check procedure in this chapter to check and replace high beam bulb.
Replace combination lever

10 To Step 11
• Referring to the service manual, replace the combination lever.
High beam on one side is not lit

△ Hint:
Set the right high beam that is not lit as an example.
Check system
1 To Step 2
• Set the light control switch at the High Beam Lamp position, to check whether the high

• Turn lamp switch to “High Beam” position to check if there is about 12V voltage
between No.2 pin of U24 and the grounding with the voltage position of a digital
multimeter.

• Check if there is continuity between No.2 pin of U11 and No.2 pin of U24, No.3 pin of
U24 and the grounding with the resistance position of a digital multimeter.
Check harness for short circuit

77
• Check if there is continuity between No.2 pin of U24 and the grounding with the
Replace bulb
5 To Step 7
• Referring to the service manual, replace the high beam lamp bulb.
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Check harness
6 To Step 7
Neither low beam lamp comes on

Check system
1 To Step 2
• Set the light control switch to the Low Beam Lamp position, to check whether the low
Check fuse
• Turn ignition switch to OFF.
• Open the central control box of the engine compartment.
• Take out dipped headlight fuse FS09 to check if the fuse is blown.
Check relay
• Apply the voltage on No.1 and No.2 pins of RL07, check if there is continuity between
No.3 and No.5 pins of RL07 with a multimeter.

• Turn lamp switch to dipped headlight position, check if there is about 12V voltage
4 between No.1 pin of U24 and the grounding with the voltage position of a digital To Step 5 To Step 7
multimeter.
• Check if there is about 12V voltage between 1No.7 pin of I20 and the grounding with
the voltage position of a digital multimeter.

5 • Check if there is continuity between No.5 pin of U24 and the grounding with a digital To Step 6 To Step 7
multimeter.
• Check if there is continuity between No.6 pin of I05 and No.5 pin of I20, No.8 pin of I05
and No.7 pin of I20 with the resistance position of a digital multimeter.

Repeat the
6 • Refer to check method of lamp switch in Check on the Vehicle to check if combination To Step 9
above steps
Check harness
7 To Step 11
Replace fuse and relay

8 To Step 11

9 To Step 11
Replace bulb
10 To Step 11
• Referring to the service manual, replace the low beam lamp bulb.
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Dipped headlight on one side is not lit

△ Hint:
Set the left dipped headlight that is not lit as an example.
Check system
1 To Step 2
• Set the light control switch to the Low Beam Lamp position, to check whether the low

• Check if there is about 12V voltage between No.1 pin of U11 and the grounding with the


Check harness
5 To Step 7
Replace bulb
6 To Step 7
• Referring to the service manual, replace the low beam lamp bulb.
Interior dimming lamp is not lit

Check system
1 To Step 2
• Turn lamp switch to small lamp position, check if interior dimming lamp works
normally.
Check fuse
• Take out position turn signal lamp fuse FS02, check if the fuse is blown.

• Check if there is about 12V voltage between No.1 pin of I20 and the grounding with the 77
LIFAN AUTO

• Check if there is a continuity between No.3 pin of I03 and the grounding with a digital
• Check if there is continuity between No.10 pin of I05 and No.8 pin of I20, No.6 pin of
I05 and No.5 pin of I20, No.2 pin of I03 and No.2 pin of I20 with the resistance position
of a digital multimeter.

• Check if there is continuity between No.1 pin of I03 and the grounding with the
Check regulating switch of backlight

Repeat the
6 • Refer to related procedure in maintenance manual, and check if regulating switch of To Step 9
above steps
backlight is in good condition.
Check harness
7 To Step 10
Replace fuse
8 • Before replacing the burnt fuse, firstly troubleshoot the circuit according to wiring To Step 10
Replace regulating switch of backlight

9 • Refer to maintenance procedure in maintenance manual to replace regulating switch of To Step 10
backlight.
Interior lamps do not light

Check system
1 To Step 2
• Turn front ceiling lamp switch and rear ceiling lamp switch to “ON”, and check if ceiling
lamps work normally.
Check fuse
• Take out ceiling lamp fuse FS06 and check if the fuse is blown out.

3 • Check if there is about 12V voltage between No.2 pin of R01, No.3 pin of R05 and the To Step 4 To Step 7
grounding with the voltage position of a digital multimeter, respectively.

4 • Check if there is continuity between No.1 pin of R01, No.1 pin of R05 and the grounding To Step 5 To Step 7
with a digital multimeter, respectively.

5 • Check if there is continuity between No.2 pin of R01, No.3 pin of R05 and the grounding To Step 7 To Step 6
with the resistance position of a digital multimeter, respectively.
Check front ceiling lamp and rear ceiling lamp

Repeat the
6 • Refer to ceiling lamp check items in this chapter, check if front ceiling lamp and rear To Step 9
above steps
ceiling lamp are in good condition.
Check harness
7 To Step 10
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Replace fuse
Replace ceiling lamp assembly

9 • Refer to maintenance procedure in maintenance manual to replace front ceiling lamp and To Step 10
rear ceiling lamp.
Front ceiling lamp is lit but rear ceiling lamp is not lit
Check system
1 To Step 2
• Turn rear ceiling lamp switch to “ON” position to check if rear ceiling lamp work
normally.

2 • Check if there is about 12V voltage between No.3 pin of R05 and the grounding with the To Step 3 To Step 5

3 • Check if there is continuity between No.1 pin of R05 and the grounding with the To Step 4 To Step 5

Check harness
5 To Step 7
Replace rear ceiling lamp assembly

6 • Refer to maintenance procedure in maintenance manual to replace rear ceiling lamp To Step 7
assembly.
Front ceiling lamp is not lit but rear ceiling lamp is lit
Check system
1 To Step 2
• Turn front ceiling lamp switch to “ON” position to check if front ceiling lamp works
normally.

77
2 • Check if there is about 12V voltage between No.2 pin of R01 and the grounding with the To Step 3 To Step 5


LIFAN AUTO
Check harness
5 To Step 7
Replace front ceiling lamp assembly

6 • Refer to maintenance procedure in maintenance manual to replace front ceiling lamp To Step 7
assembly.
Trunk light do not lighting

Check system
• Open the trunk to check if trunk lamp works normally.
Check fuse
• Take out tail lamp 1 fuse FS10 to check if the fuse is blown.

• Check if there is 12V voltage between No.2 pin of B07 and the grounding with the
4 • Disconnect trunk lamp connector B07 and trunk switch connector L03 and check if there To Step 5 To Step 7
is continuity between No.1 pin of B07 and No.1 pin of L03 with the resistance position
Check trunk lamp

5 • Refer to trunk lamp check items in this chapter to check if trunk lamp is in good To Step 6 To Step 9
condition?
Inspection of trunk switch Repeat the

6 To Step 10
• Check if trunk switch is in good condition. above steps
Check harness
7 To Step 11
Replace fuse
Replace trunk lamp

9 To Step 11
• Refer to maintenance procedure in maintenance manual to replace trunk lamp.
Replace trunk switch

10 To Step 11
• Refer to maintenance procedure in maintenance manual to replace trunk switch.
11 Check whether the trouble has been removed. The diagnosis is completed. To Step 11
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Width lamp and license plate lamp are not lit

Check system
• Turn lamp switch to small lamp position, and check if width lamp works normally.
Check fuse
• Take out width lamp, turn signal lamp fuse FS02, and check if the fuse is blown.

3 • Check if there is about 12V voltage between No.1 pin of I20 and the grounding with the To Step 4 To Step 8

4 • Check if there is continuity between No.2 pin of I20 and the grounding with the To Step 8 To Step 5

• Check if there is continuity between No.3 pin of U11, No.3 pin of U24 and the grounding
5 with a digital multimeter. To Step 6 To Step 8
• Check if there is continuity between No.2 pin of I20 and No.6 pin of U11, No.2 pin of
I20 and No.6 pin of U24 with the resistance position of a digital multimeter.

Repeat the
6 • Refer to check method of lamp switch in Check on the Vehicle to check if combination To Step 9
above steps
Check harness
7 To Step 10
Replace fuse

9 To Step 10
Front fog lamp and rear fog lamp are not lit
Check system
1 To Step 2
• Turn lamp switch to front fog lamp or rear fog lamp position, and check if fog lamp
works normally.
Check fuse
77
• Turn ignition switch to OFF, and open central control box of engine hood central control
box.
• Take out front fog lamp fuse FS08 to check if the fuse is blown.
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Check relay
• Apply the voltage on No.1 and No.2 pins of RL06, and check if there is continuity
between No.3 and No.5 pins of RL07 with a multimeter.

4 • Check if there is about 12V voltage between No.18 pin of I20 and the grounding with To Step 5 To Step 8
the voltage position of a digital multimeter.
• Check if there is about 12V voltage between No.1 pin of I18 and the grounding with the

5 • Check if there is continuity between No.1 pin of U10 and the grounding with a To Step 6 To Step 8
multimeter.
• Check if there is continuity between No.6 pin of I05 and No.5 pin of I20, No.13 pin of
I05 and No.9 pin of I20 with the resistance position of a digital multimeter.

6 • Refer to check method of lamp switch in Check on the Vehicle to check if combination To Step 7 To Step 10
Replace bulb
7 To Step 11
• Refer to check procedure in this chapter to check and replace fog lamp bulb.
Check harness
8 To Step 11
Replace fuse and relay

9 To Step 11

10 To Step 11
Front fog lamp is lit but rear fog lamp is not lit
Check system
• Turn lamp switch to rear fog lamp position to check if rear fog lamp works normally.
Check fuse
• Take out tail lamp 2 fuse FS11, check if the fuse is blown.

3 • Check if there is about 12V voltage between No.6 pin of H02 and grounding with the To Step 4 To Step 7
LIFAN AUTO

4 • Disconnect wire harness connector H02, and check if there is continuity between No.8 To Step 7 To Step 5
pin of H02 and the grounding with the resistance position of a digital multimeter.
5 • Disconnect wire harness connector H03 and H05, check if there is continuity between # To Step 6 To Step 7
pin of H02 and No.4 pin of H03, No.2 pin of H03 and the grounding, No.2 pin of H05
and the grounding with the resistance position of a digital multimeter.
Replace bulb
6 To Step 9
• Refer to check procedure in this chapter to check and replace rear headlamp assembly.
Check harness
7 To Step 9
Replace fuse
Front fog lamp on one side is not lit

△ Hint:
Set front left fog lamp that is not lit as an example.
Check system
• Turn lamp switch to front fog lamp to check if front fog lamp works normally.

• Turn combination lever to front fog lamp, and check if there is about 12V voltage
between No.2 pin of U10 and the grounding with the voltage position of a digital
multimeter.

• Disconnect wire harness connector U10, and check if there is continuity between No.1
pin of U10 and the grounding with the resistance position of a digital multimeter.

• Disconnect wire harness connector U10, and check if there is continuity between No.2
pin of U10 and the grounding with the resistance position of a digital multimeter.
Replace bulb
5 To Step 7
• Refer to check procedure in this chapter to check and replace front fog lamp bulb.
Check harness
6 To Step 7 77
LIFAN AUTO
Brake lamp does not come on

Check system
• Depress the brake pedal, to check whether the brake lamp operates normally.
Check fuse
• Take out FBCM fuse FS04, FS05 to check if the fuse is blown.

• Check if there is about 12V voltage between No.1 pin / No.3 pin of I13 and the
grounding with the voltage position of a digital multimeter, respectively.

• Check if there is continuity between No.2 pin of H03, No.2 pin of H05 and the
4 grounding with a digital multimeter. To Step 5 To Step 7
• Check if there is continuity between No.2 pin of I13 and 3No.3 pin of E01, No.4 pin
of I13 and 6No.9 pin of E01, No.3 pin of H02 and No.5 pin of H03 with the resistance
position of a digital multimeter.

• Check if there is continuity between No.3 pin of H02 and the grounding with the
Check brake lamp switch

6 • Refer to check method of brake lamp switch in maintenance manual to check if brake To Step 10 To Step 9
lamp switch is in good state.
Check harness
7 To Step 10
Replace fuse
Replace brake lamp switch

9 To Step 10
Left brake lamp is lit but right brake lamp is not lit
Check system
• Depress the brake pedal, to check whether the brake lamp operates normally.
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• Check if there is continuity between No.3 pin of H02 and No.5 pin of H05, No.2 pin of
H05 and the grounding with the resistance position of a digital multimeter.
Replace bulb
3 To Step 5
• Refer to check procedure in this chapter to check and replace right headlamp assembly.
Check harness
4 To Step 5
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LIFAN AUTO
77-48 Lighting System-Front headlamp
Front headlamp
Adjustment
1. Before Adjustment
(a). Adjust the vehicle as follows.
• Make sure there is no deformation around front headlamp.
• Park the vehicle on level ground.
• Make sure the tires are inflated with the specified pressures. (See Chapter 33 Wheels and Tires - Wheels and
Tire Assembly, On-board Check)
• Driver is in the vehicle (or counter weight is about 73kg), and the vehicle is in a state that it can set out at any
time (Fuel tank is full).
2. Inspection of illumination range of front headlamp

(a). Make sure the glass lens of front headlamp is at a distance
10m from the screen which can be either a curtain or a flat
wall.
(b). Start the engine.
(c). Turn on front headlamp.
(d). Check whether the illumination range of front headlamp is
consistent with that shown in the figure.
△ Hint:
A and B indicate the position of front headlamp respectively. H
indicates the height of front headlamp. L1 and L2 indicate the
distance between front headlamp center and the vehicle center
respectively.
(e). If not, adjust front headlamp.
3. Adjustment the range of the headlamp

(b). Screw the adjusting bolt, and adjust the illumination range
of front headlamp up to the standard range.
△ Hint:
With the optical axis adjusting switch of front headlamp in the
driving compartment, adjust the horizontal direction of front
headlamp.
LIFAN AUTO
Lighting System-Front headlamp 77-49
Inspection
1. Check high beam lamp
(a). Check the resistance between No.2 and No.3 terminals of
left/right front headlamp with the resistance position of a
digital multimeter.
Resistance: <2Ω
If the result does not meet the requirement, replace the high
beam lamp bulb.
2. Check low beam lamp

(a). Using a digital multimeter in Ohm range, measure the
resistance between the terminal 1 and 5 of the left/right
headlamp.
Resistance: <2Ω
If the result does not meet the requirement, replace the low
beam lamp bulb.
3. Check front turn signal lamp

left/right front turn signal lamp with the resistance position
Resistance: <2Ω
If the result does not meet the requirement, replace the front
turn signal lamp bulb.
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LIFAN AUTO
4. Check front width lamp

(a). Using a digital multimeter in Ohm range, measure the
resistance between the terminal 3 and 6 of the left/right
headlamp.
Resistance: <2Ω
width lamp bulb.
Replace
1. Replacement of front headlamp assembly

(b). Remove front bumper assembly.
(c). Dismantle fixed bolts of front headlamp assembly.
△ Hint:
The left and right headlamps are replaced in the same manner.
(d). Remove the headlamp assembly, and disconnect the

headlamp connector and the turn signal lamp connector.
△ Hint:
Gently take out the headlamp. When the connector is fairly
exposed, hold the front tail lamp then disconnect the connector. To
avoid damage to the harness, prevent front headlamp from being
drawn out suddenly, resulting in pulling the harness.
(e). Remove front headlamp.
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(f). Connect connectors of the headlamp and the turn signal

lamp to the headlamp assembly.
Attention :
connected in place.
(g). Install front headlamp assembly.
(h). Install the fixed bolts of front headlamp assembly, and

tighten them.
Torque: 20~25N•m
(i). Install front bumper assembly.
(k). Turn on the headlamp, to check whether it operates
normally.
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LIFAN AUTO
2. Replacement of bulb of low-beam headlight

(b). Take out the low beam rubber cover.
Attention :
The procedures for replacing the bulb of low-beam headlight
of front left headlamp are the same as those of the right one.
(c). Press down both sides of the locking bar while posing the
locking bar outward, and remove the lamp socket.
(d). Pull out the bulb of low-beam headlight outward.
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(e). Install the bulb of low-beam headlight. Press down both

sides of the locking bar while pushing the locking bar
inward, and install the lamp socket.
(f). Install the rubber shield of low-beam headlight.

(g). Connect the battery cathode cable.
3. Replacement of bulb of high-beam headlight

(b). Pull out the rubber shield of high-beam headlight outward.
Attention :
Replacement procedure for high beam bulbs of right and left
headlamps are the same.
77
LIFAN AUTO
(c). Press down both sides of the locking bar while posing the
locking bar outward, and remove the lamp socket.
(d). Pull out the bulb of high-beam headlight outward.
(e). Install the bulb of high-beam headlight. Press down both

sides of the locking bar while pushing the locking bar
inward, and install the lamp socket.
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(f). Install the rubber shield of high-beam headlight.

4. Replace turn signal lamp bulb

(b). Turn the turn signal lamp hold and take out the turn signal
lamp.
Attention :
The left and right turn signal lamp bulbs are replaced in the
same manner.
(c). Counterclockwise rotate the turn signal lamp bulb.
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LIFAN AUTO
(d). Rotate the turn signal lamp bulb clockwise and mount the
turn signal lamp.
LIFAN AUTO
Lighting System-Tail lamp 77-57
Tail lamp
Inspection
1. Check rear turn signal lamp

left / right tail lamps with the resistance position of a digital
multimeter.
Resistance: <2Ω
If the result does not meet the requirement, replace the rear
turn signal lamp bulb.
2. Check reverse light

left / right tail lamps with the resistance position of a digital
multimeter.
Resistance: <2Ω
If the result does not meet the requirement, replace the
reverse light bulb.
3. Check rear width lamp, brake lamp and rear fog lamp
(a). Connect the battery positive and negative electrodes with
No.3 and No.2, No.5 and No.2, No.4 and No.2 terminals,
respectively. Connect No.3 and No.2, No.5 and No.2 , 4
and No.2 terminals of left / right rear headlamp.
Phenomenon: rear width lamp, brake lamp and rear fog
lamp are lit one after the other.
77
△ Hint:
• Rear width lamp, brake lamp and rear fog lamp are
integrated LED lamps.
• If it does not conform to the above-mentioned conditions,
replace integrated LED lamp.
LIFAN AUTO
77-58 Lighting System-Tail lamp
Replace
1. Replacement of rear headlamp assembly

(b). Open rear compartment cover.
(c). Dismantle rear compartment trim part.
Attention :
The left and right tail lamps are replaced in the same manner.
(d). Disconnect tail lamps connector.
(e). Dismantle fixed nuts of tail lamps.
LIFAN AUTO
(f). Remove tail lamps assembly.
(g). Install tail lamps assembly.
(h). Install fixed nuts of tail lamps and tighten them.

Torque: 8~10N•m
77
LIFAN AUTO
(i). Connect tail lamps connector.

Attention :
connected in place.
(j). Install rear compartment trim parts.
(k). Close rear compartment cover.
(l). Connect the battery negative cable.
2. Replacement of bulb of rear turn signal lamp

(a). Remove the tail lamp assembly.
(b). Press down the turn signal lamp hold and simultaneously
rotate the holder counterclockwise and take out the turn
signal lamp.
Attention :
The left and right rear turn signal lamp bulbs are replaced in
the same manner.
(c). Rotate the bulb of rear turn signal lamp, and remove it.
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(d). Rotate the bulb of rear turn signal lamp, and install it.
(e). Align to the mounting hole, press the turn signal lamp
socket downwards while rotating the socket clockwise, and
then, install the turn signal lamp.
(f). Install rear headlamp assembly.
3. Replacement of bulb of reversing lamp

(a). Remove the tail lamp assembly.
(b). Replace the bulb of reversing lamp.
Attention :
Replacement procedure for reversing lamp bulb is the same
as that for rear turn signal lamp bulb. The position is at lower
side of rear turn signal lamp bulb.
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LIFAN AUTO
4. Replace rear width lamp, brake lamp and rear fog lamp
Attention :
Rear width lamp, brake lamp and rear fog lamp are integrated
LED lamps, which shall be replaced together with rear
headlamp assembly.
LIFAN AUTO
Lighting System-Front fog lamp 77-63
Front fog lamp

Inspection
1. Inspection of front fog lamp
left/right front fog lamp with the resistance position of a
digital multimeter.
Resistance: <2Ω
If it is inconsistent with the conditions above , replace rear
fog lamp bulb.
Adjustment
1. Adjustment of front fog lamp height

△ Hint:
If it is needed to adjust front fog lamp, follow the following
methods.
(a). Remove the front-end lower fender.
(b). Adjust front fog lamp through its adjusting nut with an
inner-hexagon spanner.
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LIFAN AUTO
77-64 Lighting System-Front fog lamp
Replace
1. Replacement of front fog lamp assembly

(b). Remove front bumper.
△ Hint:
For the sake of convenience, when replacing front fog lamp
assembly, it is recommended to remove front bumper assembly
firstly. Otherwise, it is need to remove the front-end lower fender
firstly.
(c). Disconnect front fog lamp connector.
Attention :
Replace procedures for left/right front fog lamp assembly are
the same.
(d). Dismantle fixed nut of front fog lamp.
(e). Take out front fog lamp assembly outwards.
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(f). Install front fog lamp assembly from outside to inside.
(g). Install the fixed nuts of front fog lamp assembly and tighten
them.
Torque: 8~10N•m
(h). Connect front fog lamp connector.

Attention :
connected in place.
(i). Install front bumper.
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LIFAN AUTO
77-66 Lighting System-Front fog lamp
2. Replacement of fog lamp bulb

(b). Remove the front-end lower fender.
(c). Remove the rubber shield of front fog lamp outwards.
Attention :
Replace procedures for left/right front fog lamp bulbs are the
same.
(d). Press down both sides of the locking bar while pushing
the locking bar outward, and then, take out front fog lamp
socket.
(e). Disconnect the connecting wires of front fog lamp bulb.

(f). Take out front fog lamp bulb assembly.
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(g). Replace front fog lamp bulb assembly, connect its connector
and install its socket.
(h). Press down both sides of the locking bar while pushing the
locking bar inwards, and install front fog lamp socket.
(i). Install the rubber shield of front fog lamp.

(j). Install the front-end lower fender.
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LIFAN AUTO
77-68 Lighting System-Side turn signal lamp
Side turn signal lamp

Inspection
1. Check side turn signal lamp
(a). The battery positive and negative electrodes are connected
with No.1 and No.2 terminals on the component side of
U14 or U21 connector.
Phenomenon: side turn signal lamp is lit
Attention :
Side turn signal lamp is LED lamp. The method of measuring
the resistance cannot be used to check the result.
Replace
1. Replace side turn signal lamp assembly

(b). Push side turn signal lamp to rear end of the vehicle, at the
same time, pull side turn signal lamp outwards, and take out
side turn signal lamp.
Attention :
The left and right side turn signal lamp assemblies are replaced
in the same manner.
LIFAN AUTO
Lighting System-Side turn signal lamp 77-69
(c). Disconnect the side turn signal lamp connector.

(d). Take off the side turn signal lamp.
(e). Mount the side turn signal lamp and connect the connectors.
(f). Install side turn signal lamp assembly.
77
LIFAN AUTO
77-70 Lighting System-Step lamp
Step lamp
Inspection
1. Inspect step lamp

(a). Use a digital multimeter resistance scale to test the
resistance between No.1 and No.2terminal of left/Front
right step lamp.
Resistance: <2Ω
ceiling light bulb.
Replace
1. Replace step lamp assembly

(b). Use flat-blade screwdriver to pry step lamp assembly.
Attention :
• Use adhesive tape to wind the end of flat-blade
screwdriver, to avoid damaging inner protective plate of
from door.
• Steps for replacing left and right door assemblies are the
same.
LIFAN AUTO
Lighting System-Step lamp 77-71
(c). Disconnect step lamp connector.

(d). Remove step lamp.
(e). Connect connector and install step lamp assembly.
2. Replace step lamp bulb.

(b). Use flat-blade screwdriver to pry step lamp assembly.
Attention :
• Use adhesive tape to wind the end of flat-blade
screwdriver, to avoid damaging inner protective plate of
from door.
• Steps for replacing left and right step lamp bulbs are the
same
77
LIFAN AUTO
77-72 Lighting System-Step lamp
(c). Dismantle step lampshade.
(d). Remove step lamp bulb.

(e). Install step lamp bulb.
(f). Install step lampshade.
(g). Install step lamp assembly.
(h). Connect the battery negative cable.
LIFAN AUTO
Lighting System-Front ceiling light 77-73
Front ceiling light

Inspection
1. Check front ceiling light

(a). Place front ceiling lamp switch to DOOR position, and
use a digital multimeter resistance scale to test resistance
between No.2and No.3 terminals of front ceiling lamp.
Resistance: <2Ω
(b). Place front ceiling lamp switch to OFF position, and use a
digital multimeter resistance scale to test resistance between
No.2, No.1 and No.3 terminals of front ceiling lamp.
Resistance value :>1MΩ
(c). Press front ceiling lamp switch, and use a digital multimeter
resistance scale to test resistance between No.2and No.1
terminals of front ceiling lamp.
Resistance: <2Ω
If the above conditions are not satisfied, replace front instep
lamp or bulb.
Replace
1. Replacement of front ceiling light assembly

(b). Unscrew two fixed screws of ceiling lamp.
(c). Remove ceiling lamp assembly.
△ Hint:
Use flat-blade screwdriver to pry front ceiling lamp assembly.
Attention :
To avoid damage to the roof trim, wrap the tip of the flat-blade
screwdriver with adhesive tape.
77
LIFAN AUTO
77-74 Lighting System-Front ceiling light
(d). Disconnect front ceiling lamp connector.

(e). Remove front ceiling lamp.
(f). Install front ceiling lamp, and connect front ceiling lamp
connector.
(g). Install fixed screw of front ceiling lamp and tighten it.
Torque: 4 ~ 5 N•m
LIFAN AUTO
Lighting System-Front ceiling light 77-75
2. Replacement of front ceiling light bulb

(b). Remove front ceiling light cover.
(c). Remove front ceiling light bulb.
(d). Mount the front ceiling light bulb.
77
LIFAN AUTO
77-76 Lighting System-Front ceiling light
(e). Mount the front ceiling light cover.

(f). Connect the battery cathode cable.
LIFAN AUTO
Lighting System-Rear ceiling light 77-77
Rear ceiling light

Inspection
1. Inspection of rear roof lamp
(a). Place rear ceiling lamp switch to DOOR position, and use a
No.3 and No.2terminals of rear ceiling lamp.
Resistance: <2Ω
(b). Place rear ceiling lamp switch to OFF position, and use a
No.3, No.1 and No.2terminals of rear ceiling lamp.
Resistance value :>1MΩ
(c). Place rear ceiling lamp switch to ON position, and use a
No.3 and No.1 terminals of rear ceiling lamp.
Resistance: <2Ω
If the measured resistance is inconsistent with the conditions
above, replace rear ceiling light or its bulb.
Replace
1. Replacement of rear ceiling light assembly

(b). Use flat-blade screwdriver to pry rear ceiling lamp
assembly.
Attention :
To avoid damage to the roof trim, wrap the tip of the flat-blade
screwdriver with adhesive tape.
77
LIFAN AUTO
77-78 Lighting System-Rear ceiling light
(c). Disconnect rear ceiling lamp connector.

(d). Remove rear ceiling lamp.
(e). Install rear ceiling lamp, and connect rear ceiling lamp
connector.
2. Replacement of rear roof lamp bulb

(b). Remove rear ceiling light cover with a flat-blade
screwdriver.
Attention :
Wrap adhesive tape around the tip of screwdriver, to avoid
damage to the lamp shade.
LIFAN AUTO
Lighting System-Rear ceiling light 77-79
(c). Remove rear ceiling light bulb.
(d). Install rear ceiling light bulb.
(e). Install rear ceiling light cover

77
LIFAN AUTO
77-80 Lighting System-High-mounted brake lamp
High-mounted brake lamp

Inspection
1. Inspection of high-mounted brake lamp

(a). Connect the positive and negative cables of battery
respectively to No.2and No.1 terminals.
Phenomenon: High-mounted brake lamp will be
illuminated.
Attention :
The high-mounted brake lamp is a LED one, so it cannot be
measured through the resistance check method.
Replace
1. Replacement of high-mounted brake lamp assembly

(b). Remove the shelf trim panel assembly.
(c). Remove the two fixed screws of high-mounted brake lamp .
(d). Remove high-mounted brake lamp .
(e). Install high-mounted brake lamp .
(f). Install the two fixed screws of high-mounted brake lamp .
Torque: 4 ~ 5 N•m
(g). Install the shelf trim panel assembly.
LIFAN AUTO
Lighting System-High-mounted brake lamp 77-81
Trunk light
Inspection
1. Inspection of trunk light

(a). Use a digital multimeter resistance scale to test the
resistance between No.1 and No.2terminal of trunk lamp.
Resistance: <2Ω
If the measured resistance is inconsistent with the conditions
above , replace trunk light or its bulb.
Replace
1. Replacement of trunk license plate lamp assembly

(b). Remove the shelf trim panel assembly.
(c). Disconnect trunk light connector.
77
LIFAN AUTO
77-82 Lighting System-High-mounted brake lamp
(d). Remove trunk license plate lamp assembly.

△ Hint:
Press the four horns of trunk light assembly from the inside of
trunk, and remove the trunk light assembly upwards.
(e). Install the trunk light assembly downwards, and connect its
connector.
Attention :
connected in place.
(f). Install the shelf trim panel assembly.
1 1
2. Replacement of trunk light bulb

(b). Open rear hatch.
(c). Raise up the cover of trunk light bulb, and rotate and
remove the bulb.
(d). Install trunk light bulb.
(e). Close rear hatch.
LIFAN AUTO
Lighting System-License plate lamp 77-83
License plate lamp

Inspection
1. Inspection of license plate lamp
(a). Connect the positive and negative cables of battery
respectively to No.2and No.1 terminals of left/right license
plate lamp.
Phenomenon: License plate lamp will be illuminated.
Attention :
The license plate lamp is a LED one, so it cannot be measured
through the resistance check method.
Replace
1. Replace license plate lamp assembly.

(b). Dismantle trimming strip of rear hatch.
(c). Press license plate lamp outside; meanwhile use flat-blade
screwdriver to pry license plate lamp assembly from inner
side.
Attention :
To avoid damage to the paint on the surface of rear hatch,
wrap the tip of the flat-blade screwdriver with adhesive tape.
77
LIFAN AUTO
77-84 Lighting System-License plate lamp
(d). Disconnect license plate lamp connector.

(e). Remove license plate lamp assembly.
(f). Place license plate lamp in good condition and connect

license plate lamp connector.
Attention :
connected in place.
(g). Install license plate lamp assembly
(h). Install trimming strip of rear hatch.
LIFAN AUTO
Horn and cigarette lighter
Horn system................................................................ 78-1

Preparation............................................................. 78-1
Wiring diagram....................................................... 78-3
On-Vehicle check................................................... 78-5
Horn does not sound............................................... 78-6
Horn stays on.......................................................... 78-8
Only the tweeter is soundless................................. 78-8
Only the bass horn is soundless............................. 78-9
Compound horn....................................................... 78-10
Inspection............................................................. 78-10
Replace................................................................. 78-11
Horn switch.............................................................. 78-13
Inspection............................................................. 78-13
Replace................................................................. 78-13
Cigarette lighter and standby power supply......... 78-14
Preparation........................................................... 78-14
Repair specifications............................................ 78-14
Wiring diagram..................................................... 78-16
On-Vehicle check................................................. 78-18
Cigarette lighter does not operate......................... 78-19
Standby power supply doesn't work..................... 78-20
Cigarette litghter...................................................... 78-21
Replace................................................................. 78-21
Standby power supply............................................. 78-24
Replace................................................................. 78-24
78
LIFAN AUTO
Horn and Cigarette Lighter-Horn system 78-1
Horn system
Preparation

resistance
Removable the cabin airbag

2 Circlip pliers
circlips.
Power supply 12V
Alt speaker horn resistance 4Ω
Bass speaker horn resistance 4Ω
78
Item N•m
Compound horn fixed bolts. 20~25N•m
LIFAN AUTO
78-2 Horn and Cigarette Lighter-Horn system
Components diagram
1 Horn switch (driver airbag) 4 Bass horn
2 Clock spring 5 Alt horn
3 Horn relay 6 Horn fuse
LIFAN AUTO
78
78-3
Horn system
Engine compartment
central control box
Horn and Cigarette Lighter-Horn system
LIFAN AUTO
Clock spring
Bass horn Alt horn
Horn switch
Wiring diagram
78-4 Horn and Cigarette Lighter-Horn system
Terminal definition
U02 to Bass horn
U01 to Bass horn
Terminal Terminal
No. No.
1 RY Bass horn (+) 1 B Bass horn (-)
U05 to Alt horn I11 to Clock spring
Terminal Terminal
No. No.
1 RY Alt horn (+) 1 GV Steering wheel switch (+)
2 WO Horn switch

U06 to Alt horn
4 B Background lighting lamp (-)
5 GW Steering wheel switch (-)

No.
1 B Alt speaker horn (-)
LIFAN AUTO
Horn and Cigarette Lighter-Horn system 78-5
On-Vehicle check
1. Checking function
(a). Park the vehicle stably, start parking brake, and open the
door window.
(b). Click the horn switch and listen the sound from the horn.
Symptom: Intermittent beeps.
(c). Press the horn switch long and listen the sound from the
horn.
Symptom: Continuous beeps.
△ Hint:
If the horn does not produce beeps, troubleshoot the problem
according to the instructions.
2. Inspection of fuse and relay

(b). Open the central control box of the engine compartment.
(c). Check whether the horn fuse is blown.
(d). Check the horn relay for damage.
△ Hint:
If the horn fuse or relay is damaged, please replace it.
78
LIFAN AUTO
78-6 Horn and Cigarette Lighter-Troubleshooting
Troubleshooting
these parts.
3. Horn switch (damaged) Repair or replace

Horn does not sound
4. Clock spring (wire harness is damaged) Replace.
5. Horn (damaged) Replace.
6. Relay (damaged) Replace.
2. Wire harness (short-circuit) Repair or replace the harness or connector
Horn stays on 2. Horn switch (damaged) Repair or replace
3. Relay (damaged) Replace.
1. Wire harness (open-circuit) Repair or replace the harness or connector

Only the tweeter is
soundless.
2. Alt horn (damaged) Replace.
1. Wire harness (open-circuit) Repair or replace the harness or connector

Only the bass horn is
soundless.
2. Bass horn (damaged) Replace.
Horn does not sound

Check system
• Hold down the horn switch, to check whether the horn sounds.
Check fuse
• Open the engine hood.
• Open the central control box of the engine compartment.
• Inspect whether horn fuse FS32is burned out.
Check relay
3 • Dismantle horn relay RL16. To Step 4 To Step 11
• Inspect whether horn relay RL16 works normally.
Check horn switch

4 • Remove the driver airbag. To Step 5 To Step 12
• Check whether the horn switch contact is normal.
LIFAN AUTO
Horn and Cigarette Lighter-Troubleshooting 78-7

• Disconnect the airbag harness and the electric horn switch harness.
• Remove the combination lever shield.
• Disconnect clock spring connector I11.
• Use a digital multimeter resistance scale to inspect whether wire harness between
No.2terminal of I11 and horn switch at the top of clock spring is connected.
Check the harness and connector (Electric horn relay--clock spring).

• Use a digital multimeter resistance scale to inspect whether wire harness between
No.2terminal of I11 and No.2pin of RL16 is connected.
Check the harness and connector (Electric horn relay-- Alt horn and bass horn).
• Disconnect bass horn connector U01.
• Press horn switch, and use a digital multimeter voltage scale to inspect whether the
7 voltage between No.1 terminal of U01 and grounding is battery voltage. To Step 8 To Step 10
• Disconnect alt speaker horn connector U05.
voltage between No.1 terminal of U05 and grounding is battery voltage.
Check the harness and connector (Alt horn and bass horn--ground).
8 of U02and grounding is lower than 2Ω. To Step 9 To Step 10
of U06 and grounding is lower than 2Ω.
Replace horn
9 • Replace the alt horn and the bass horn by referring to the maintenance procedures in the To Step 14
Maintenance Manual.
Check harness
10 To Step 14
Replacement of fuse or relay

• Before replacing the burnt fuse, firstly troubleshoot the circuit according to Wiring
11 To Step 14
Replace horn switch

12 To Step 14
• Referring to the repair manual, replace the horn switch.

13 • Replace the clock spring by referring to the maintenance procedures in the Repair To Step 14
Manual.
78
LIFAN AUTO
Horn stays on
Check relay
1 • Dismantle horn relay RL16. To Step 6 To Step 2
• Inspect whether horn relay RL16 is damaged.
Check horn switch

2 • Remove the driver airbag. To Step 7 To Step 3
• Check whether the horn switch always contacts.
Check the harness and connector (Electric horn relay--clock spring).

• Check to see whether No. 2 terminal of I06 and earthing terminal are conductive with a
digital multimeter.
Check the harness and connector (Electric horn relay-- Alt horn and bass horn).
• Use a digital multimeter voltage scale to inspect whether the voltage between No.1 of
Repeat the
4 U01 and grounding is battery voltage. To Step 5
above steps
• Use a digital multimeter voltage scale to inspect whether the voltage between No.1 of
U05 and grounding is battery voltage.
Check harness
5 To Step 8
Replace the relay

6 To Step 8
Replace horn switch

7 To Step 8
• Referring to the repair manual, replace the horn switch.
Only the tweeter is soundless.

Inspection of harness and connector (Electric horn relay--loud-tone horn)

Inspection of harness and connector (Alt horn to the ground)

of U06 and grounding is lower than 2Ω.
Replacement of alt horn

3 To Step 5
• To replace the alt horn, refer to the maintenance procedures in the Repair Manual.
Check Harness
4 To Step 5
LIFAN AUTO
Only the bass horn is soundless.

Inspection of harness and connector (Electric horn relay--bass horn)

Inspection of harness and connector (bass horn--ground)

of U02and grounding is lower than 2Ω.
Replacement of bass horn

3 To Step 5
• To replace the bass horn, refer to the maintenance procedures in the Repair Manual.
Check harness
4 To Step 5
78
LIFAN AUTO
78-10 Horn and Cigarette Lighter-Compound horn
Compound horn
Inspection
1. Open engine hood.

2. Dismantle front bumper.
3. Disconnect Connector from Horn
4. Check horn
(a). Using a digital multimeter in 200Ω range, measure the
resistance between the two terminals of the horn.
(b). or connect two terminals of horn wire harness respectively
to the positive and negative cables.
Sign: Beeps
△ Hint:
If no continuity exists between the two terminals of the horn, or the
horn does not sound, replace the horn.
LIFAN AUTO
Horn and Cigarette Lighter-Compound horn 78-11
Replace

2. Dismantle front bumper
3. Remove horn
(a). Disconnect the connector from the horn.
(b). Remove the horn fixed bolt.

(c). Remove the horn.
4. Install horn
(a). Install the horn. Tighten the fixed bolt.
78
LIFAN AUTO
78-12 Horn and Cigarette Lighter-Compound horn
(b). Connect the electric horn connector.

Attention:
connected in place.
5. Press horn switch to check whether horn sounds normally.

6. Install front bumper.
7. Close engine hood.
LIFAN AUTO
Horn and Cigarette Lighter-Horn switch 78-13
Horn switch
Inspection
1. Press and hold horn switch
2. When slowly releasing the horn switch, resistance can be
felt.
△ Hint:
The horn switch made of copper plate, which is riveted to the
driver airbag is difficult to be corrupted or damaged. Generally,
the horn switch failure is caused by the damaged return spring.
Therefore horn Checkion mainly refers to the Checkion on return
spring.
Replace
△ Hint:
Horn switch is normally replaced with driver's airbag. If horn
switch is in bad connection or frequently contact, it is necessary to
replace return spring of the switch.
1. Dismantle driver's airbag (See Chapter 72- Safety
Protection Device - Driver airbag, Replacement)
2. Dismantle return spring of horn switch.

3. Install return spring of horn switch. 78
4. Install driver airbag (See Chapter 72- Safety Protection
Device - Driver Airbag, Replacement)
5. Check whether the return spring of the horn switch is
damaged.
LIFAN AUTO
78-14 Horn and Cigarette Lighter-Cigarette lighter and standby power supply
Cigarette lighter and standby power supply

Preparation

and resistance

2 Screwdriver
decorative strips
Cigarette lighter power supply 12V
Standby power supply 12V
Item N•m
Front ashtray fixed screws 4~6
LIFAN AUTO
Horn and Cigarette Lighter-Cigarette lighter and standby power supply 78-15
Components diagram
1 Cigarette Lighter 2 Onboard standby power supply
78
LIFAN AUTO
Cigarette lighter, spare power supply
Horn and Cigarette Lighter-Cigarette lighter and standby power supply
Driver compartment
central control box
LIFAN AUTO
Cigarette lighter Spare power supply
Wiring diagram
78-16
Horn and Cigarette Lighter-Cigarette lighter and standby power supply 78-17
Terminal definition
I20 to Cigarette lighter I26-1 to External power supply
Terminal Terminal
No. No.
1 V Background lighting lamp (+) 1 B External power supply (+)
2 RBl Cigarette lighter (+)
3 B Cigarette lighter (-) I26-2 to External power supply

No.
1 B External power supply (-)
78
LIFAN AUTO
78-18 Horn and Cigarette Lighter-Cigarette lighter and standby power supply
On-Vehicle check
1. Check fuse
(a). Remove the glove box on the left lower panel of the
instrument console .
(b). Inspect whether cigarette lighter fuse is burned out.
(c). Inspect whether standby power supply fuse is burned out.
△ Hint:
1 is cigarette lighter fuse, and 2 is standby power supply fuse.
2. Check cigarette lighter power supply

(b). Disconnect cigarette lighter connector I22.
(c). Turn ignition switch to ACC.
(d). Use a digital multimeter voltage scale to check the voltage
between No.2 terminal of I22 and grounding.
3. Inspect the power supply source of standby power

supply
(a). Disconnect the battery negative cable.
(b). Disconnect standby power supply connector I26.
(c). Connect negative terminal of battery.
(d). Use a digital multimeter voltage scale to check the voltage
between No.1 terminal of I26 and grounding.
LIFAN AUTO
Troubleshooting
The following table can help you to find the cause of the fault. Number sequence indicates priority sequence of the fault.
Inspect each part according to the sequence. If necessary, replace the part.

Cigarette lighter doesn't
2. Cigarette lighter (damaged) Replace.
work.

Standby power supply
2. Standby power supply (damaged) Replace.
doesn't work.
Cigarette lighter does not operate

Check fuse
• Inspect whether cigarette lighter fuse FS33 is burned out.
• Inspect power supply circuit.

• Dismantle cigarette light.
2 • Disconnect cigarette lighter connector I22. To Step 3 To Step 4

• Use a digital multimeter voltage scale to inspect whether the voltage between
No.2terminal of connector I22and grounding is battery voltage.
Inspect grounding circuit.

• Dismantle cigarette light.
• Disconnect cigarette lighter connector I22.
terminal of connector I22and grounding is lower than 2Ω.
Check harness
4 To Step 7
Replace fuse
5 To Step 7
• Before replacing the burnt fuse, firstly troubleshoot the circuit according to Wiring
78
Replace the cigarette lighter.
6 • For replacement of cigarette lighter, refer to the repair steps specified in maintenance To Step 7
manual.
LIFAN AUTO
Standby power supply doesn't work.

Check fuse
• Inspect whether standby power supply fuse SB12is burned out.
• Inspect power supply circuit

• Dismantle standby power supply.
2 • Dismantle standby power supply connector I26. To Step 3 To Step 4
• Connect negative terminal of battery.

• Use a digital multimeter voltage scale to inspect whether the voltage between No.1
terminal of I26 and grounding is battery voltage. Voltage:
Inspect grounding circuit

• Dismantle standby power supply.
• Dismantle standby power supply connector I26.
Check harness
4 To Step 7
Replace fuse
Replace standby power supply.

6 • For replacement of standby power supply, refer to the repair steps specified in To Step 7
maintenance manual.
LIFAN AUTO
Horn and Cigarette Lighter-Cigarette litghter 78-21
Cigarette litghter
Replace
1. Turn ignition switch to OFF position.
2. Dismantle trimming frame components of shifting panel
body and console.
△ Hint:
Before dismantling of trimming frame components of console, it
is necessary to dismantle console assembly and move it towards
the rear of vehicle body until there is sufficient space for tilting
trimming frame components of console between trimming
frame components of console and right lower protective panel
of dashboard panel. (See Chapter 81, Dashboard and Console -
Console, Replacement)
3. Dismantle front ashtray assembly.

(a). Dismantle 4 fixed screws of front ashtray assembly.
(b). Take out front ashtray assembly.
(c). Disconnect the cigarette lighter connector.
(c). Take out ashtray assembly.
4. Dismantle cigarette lighter

(a). Dismantle cigarette lighter assembly from ashtray assembly.
Attention:
While dismantling, pay attention to the position of spring
retainer of cigarette lighter, do not force to take it out.
78
LIFAN AUTO
78-22 Horn and Cigarette Lighter-Cigarette litghter
5. Install cigarette lighter.

(a). Install cigarette lighter onto the ashtray assembly.
△ Hint:
While installing, make the cigarette lighter protrusion align with
slot of ashtray.
6. Install front ashtray assembly.

(a). Connect cigarette lighter connector.
Attention:
connected in place.
(b). Install front ashtray assembly.
(c). Install fixed screws of front ashtray assembly and tighten

them.
Torque: 4~6N•m
LIFAN AUTO
7. Install trimming frame components of shifting panel body

and console.
78
LIFAN AUTO
78-24 Horn and Cigarette Lighter-Cigarette litghter
Standby power supply

Replace
2. Open armrest box cover of console.
3. Dismantle standby power supply assembly.

(a). Use flat-blade screwdriver to pry standby power supply
assembly.
Attention:
Use adhesive tape to wind the end of flat-blade screwdriver to
avoid damaging console.
(b). Disconnect standby power supply connector and data

connector.
(c). Take out standby power supply assembly.
LIFAN AUTO
4. Install standby power supply assembly.

(a). Connect standby power supply connector and data
connector.
(b). Install standby power supply assembly.
5. Close armrest box cover of console.

6. Connect the battery negative cable.
78
LIFAN AUTO
• Memo •
LIFAN AUTO
Vehicle trim
Vehicle trim................................................................. 81-1

Preparation............................................................. 81-1
Precautions............................................................. 81-2
Sunvisor...................................................................... 81-3
Replace................................................................... 81-3
Front doorsill trim panel........................................... 81-5
Replace................................................................... 81-5
Rear doorsill trim panel............................................ 81-6
Replace................................................................... 81-6
A pillar panel.............................................................. 81-7
Replace................................................................... 81-7
B pillar panel.............................................................. 81-9
Replace................................................................... 81-9
C pillar panel............................................................ 81-13
Replace................................................................. 81-13
Front door inside guard board............................... 81-16
Replace................................................................. 81-16
Rear door inside guard board................................. 81-20
Replace................................................................. 81-20
Safety handle and roof............................................. 81-24
Replace................................................................. 81-24
Carpet........................................................................ 81-31
Replace................................................................. 81-31
Windscreen............................................................... 81-37
Replace................................................................. 81-37
Rear windshield........................................................ 81-42
Replace................................................................. 81-42
Front bumper........................................................... 81-45
Replace................................................................. 81-45
Rear bumper............................................................. 81-47
Replace................................................................. 81-47
Mudguard................................................................. 81-49 81
Replace................................................................. 81-49
Engine oil filler cap.................................................. 81-50
Replacement......................................................... 81-50
LIFAN AUTO
Vehicle Trim-Vehicle trim 81-1
Vehicle trim
Preparation
1. Special tool
1 Glass sucker For carrying glass
2. Recommended Tools
1 Screwdriver For removing screws
2 Cutter For cutting glass adhesive
81
Quick wrench, extension
3 For removing fixed bolts
rod and sleeve
4 Wire rope For cutting glass adhesive
LIFAN AUTO
81-2 Vehicle Trim-Vehicle trim
Torque specifications
Item N•m
Fixed screws of window lifter control box 5~6
Fixed screws of front door inner handle assembly 5~6
Fixed screws of rear door inner handle assembly 5~6
Front bumper assembly set bolts 6~12
Rear bumper assembly set bolts 6~12
Fixed screws of mudguard 5~6
Engine oil filler cap fixed bolt 6~12
Precautions
1. Do not use any sharp tool to remove interior trim panels. If you have to use it, wrap it with cloth.
2. Before disconnecting a connector, disconnect the cable from negative battery terminal.
LIFAN AUTO
Vehicle Trim-Sunvisor 81-3
Sunvisor
Replace
1. Remove sunvisor
(a). Turn over sunvisor and remove them from fixed hook.
△ Hint:
Replacement steps for the left sunvisor is the same for the right
one.
(b). Use a "flat-blade" screwdriver to pry a certain distance of

lock section of big fixed seat component of sunvisor.
(c). Rotate down to remove big fixed seat component of

sunvisor and sunvisor assembly.
81
LIFAN AUTO
81-4 Vehicle Trim-Sunvisor
(d). Rotate down to remove fixed hook of sunvisor.
2. Install sunvisor.
(a). Install fixed hook of sunvisor to the roof.
(b). First unlock the lock section of big fixed seat component of
sunvisor.
(c). Press upward the big fixed seat component of sunvisor to

the roof, and press upward the lock section.
(d). Install sunvisor onto fixed hook.
LIFAN AUTO
Vehicle Trim-Front doorsill trim panel 81-5
Front doorsill trim panel

Replace
△ Hint:
Replacement steps for left and right doorsill trim panel are the same.
1. Dismantle front doorsill trim panel

(a). Use a "flat-blade" screwdriver to pry plastic buckle on front
doorsill trim panel, and remove front doorsill trim panel.
2. Install front doorsill trim panel
(a). Install front doorsill trim panel onto mounting position, and
use force to push front doorsill trim panel to make plastic
snap-fitss onto proper position.
81
LIFAN AUTO
81-6 Vehicle Trim-Rear doorsill trim panel
Rear doorsill trim panel

Replace
△ Hint:
Replacement steps for left and rear doorsill trim panel are the same.
1. Dismantle rear doorsill trim panel

(a). Use a “flat-blade” screwdriver to pry plastic snap-fits on
rear doorsill trim panel, and remove rear doorsill trim panel.
2. Install rear doorsill trim panel
(a). Install rear doorsill trim panel onto mounting position, and
use force to push rear doorsill trim panel to make plastic
snap-fits onto proper position.
LIFAN AUTO
Vehicle Trim-Rear doorsill trim panel 81-7
A pillar panel
Replace
△ Hint:
Replacement steps of left and right A pillar trim panels are the same.
1. Replace lower A pillar trim panel.

(a). Dismantle front doorsill trim panel.
(b). Use a “flat-blade” screwdriver to pry plastic buckle on

lower A pillar trim panel, and remove lower A pillar trim
panel.
(c). Install lower A pillar trim panel onto mounting position, and
use force to push lower A pillar trim panel to make plastic
snap-fits onto proper position.
81
LIFAN AUTO
81-8 Vehicle Trim-Rear doorsill trim panel
2. Replace upper A pillar trim panel.

(a). Unplug front door opening trim weather-strip near lower A
pillar trim panel.
(b). Use a "flat-blade" screwdriver to pry plastic snap-fit and
square plastic snap-fits on upper A pillar trim panel, and
remove lower A pillar trim panel.
(c). Install upper A pillar trim panel onto windshield column,
align with positioning pin and use force to push upper A
pillar trim panel to make plastic snap-fitss and square plastic
buckle onto proper position.
(d). Install front door opening trim weather-strip near upper A
pillar trim panel.
LIFAN AUTO
Vehicle Trim-B pillar panel 81-9
B pillar panel
Replace
△ Hint:
Replacement steps for left and right B pillar trim panel are the same.
1. Replace lower B pillar trim panel.

(a). Dismantle front doorsill trim panel (See Chapter 81 Vehicle
Trim - Front Doorsill Trim Panel, Replacement).
(b). Dismantle rear doorsill trim panel. (See Chapter 81 Vehicle

Trim - Rear Doorsill Trim Panel, Replacement).
(c). Unplug front rear door opening trim weather-strips near
lower B pillar trim panel.
(d). Use a “flat-blade” screwdriver to pry fixed snap-fit of lower

B pillar trim panel, and remove lower B pillar trim panel.
(e). Install lower B pillar trim panel onto B pillar, and use force
to push lower B pillar trim panel to make fixed snap-fits
onto proper position.
(f). Install front rear door opening trim weathers trio near lower
B pillar trim panel.
(g). Install front doorsill trim panel (See Chapter 81 Vehicle
(h). Install rear doorsill trim panel (See Chapter 81 Vehicle Trim
- Rear Doorsill Panel, Replacement). 81
LIFAN AUTO
81-10 Vehicle Trim-B pillar panel
2. Replace upper B pillar trim panel.

(a). Dismantle front doorsill trim panel.
(b). Dismantle rear doorsill trim panel.
(c). Unplug front rear door opening trim weather-strips near
(b). Dismantle lower B pillar trim panel.
(e). Dismantle fixed plate of front seat belt (See Chapter 72

Safety Protection Device - Front Seat Belt, Replacement)
• Unfold lower fixed plate protective cover of front seat
belt.
• Dismantle fixed bolts of fixed plate of front seat belt.
• Remove lower fixed plate of front seat belt.
(f). Dismantle two fixed screws under the upper B pillar trim
panel.
LIFAN AUTO
Vehicle Trim-B pillar panel 81-11
(g). Use a "flat-blade" screwdriver to pry plastic snap-fits of

upper B pillar trim panel, and remove upper B pillar trim
panel.
△ Hint
When removing upper B pillar trim panel from B pillar, make the
seat belt pass through the channel of upper B pillar trim panel.
(h). Install upper B pillar trim panel onto B pillar, and use force
to push plastic snap-fits onto proper position.
Attention :
Seat belt height adjuster button requires to be adjusted to the
lowest position. After plastic snap-fits are installed properly,
before installing screws, it is necessary to inspect whether seat
belt height adjuster can work normally.
△ Hint
When installing upper B pillar trim panel, make the seat belt pass
through the channel of upper B pillar trim panel.
(i). Install 2 fixed screws under upper B pillar trim panel.
81
(j). Install lower fixed plate of front seat belt (See Chapter 72
Safety Protection Device - Seat Belt, Replacement).
LIFAN AUTO
81-12 Vehicle Trim-B pillar panel
(k). Install lower B pillar trim panel.

(l). Install front and rear door opening trim weather-strips near
(m). Install front doorsill trim panel.
(n). Install rear doorsill trim panel.
LIFAN AUTO
Vehicle Trim-C pillar panel 81-13
C pillar panel
Replace
△ Hint:
Replacement steps of left and right C pillar trim panels are the same.
1. Replace lower C pillar trim panel.

(a). Dismantle rear doorsill trim panel (See Chapter 81 Vehicle
(b). Unplug rear door opening trim weather-strip near lower C
pillar trim panel.
(c). Dismantle rear row seat soft cushion and rear row seat
side backrest (See Chapter 84 Seat - Rear Row Seat,
Replacement).
(d). Use a “flat-blade” screwdriver to pry fixed snap-fit of lower

C pillar trim panel, and remove lower C pillar trim panel.
(e). Install lower C pillar trim panel onto C pillar, and use force
to push plastic snap-fits onto proper position.
(f). Install rear door opening trim weather trip on lower C pillar
trim panel. 81
LIFAN AUTO
81-14 Vehicle Trim-C pillar panel
(g). Install rear row seat side backrest and rear row seat cushion
(See Chapter 84 Seat - Rear Row Seat, Replacement).
(h). Install rear doorsill trim panel (See Chapter 81 Vehicle Trim
- Rear Doorsill Panel, Replacement).
2. Replace middle C pillar trim panel.

(a). Dismantle rear row seat side backrest and rear row seat
cushion.
(c). Unplug rear door opening trim weather-strip on lower C
pillar trim panel side.
(d). Dismantle lower C pillar trim panel.
(e). Use a "flat-blade" screwdriver to pry plastic snap-fits of
middle C pillar trim panel, and remove middle C pillar trim
panel.
(f). Install middle C pillar trim panel onto C pillar, and use
force to push the plastic snap-fits onto proper position.
(g). Install rear door opening trim weather-strip on lower C
(h). Install rear doorsill trim panel.
(i). Install rear row seat side back and rear row seat cushion.
LIFAN AUTO
Vehicle Trim-C pillar panel 81-15
3. Replace upper C pillar trim panel.

(a). Dismantle rear row seat side backrest and rear row seat
cushion.
(c). Unplug rear door opening trim weather-strip on lower C
(d). Dismantle lower C pillar trim panel.
(e). Dismantle middle C pillar trim panel.
(f). Use a "flat-blade" screwdriver to pry plastic snap-fits of
upper C pillar trim panel, and remove upper C pillar trim
panel.
(g). Install upper C pillar trim panel onto C pillar, and use force
to push the plastic snap-fits onto proper position.
(h). Install middle C pillar trim panel.
(i). Install lower C pillar trim panel.
(j). Install rear door opening trim weather-strip on lower C
(k). Install rear doorsill opening trim panel.
(l). Install rear row seat side back and rear row seat cushion.
81
LIFAN AUTO
81-16 Vehicle Trim-Front door inside guard board
Front door inside guard board

Replace
1. Remove front door inside guard board
(a). Pull front door inner handle, and use screwdrivers to pry
inner handle cover plate, and dismantle fixed screws of
inner handle.
(b). Take out PVC rubber cushion, and use screwdrivers to

dismantle fixed bolts of front door window lifter control
box.
(c). Use a “flat-blade” screwdriver to pry window lifter control

box.
LIFAN AUTO
Vehicle Trim-Front door inside guard board 81-17
(d). Rotate window lifter control box, disconnect wire harness

connector, and remove window lifter control box.
(e). Use a "flat-blade" screwdriver to pry front door handle

cover plate, and dismantle fixed screws of front door
handle, and remove front door handle.
△ Hint:
This step is only applicable to the dismantling of Front right door
inner trim panel.
(f). Using a flat-tip screwdriver, prise off the clips for front door
inside guard board.
(g). Take a few distance from front door inner trim panel, and
take out front door inner handle assembly from front door
inner trim panel, and remove front door inner trim panel.
81
LIFAN AUTO
81-18 Vehicle Trim-Front door inside guard board
2. Install front door inside guard board

(a). Install front door inner handle assembly onto front door
inner trim panel.
(b). Align the clips of rear door inside guard board with the
holes. Then push the clips to positions.
(c). Connect window lifter control box wire harness connector.
(d). Install window lifter control box onto proper position.

(e). Install fixed screws of window lifter control box and tighten
them, and PVC rubber cushion.
Torque: 5 ~ 6N•m
LIFAN AUTO
Vehicle Trim-Front door inside guard board 81-19
(f). Install fixed screws of front door inner handle assembly and
tighten them.
Torque: 5 ~ 6N•m
(g). Pull front door inner handle, and install front door inner
handle cover plate.
(h). Install front door handle and fixed screws, and tighten them.
(i). Install front door handle cover plate.
△ Hint:
This step is only applicable to the installation of front right door
inner trim panel.
81
LIFAN AUTO
81-20 Vehicle Trim-Rear door inside guard board
Rear door inside guard board

Replace
1. Remove rear door inside guard board
(a). Use a “flat-blade” screwdriver to pry rear door handle
cover plate, dismantle rear door handle fixed screws, and
dismantle fixed screws of rear power window control box
(b). Pull rear door inner handle, use screwdrivers to pry inner
handle cover plate, and dismantle fixed screws of inner
handle.
(c). Use a “flat-blade” screwdriver to pry window lifter control

box.
LIFAN AUTO
Vehicle Trim-Rear door inside guard board 81-21
(d). Rotate window lifter control box, disconnect wire harness

connector, and remove window lifter control box.
(e). Using a flat-tip screwdriver, prise off the clips for rear door
inside guard board.
(f). Take a few distance from rear door inner trim panel, and
take out rear door inner handle assembly from front door
inner trim panel, and remove rear door inner trim panel.
2. Install rear door inside guard board

(a). Install the rear door inside handle assembly to the rear door
inside guard board.
(b). Align the clips of rear door inside guard board with the
holes. Then push the clips to positions.
81
LIFAN AUTO
81-22 Vehicle Trim-Rear door inside guard board
(c). Connect window lifter control box wire harness connector.
(d). Install window lifter control box onto proper position.
(e). Install the rear door inside handle assembly. Tighten the
retaining screws.
Torque: 5 ~ 6N•m
(f). Pull rear door inner handle, and install rear door inner
handle cover plate.
LIFAN AUTO
Vehicle Trim-Rear door inside guard board 81-23
(g). Install fixed screws of rear door handle and fixed screws of
rear power window control box, and rear door handle cover
plate.
81
LIFAN AUTO
81-24 Vehicle Trim-Safety handle and roof
Safety handle and roof

Replace
1. Dismantle safety handle
(a). Press safety handle, and use a “flat-blade” screwdriver to
pry protective cover of mounting seat of safety handle.
(b). Take out safety handle.

(c). Take out metal clamp of safety handle.
2. Install safety handle

(a). Install metal clamp of safety handle onto safety handle.
LIFAN AUTO
Vehicle Trim-Safety handle and roof 81-25
(b). Install safety handle assembly onto mounting position and

make snap-fit onto proper position.
(c). Install fixed snap-fits cover of safety handle.
3. Dismantle roof
(a). Dismantle sunvisor (See Chapter 81 Vehicle Trim -Sunvisor,
Replacement).
81
LIFAN AUTO
(b). Dismantle safety handle (See Chapter 81 Vehicle Trim -

Safety Handle and Roof, Replacement)
(c). Dismantle front dome lamp (See Chapter 77 Illumination

System - Front Dome Lamp, Replacement).
(d). Dismantle rear dome lamp (See Chapter 77 Illumination
System - Rear Dome Lamp, Replacement).
(e). Dismantle upper A pillar trim panel (See Chapter 81 Vehicle

Trim - A Pillar Trim Panel, Replacement).
LIFAN AUTO
(f). Dismantle B pillar trim panel (See Chapter 81 Vehicle Trim

- B Pillar Trim Panel, Replacement)
(g). Dismantle C Pillar panel (See Chapter 81 Vehicle Trim-C

Pillar panel, Replacement).
(h). Dismantle plastic snap-fits of the roof.

(i). With the help of an assistant, take out the roof from the
vehicle.
81
LIFAN AUTO
4. Install the roof

(a). Install the roof to mounting position.
(b). Install plastic snap-fits of the roof.
Attention :
Before installing plastic snap-fits, dome lamp wire harness
must be straightened, to avoid wire harness being pressed
inside the roof.
(c). Install C pillar panel (See Chapter 81 Vehicle Trim - C

Pillar Panel, Replacement).
(d). Install lower B pillar trim (See Chapter 81Vehicle Trim - B

Pillar Trim Panel, Replacement)
LIFAN AUTO
(e). Install upper A pillar trim panel (See Chapter 81 Vehicle

(f). Install front dome lamp (See Chapter 77 Illumination

System - Front Dome Lamp, Replacement).
(g). Install rear dome lamp (See Chapter 77 Illumination System
- Rear Dome Lamp, Replacement).
(h). Install safety handle (See Chapter 81 Vehicle Trim - Safety

Handle, Replacement).
81
LIFAN AUTO
(i). Install sunvisor (See Chapter 81 Vehicle Trim -Sunvisor,

Replacement).
LIFAN AUTO
Vehicle Trim-Carpet 81-31
Carpet
Replace
1. Dismantling of floor carpet.
(a). Dismantle console assembly (See Chapter 85 Dashboard
and Console - Console, Replacement).
(b). Dismantle front doorsill trim panel (See Chapter 81 Vehicle

Trim -Front Doorsill Trim Panel, Replacement).
(c). Dismantle lower A pillar trim panel (See Chapter 81 Vehicle

Trim -A Pillar Trim Panel, Replacement).
81
LIFAN AUTO
81-32 Vehicle Trim-Carpet
(d). Dismantle rear doorsill trim panel (See Chapter 81 Vehicle

(e). Dismantle lower B pillar trim panel (See Chapter 81 Vehicle

trim -B Pillar Trim Panel, Replacement).
(f). Dismantle fixed bolts of lower pressure plate of seat belt.
LIFAN AUTO
(g). Dismantle rear row seat (see Chapter 84 Seat - Rear Seat,
Replacement).
(h). Dismantle driver seat (See Chapter 84 Seat - Driver,

Replacement).
(i). Dismantle front passenger seat (See Chapter 84 - Seat,
Front Passenger, Replacement).
(j). Dismantle snap-fits of floor carpet, and take out floor carpet.
81
LIFAN AUTO
2. Install the carpet

(a). Lay floor carpet assembly, and install snap-fits of floor
carpet.
(b). Install front passenger seat (See Chapter 84 Seat - Front

Passenger Seat, Replacement).
(c). Install driver seat (See Chapter 84 Seat - Driver Seat,
Replacement).
(d). Install rear row seat (see Chapter 84 Seat - Rear Row Seat,
Replacement).
LIFAN AUTO
(e). Install fixed bolts of lower pressure plate of seat belt.
(f). Install lower B pillar trim panel (See Chapter 81 Vehicle

Trim - B Pillar Trim Panel, Replacement).
(g). Install rear doorsill trim panel (See Chapter 81 Vehicle Trim
- Rear Doorsill Trim Panel, Replacement).
81
LIFAN AUTO
(h). Install lower A pillar trim panel (See Chapter 81 Vehicle

(i). Install front doorsill trim panel (See Chapter 81 Vehicle

(j). Install console assembly (See Chapter 85 Dashboard and

Console - Console, Replacement).
LIFAN AUTO
Vehicle Trim-Windscreen 81-37
Windscreen
Replace
1. Remove the front windshield
(a). Dismantle upper B pillar trim panel (See Chapter 81 Vehicle
(b). Dismantle interior rearview Mirror (See Chapter 83 Power

Window and Rearview Mirror - Interior Rearview Mirror,
Replacement).
(c). Dismantle cowl top grille assembly.

(d). Dismantle wiper assembly (See Chapter 86 Wiper and 81
Washer System - Windshield Wiper, Replacement).
LIFAN AUTO
81-38 Vehicle Trim-Windscreen
(e). Use flat-blade tools to carefully pry front windshield trim

strip, and remove weather-strip.
(f). Use cutter to cut a few section of glass sealant.
Cutting
(g). Let a fine steel wire pass through vehicle body and glass
from interior side.
(h). Tie wooden block or similar block on both ends of the wire.
(i). Cover defroster port.
Warning:
Broken glass entering the defroster exhaust may be blown into
the passenger room and cause injury.
Safety cushion
(j). Pull the fine steel wire to cut adhesive object.
△ Hint:
Protective belt
Before pulling fine steel wire, it is necessary to stick a protective
film on the surface of vehicle body around front windshield. Place
a safety pad on the instrument table to avoid scuffing.
(k). With the help of assistant, remove the windshield from

vehicle by a glass sucker.
LIFAN AUTO
2. Install the front windshield

(a). Use a cutter to cut rough bonding agent on the surface of
vehicle body, and use a cloth to dip cleaning agent to clean
the contact surface of vehicle body.
Adhesive
(b). Use a sucking disc to suck glass, and place glass onto
mounting position. Inspect whether the contact surface
around glass is flat and smooth, and make a mark between
glass and vehicle body.
(c). Dismantle glass.
(d). Use brushes or sponge to apply primer on the exposed

vehicle body and glass edge.
△ Hint:
Correct
If primer is applied to other areas, wipe it away before it is dry.
Priming lacquer
(e). Apply sealant on glass.
81
Error
Priming lacquer
Binder adhesive
LIFAN AUTO
81-40 Vehicle Trim-Windscreen
(f). Use a sucking disc to place glass onto mounting position

according to the mark, and press it slight along the edge.
△ Hint:
If the old glass is used, it is necessary to clean residual sealant.
(g). Clean residual bonding agent and add bonding agent on the
edge of glass.
(h). Install glass weather-strip.
(i). Install wiper assembly (See Chapter 86 Wiper and Washer

System - Wiper, Replacement)
(j). Install cowl top grille assembly.
(k). Install interior rearview Mirror (See Chapter 83 Power

Window and Rearview Mirror - Interior Rearview Mirror,
Replacement).
LIFAN AUTO
(i). Install upper A pillar trim panel (See Chapter 81 Vehicle

3. Rainfall test
(a). Conduct rain test and use glass sealant to seal all leakage.
△ Hint:
Rain test should be conducted after the drying and cementing of
glass sealant.
81
LIFAN AUTO
81-42 Vehicle Trim-Rear windshield
Rear windshield
Replace
1. Dismantle rear windshield
(a). Dismantle C Pillar panel (See Chapter 81 Vehicle Trim-C
Pillar panel, Replacement).
(b). Disconnect filter connector and positive and negative
connectors of electric heater.
(c). Use a flat-blade tool to carefully pry rear windshield

weather trip, and remove weather trip.
(d). Use cutter to cut a small section of glass sealant.
Cutting
(e). Let a fine steel wire pass through vehicle body and glass
from interior side.
(f). Tie wooden block or similar block on both ends of the wire.
(g). Pull the fine steel wire to cut adhesive object.
△ Hint:
Before pulling fine steel wire, it is necessary to stick a protective
film on the surface of vehicle body around rear windshield. Place a
safety pad on the instrument table to avoid scuffing.
LIFAN AUTO
Vehicle Trim-Rear windshield 81-43
(h). With the help of an assistant, use sucking disc to remove

rear windshield from the vehicle.
2. Install rear windshield

(a). Use a cutter to cut rough bonding agent on the surface of
vehicle body, and use a cloth to dip cleaning agent to clean
the contact surface of vehicle body.
Adhesive
(b). Use a sucking disc to suck glass, and place glass onto
mounting position. Inspect whether the contact surface
around glass is flat and smooth, and make a mark between
glass and vehicle body.
(c). Dismantle glass.
81
LIFAN AUTO
81-44 Vehicle Trim-Rear windshield
(d). Use brushes or sponge to apply primer on the exposed

vehicle body and glass edge.
△ Hint:
Correct
If primer is applied to other areas, wipe it away before it is dry.
Priming lacquer (e). Apply sealant on glass.
Error
Priming lacquer
Binder adhesive
(f). Use a sucking disc to place glass onto mounting position

according to the mark, and press it slight along the edge.
(g). Clean residual bonding agent
(h). Add bonding agent on the edge of glass.
(i). Connect filter connector and positive and negative

connectors of electric heater.
(g). Install C pillar panel (See Chapter 81 Vehicle Trim-C Pillar
panel, Replacement).
3. Rainfall test
(a). Conduct rain test and use glass sealant to seal all leakage.
△ Hint:
Rain test should be conducted after the drying and cementing of
glass sealant.
LIFAN AUTO
Vehicle Trim-Front bumper 81-45
Front bumper
Replace
1. Remove Front bumper
(a). Dismantle fixed screws of front wheel mudguard and front
bumper.
(b). Dismantle inlay clamp of upper horizontal beam trim panel

of water tank, and remove trim panel of upper horizontal
beam of water tank.
(c). Dismantle fixed bolts of front bumper assembly.

(d). Remove a small section of front bumper, and disconnect 81
front fog lamp connector.
(e). Remove the front bumper.
LIFAN AUTO
81-46 Vehicle Trim-Front bumper
(2). Remove front bumper assembly.

(a). Connect front fog lamp connector.
(b). Install front bumper onto mounting position.
(c). Tighten the front bumper assembly fixed bolt.
Torque: 6 ~ 12N•m
(d). Install trim panel of upper horizontal beam of water tank

and tighten it with inlay clamp.
(e). Install front wheel mudguard and tighten fixed screws.

Torque: 5 ~ 6N•m
LIFAN AUTO
Vehicle Trim-Rear bumper 81-47
Rear bumper
Replace
1. Remove the rear bumper
(a). Dismantle fixed screws of rear wheel mudguard.
(b). Dismantle fixed screws and fixed snap-fit of rear bumper

assembly.
(c). Remove a small section of rear bumper, and disconnect

reverse radar probe connector.
81
(d). Remove rear bumper assembly.
LIFAN AUTO
81-48 Vehicle Trim-Rear bumper
2. Mount the rear bumper assembly.

(a). Connect reverse radar probe connector.
(b). Install rear bumper assembly onto mounting position.

(c). Mount the rear bumper assembly set bolts and then tighten
them.
Torque: 6 ~ 12N•m
(d). Install fixed screws of rear wheel mudguard.

Torque: 5 ~ 6N•m
LIFAN AUTO
Vehicle Trim-Mudguard 81-49
Mudguard
Replace
1. Replace front mudguard
(a). Dismantle fixed screws and plastic snap-fits of front
mudguard.
(b). Take out the front mudguard.
(c). Install front mudguard.
△ Hint:
Installation is in reverse order with dismantling.
2. Replace rear mudguard.

(a). Dismantle fixed screws and plastic snap-fits of rear
mudguard.
(b). Take out rear mudguard.
(c). Install rear mudguard.
△ Hint:
Installation is in reverse order with dismantling.
81
LIFAN AUTO
81-50 Vehicle Trim-Engine oil filler cap
Engine oil filler cap

Replacement
1. Remove Engine oil filler cap
(a). Pull the fuel tank cable opener, which is located on the left
below the driver seat, to open the engine oil filler cap.
(b). Remove the engine oil filler cap fixed bolt.

(c). Remove the engine oil filler cap.
2. Install engine oil filler cap

(a). Place the engine oil filler cap in position.
(b). Tighten the engine oil filler cap fixed bolt.
Torque: 6 ~ 12N•m
LIFAN AUTO
Vehicle Trim-Engine oil filler cap 81-51
(c). Close the engine oil filler cap.
81
LIFAN AUTO
• Memo •
LIFAN AUTO
Door and lock
Door and lock............................................................. 82-1

Preparation............................................................. 82-1
Precautions............................................................. 82-2
Door............................................................................. 82-4
Adjustment............................................................. 82-4
Replace........................................................................ 82-5
Door hinge and check................................................ 82-9
Replace................................................................... 82-9
Door lock buckle...................................................... 82-13
Adjustment........................................................... 82-13
Replace................................................................. 82-14
Front door lock......................................................... 82-15
Replace................................................................. 82-15
Rear door lock.......................................................... 82-22
Replace................................................................. 82-22
Engine hood.............................................................. 82-29
Adjustment........................................................... 82-29
Replace................................................................. 82-30
Front compartment door lock................................. 82-31
Replace................................................................. 82-31
Rear trunk lid........................................................... 82-32
Replacement......................................................... 82-32
Rear compartment door lock.................................. 82-33
Replace................................................................. 82-33
82
LIFAN AUTO
Door and Lock- 82-1
Door and lock

Preparation

rod and sleeve
82
LIFAN AUTO
82-2 Door and Lock-
Item N•m
Fixed bolts of upper and lower hinges of vehicle body 30~36
Fixed bolts of upper and lower hinges of door 30~36
Door check fixed bolt on vehicle body side 30~36
Door check fixed bolt on door side 30~36
Door lock catch fixed screw 10~12
Fixed bolts of locking device 5~7
Fixed screws of lock body protection sleeve 5~7
Door lock body fixed screw 10~12
Fixed bolts of door lock body bracket 10~12
Fixed screws of door outer handle base 5~7
Fixed screws of door lock cylinder 10~12
Engine hood hinge fixed bolts 30~36
Trunk lid hinge fixed bolts 30~36
Fixed bolts of front compartment door lock 10~12
Fixed bolts of rear compartment door lock 10~12
Precautions
2. It is strictly forbidden to unlock door when the key is damaged or broken, to avoid damage of lock core.
3. Support the door when repairing the door or door lock.
LIFAN AUTO
Door and Lock- 82-3
Troubleshooting
these parts.
1. Lock catch (improper adjustment ) Adjust the lock buckle

Tightness of the closed
door does not meet the
2. Door lock assembly (door lock
requirement. Replace door lock
assembly is damaged)
1. Inner handle (damaged) Replace

Door cannot be locked or
opened from inside
2. Door lock (damaged) Replace
1. Lock core (damaged) Replace

Door cannot be locked or
opened with key
2. Lock (damaged) Replace
Key cannot turn 1. Lock core (damaged) Replace
82
LIFAN AUTO
82-4 Door and Lock-
Door
Adjustment
△ Hint:
Door adjustment methods are the same. To facilitate adjustment, it is necessary to remove fender before adjustment of
front door. Now, take adjustment of Front left door as an example.
1. Adjust front left door assembly.

(a). Unscrew fixed bolts of upper and lower hinges on vehicle
body side.
(b). After adjustment, tighten fixed bolts of hinges.
△ Hint:
Clearance between front door and upper section of rear door is
5.5±0.7mm, door panel is 5.5±0.7mm, clearance between front
door and A pillar is 6.5±1mm; clearance between front and rear
doors and doorsill is 6±1mm; surface difference is 0~0.5mm.
(c). Unscrew fixed bolts of upper and lower hinges of the door.
(d). After adjustment, tighten fixed bolts of hinge.
LIFAN AUTO
Door and Lock- 82-5
Replace
△ Hint:
Replacement steps between doors are basically the same. Take the replacement of front door as an example. Difference
between driver seat belt and co-driver seat belt will be indicated.
1. Remove front door assembly
(a). Dismantle lower A pillar trim panel (See Chapter 81 Vehicle
△ Hint:
Replacement of rear door requires dismantling of B pillar trim
panel (See Chapter 81 Vehicle Trim - B Pillar Trim Panel,
Replacement).
(b). Disconnect door main wire harness connector.

△ Hint:
Dismantle B pillar trim panel, you can see rear door main wire
harness connector.
82
(c). Remove set bolts of vehicle body side stopper.
LIFAN AUTO
82-6 Door and Lock-
(d). Dismantle fixed bolts of upper hinge on door side.
(e). With the help from an assistant, remove the lower hinge
fixed bolt on door side.
(f). Remove front door.
2. Install front door assembly

(a). With the help from an assistant, place the door in the
position. Tighten the upper hinge fixed bolt on door side.
LIFAN AUTO
Door and Lock- 82-7
(b). Install fixed bolts of upper hinge on door side and pre-
tighten them.
(c). Install fixed bolts of vehicle body check and tighten them.
(d). Adjust door, and tighten fixed bolts of upper and lower
hinges of door.
(e). Insert door wire harness through mounting hole of vehicle

body wire harness, to ensure that wire harness sheath
is installed reliably. Connect vehicle door wire harness
connector.
82
LIFAN AUTO
82-8 Door and Lock-
(f). Install lower A pillar trim panel (See Chapter 81 Vehicle

△ Hint:
If replacing rear door, install lower B pillar trim panel (See Chapter
81 Vehicle Trim - B Pillar Trim Panel, Replacement).
LIFAN AUTO
Door and Lock- 82-9
Door hinge and check

Replace
1. Replace front door hinge.
Attention :
To avoid realigning door, do not remove the two door hinges at
the same time. Replace the door hinge one by one.
△ Hint:
Removal and installation method for lower hinge is the same for
upper hinge.
(a). Dismantle fender.
△ Hint:
When dismantling rear door hinge, front door should be opened.
(b). Dismantle fixed bolts of upper hinge on door side.
(c). Dismantle fixed bolts of upper hinge on vehicle body side. 82

(d). Remove door hinge.
△ Hint:
Before taking off the door hinge, make the fitting marks of hinges
on the door surface using a marker pen or other proper tool.
LIFAN AUTO
82-10 Door and Lock-
(e). Install door hinge onto mounting position according to the

mark.
(f). Tighten the upper hinge fixed bolt on vehicle body side.
(g). Tighten the upper hinge fixed bolt on door side.

(h). Install fender.

△ Hint:
The clearance between the fender and adjacent sheet metal parts is
headlamp clearance 2±0.5mm; Bumper clearance is 0.5±0.5mm;
side wall clearance is 3.5±0.5mm; door clearance is 5±1mm;
front engine hood clearance is 4±1; doorsill clearance is 5±0.5mm
(surface difference 0~0.5mm); surface difference of the above
fenders and adjacent sheet metal parts (except doorsill surface
difference) is -1~0mm;
LIFAN AUTO
Door and Lock- 82-11
2. Replace door check

△ Hint:
Replacement methods of all door stoppers are the same.
(a). Dismantle door trim panel (See Chapter 81 Vehicle Trim -
Front/ Rear Door Trim Panel, Replacement).
(b). Remove the door check fixed bolt on vehicle body side.
(c). Remove the door check fixed bolt on door side.

(d). Remove door check.
82
LIFAN AUTO
(e). Place the door check in position.

(f). Tighten the door check fixed bolt on door side.
(g). Tighten the door check fixed bolt on vehicle body side.
(h). Install door trim panel (See Chapter 81 Vehicle Trim -

Front/ Rear Door Trim Panel, Replacement).
LIFAN AUTO
Door lock buckle

Adjustment
Attention :
Before adjusting lock catch, the door shall be located properly.
1. Adjust door lock buckle

(a). Loosen the door lock buckle fixed screw.
(b). Use rubber hammer to strike door lock buckle, and

conduct up/down, right/left adjustment according to the
requirements.
(c). Tighten the door lock buckle fixed screw.

82
LIFAN AUTO
Replace
1. Remove door lock buckle
(a). Remove the door lock buckle fixed screw.
(b). Remove the door lock buckle.
2. Install door lock buckle

(a). Place the door lock buckle in position.
(b). Pretighten the door lock buckle fixed screw.
(c). Adjust the door lock buckle.
(d). Tighten the door lock buckle fixed screw.
LIFAN AUTO
Front door lock

Replace
1. Remove front door lock
(a). Dismantle front door trim panel (See Chapter 81 Vehicle
Trim - Front Door Trim Panel, Replacement).
(b). Disconnect stopper wire harness connector.
(c). Dismantle fixed bolts cover of door lock core.

(d). Dismantle fixed bolts of door lock core.
(e). Use screwdrivers to release snap-fits of lock core and lock

connecting rod, and disconnect the connection between pull
rod and lock core.
82
LIFAN AUTO
(f). Take out door outer handle cap.
(g). Remove washer between door outer handles.

△ Hint:
Push door outer handle towards door lock core and remove door
outer handle.
(h). Dismantle fixed bolts and their plastic snap-fits of door

outer handle base.
LIFAN AUTO
(i). Dismantle fixed bolts of door lock bracket.
(j). Remove the door lock body fixed screw.
(k). Disconnect the connection between door inner handle cable

and door lock.
(l). Remove door lock assembly.
82
LIFAN AUTO
(m). Dismantle fixed screws of lock protective sleeve, and

remove lock protective sleeve.
(n). Dismantle fixed bolts of stopper, and remove stopper.
2. Install front door lock

(a). Install stopper onto proper mounting position, and tighten
fixed bolts.
Torque: 5 ~ 7N•m
LIFAN AUTO
(b). Install lock protective sleeve onto proper position, and use
screwdriver to tighten fixed screws.
Torque: 5 ~ 7N•m
(c). Connect door inner handle cable to inner handle and lock.
(d). Place the door lock body assembly in position.

(e). Tighten the door lock body fixed screw.
(f). Install fixed bolts of door lock bracket and tighten them. 82
(g). Install plastic snap-fits onto the base, and fixed screws of
door outer handle base and tighten them.
Torque: 5 ~ 7N•m
LIFAN AUTO
(h). Install door outer handle washer.

(i). Let the door outer handle pass through mounting hole and
then pull it forward to install it onto outer handle base.
△ Hint:
Pull outer handle outwards, and visually inspect whether outer
handle is installed to proper position.
(j). Install door outer handle cap.
(k). Connect lock core pull rod and clamp snap-fit of pull rod
well.
LIFAN AUTO
(i). Install fixed screws of door lock core and tighten them.
(m). Install fixed screw protective cover of door lock core.
(n). Connect door lock motor wire harness connector.

(o). Install front door inner trim panel (See Chapter 81 Vehicle
Trim - Front Door Inner Trim Panel, Replacement).
82
LIFAN AUTO
Rear door lock

Replace
1. Dismantle rear door lock
(a). Dismantle rear door inner trim panel (See Chapter 82
Vehicle Trim - Rear Door Inner Trim Panel, Replacement).
(b). Dismantle two fixed bolts of rear door glass sliding rail and
fixed screws on its upper section.
△ Hint:
When dismantling rear door lock, it is necessary to dismantle rear
window glass and rear door glass sliding rail.
(c). Disconnect door lock motor wire harness connector.
(d). Dismantle fixed bolts of door lock bracket.
LIFAN AUTO
(e). Dismantle door lock fixed bolts.
(f). Dismantle the connection between door inner handle cable

and door lock.
(g). Remove door lock assembly.
(h). Dismantle fixed screws of lock protective sleeve, and

remove lock protective sleeve.
82
LIFAN AUTO
(i). Dismantle fixed bolts of stopper, and remove stopper.
(j). Dismantle fixed bolts of door outer handle cap.

(k). Remove door outer handle cap.
(l). Remove washer between door outer handles.

△ Hint:
Push door outer handle towards door handle cap and remove door
outer handle.
LIFAN AUTO
(m). Dismantle fixed screws and plastic snap-fits of door outer

handle base.
(n). Remove door outer handle base and plastic snap-fits.
2. Install rear door lock

(a). Install plastic snap-fits on outer handle base, and outer
handle base onto mounting position, and tighten fixed
screws.
Torque: 5 ~ 7N•m
(b). Install washer between door outer handles.

(c). Push rear door outer handle forwards to install it to outer
handle base through mounting hole.
△ Hint:
Pull outer handle outwards, and visually inspect whether outer
handle is installed to proper position.
(d). Install door outer handle cap. 82
LIFAN AUTO
(e). Install stopper onto mounting position, and tighten fixed

bolts.
Torque: 5 ~ 7N•m
(f). Install lock protective sleeve onto mounting position, and

use screwdrivers to tighten fixed screws.
Torque: 5 ~ 7N•m
(g). Install door inner handle cable onto door lock.
LIFAN AUTO
(h). Install fixed screws of door lock and tighten them.

(i). Install fixed bolts of door lock bracket and tighten them.
(j). Connect door lock motor wire harness connector.
82
LIFAN AUTO
(k). Install fixed bolts and screws of rear door glass sliding raid.
△ Hint:
If glass sliding rail and door window glass are dismantled during
dismantling of door lock, it is necessary to install glass sliding rail
and door window glass after the installation of door lock.
(l). Install rear door inner trim panel (See Chapter 81 Vehicle
Trim - Rear Door Inner Trim Panel, Replacement).
LIFAN AUTO
Engine hood
Adjustment
2. Rotate two engine hood anti-impact blocks on the
vehicle body, and adjust position of engine hood anti-
impact blocks up and down, to achieve adjustment in
height direction.
△ Hint:
Clearance is 2~6mm, and surface difference is -2~2mm.
3. Adjust connecting bolt between engine hood and engine

hood hinge to achieve adjustment of engine hood in
front and rear directions.
4. Adjusting fixed bolts of engine hood hinge to achieve

82
adjustment of engine hood in left and right directions.
5. Close engine hood.
LIFAN AUTO
Replace
1. Replace engine hood.

(a). Open and support engine hood.
(b). Disconnect the connection between washer hose and washer
nozzle (See Chapter 86 Wiper and Washer System - Nozzle,
Replacement).
(c). Dismantle fixed bolts between engine hood hinge and

engine hood.
(d). Remove engine hood.
(e). Install engine hood onto mounting position.
(f). Install fixed bolts between engine hood hinge and engine
hood and tighten them.
(g). Install washer hose onto washer nozzle (See Chapter 86

Wiper and Washer System -Nozzle, Replacement).
(h). Adjust engine hood.
2. Replace engine hood hinge.

(a). Dismantle engine hood.
(b). Dismantle fixed bolts of engine hood, and remove engine
hood hinge.
(c). Install engine hood hinge and tighten fixed bolts of engine
hood hinge.
(d). Install engine hood.
(e). Adjust engine hood.
LIFAN AUTO
Front compartment door lock

Replace
1. Replace front compartment door lock.
(a). Dismantle front bumper assembly (See Chapter 81 Vehicle
Trim - Front Bumper, Replacement).
(b). Dismantle fixed bolts of front compartment door lock.
(c). Rotate front compartment door lock, and disconnect the

connection between front compartment door lock and
compartment door lock cable.
(d). Install front compartment door lock cable onto front
compartment door lock.
(e). Install front compartment door lock onto mounting position,
and tighten fixed bolts of front compartment door lock.
(f). Install front bumper assembly (See Chapter 81 Vehicle Trim
- Front Bumper, Replacement).
82
LIFAN AUTO
Rear trunk lid

Replacement
1. Replace trunk lid.
(a). Dismantle trunk trim panel.
(b). Disconnect rear compartment door lock wire harness
connector.
(c). Dismantle fixed bolts of trunk lid and trunk hinge, and
remove trunk lid.
(d). Install trunk lid onto mounting position.
(e). Install fixed bolts of trunk lid and trunk lid hinge and
tighten them.
(f). Connect rear compartment door lock wire harness
connector.
(g). Install trunk lid trim panel.
(h). Close trunk lid.
2. Replace trunk lid.

(a). Dismantle trunk lid.
(b). Dismantle shelf panel.
(c). Dismantle fixed pin of trunk lid hinge.
(d). Install fixed pin of trunk lid hinge.
(e). Install shelf panel.
(f). Install trunk lid.
LIFAN AUTO
Rear compartment door lock

Replace
1. Replace compartment door lock.
(a). Dismantle trunk lid trim panel.
(b). Disconnect rear compartment door lock wire harness

connector.
82
(c). Dismantle fixed bolts of rear compartment door lock.
(d). Install rear compartment door lock onto mounting position
and tighten fixed bolts.
(e). Connect compartment door lock wire harness connector.
(f). Install trunk lid trim panel.
LIFAN AUTO
• Memo •
LIFAN AUTO
Power window and rearview mirror
Power window and rearview mirror........................ 83-1

Preparation............................................................. 83-1
Precautions............................................................. 83-1
Wiring diagram....................................................... 83-2
Fault code (DTC) list............................................ 83-15
B104011............................................................... 83-17
B104015............................................................... 83-17
B104111............................................................... 83-17
B104115............................................................... 83-17
B104211............................................................... 83-18
B104215............................................................... 83-18
B104311............................................................... 83-19
B104315............................................................... 83-19
All power windows do not work.......................... 83-20
Neither of power rearview mirrors on both sides
works.................................................................... 83-20
Left rearview mirror does not work..................... 83-20
Right rearview mirror does not work................... 83-21
Left power rearview mirror can't work in UP/DOWN
directions.............................................................. 83-22
Left rearview mirror does not work in left/right
direction................................................................ 83-23
Right rearview mirror does not work in up/down
direction................................................................ 83-24
Right rearview mirror does not work in left/right
direction................................................................ 83-25 83
Front power window................................................ 83-26
Replace................................................................. 83-27
Rear power window................................................. 83-31
Replace................................................................. 83-32
Interior rearview mirror......................................... 83-36
Adjustment........................................................... 83-37
Replace................................................................. 83-38
Exterior rearview mirror........................................ 83-39
Adjustment........................................................... 83-39
Replace................................................................. 83-39
LIFAN AUTO
Power Window and Rearview Mirror-Power window and rearview mirror 83-1
Power window and rearview mirror

Preparation

rod and sleeve
Item N•m
Front door guideway fixed bolt 10~12
Front glass lifter motor fixed bolt 4
Connecting bolts of glass assembly and window regulator 10~12
Glass lifter assembly fixed bolt 10~12

83
Fixed bolts of rear window regulator motor 5~7
Rear glass lifter assembly fixed bolt 10~12
Fixing screws of interior rearview mirror assembly 5~7
Exterior rearview mirror assembly fixed nut 10~12
Precautions
1. If it is necessary to dismantle and repair the circuit during the course of maintenance, disconnect the battery
negative electrode cable.
2. If it is required to open the door for removal during maintenance, support the door with a rod.
3. Do not use sharp tools to remove the trim panel and other wearing parts.
LIFAN AUTO
Front left door control
Power Window and Rearview Mirror-Power window and rearview mirror
Driver compartment
central control box
Front leftdoor
LIFAN AUTO
Battery power supply Battery power supply Step lamp control Background light
power
Front left door control unit
Glass lift Glass lower
Child lock
switch
Front left door window
Front left Front right Rear left Rear right
regulator switch
Wiring diagram Down Up
Front left door
window regulator motor
83-2
83
83-3
Front left door control system

Front left door
control unit
Key unlocking Key lockout Unlock Lockout Door open reminder singal
LIFAN AUTO
OFF ON Front left central lock motor
Front right door control
Driver compartment
central control box
Front right Interior dimming lamp CAN system
LIFAN AUTO
Battery power supply Battery power supply Door lamp control Background light
power
Front right door control unit
Front right door
window regulator
Front right central Front right door
lock motor window regulator
OFF ON motor
83-4
83
83-5
Rear right door control

Driver compartment
central control box
LIFAN AUTO
power
Rear left door control unit
Rear left door
window regulator
Rear left central lock Rear left door
motor window regulator
OFF ON
Rear right door control system
Driver compartment
central control box
LIFAN AUTO
power
Rear right door
Rear right door
window regulator
Rear right central lock Rear right door
motor window regulator
OFF ON lower lift
83-6
83
83-7
Exterior rearview mirror control

Driver compartment
central control box
Rearview mirror
adjusting switch
LIFAN AUTO
Left exterior Right outside
rearview mirror rearview mirror
83-8 Power Window and Rearview Mirror-Power window and rearview mirror
Terminal definition
D01 to Front right power rearview mirror D04 to Front left door control unit
Terminal Terminal
No. No.
1 BrG Left rotation of rearview mirror (+) 1 - -
2 WR Heating of rearview mirror (+) 2 - -
3 - - 3 - -
4 BrR Upper rotation of rearview mirror 4 - -
Right and lower rotation of rearview 5 - -

5 GrV
mirror.
6 - -
6 B Heating of rearview mirror (-)
7 - -
D06 to Front left door window regulator motor 8 - -
10 B Grounding
11 G LIN
Terminal 12 V Background lighting lamp (+)

Color Function
No.
13 OBr Key unlock
1 WR Glass lifting (+)
14 OV Key lock
2 WB Glass descending (+)
15 OG Door unlocked signal
16 GB Step lamp control

D05 to Front left door control unit
K02 to Front right door window regulator motor

No.
1 - - Terminal Color Function

No.
2 - -
3 - -
4 - -
5 OW Unlocking
6 OR Locking
7 B Grounding
8 RV Battery power supply
9 WB Glass lifting
10 WR Glass descending
LIFAN AUTO
K04 to Front right door control unit K05 to Front right door control unit
Terminal Terminal
No. No.
1 - - 1 - -
2 - - 2 - -
3 - - 3 - -
4 - - 4 - -
5 WR Glass lifting 5 - -
6 WB Glass descending 6 - -
7 RV Battery power supply 7 - -
8 B Grounding 8 - -
9 OR Locking 9 RW Battery power supply
10 OW Unlocking 10 B Grounding
11 G LIN

K06 to Front right power rearview mirror
13 GB Front right step lamp control
14 - -
15 - -
16 - -
Terminal I04 to Power rearview mirror switch

Color Function
No.
1 GrY Left rotation of rearview mirror (+)
2 WR Heating of rearview mirror (+)
3 - - Terminal 83
Color Function
No.
4 BrW Upper rotation of rearview mirror
1 B Grounding
5 GrV Right and lower rotation of rearview mirror.
Lower and right rotation of exterior
6 B Heating of rearview mirror (-) 2 GrV
rearview mirror

M02 to Rear left door window regulator motor
5 BrG Left rotation of left exterior rearview mirror
Upper rotation of left exterior rearview

6 BrR
mirror
7 - -
Terminal Color Function 8 - -
No.
Upper rotation of right exterior
1 WR Glass lifting (+) 9 BrW
rearview mirror
Left rotation of right exterior rearview
10 GrY
mirror
LIFAN AUTO
83-10 Power Window and Rearview Mirror-Power window and rearview mirror
M04 to Rear left door control unit M05 to Rear left door control unit
Terminal Terminal
No. No.
1 - - 1 - -
2 - - 2 - -
3 - - 3 - -
4 - - 4 - -
5 WR Glass lifting 5 - -
6 WB Glass descending 6 - -
7 R Battery power supply 7 - -
8 B Grounding 8 - -
9 OR Locking 9 RW Battery power supply
10 OW Unlocking 10 B Grounding
11 G LIN
N05 to Rear right door control unit 12 V Background lighting lamp (+)
13 - -
14 - -
15 - -
16 - -
No.
1 - -
N02 to Rear right door window regulator motor
2 - -
3 - -
4 - -
5 - -
Terminal
6 - - Color Function
No.
7 - -
8 - -
10 B Grounding
11 G LIN
13 - -
14 - -
15 - -
16 - -
LIFAN AUTO
N04 to Rear right door control unit

No.
1 - -
2 - -
3 - -
4 - -
5 WR Glass lifting
8 B Grounding
9 OR Locking
10 OW Unlocking
83
LIFAN AUTO
83-12 Power Window and Rearview Mirror-Troubleshooting
Troubleshooting
Read and clear DTCs
(DTC)
interface.

Series selection
Chongqing Lifan
System Help About Power off

configuration
(c). Select the diagnostic program V5. 0 version, and then

click "OK".
Demo
OK
Cancel


LIFAN AUTO
Power Window and Rearview Mirror-Troubleshooting 83-13
(d). Select and enter into “Body System”.

Anti-theft system
Vehicle body system
A/C System Return
(e). Select “Body Control System (HIRAIN FBCM)”.
Vehicle body system LIFAN Dedicated\Chongqing Lifan\V5.0\Vehicle body system
Vehicle body system (HIRAIN FBCM) Previous page
Vehicle body system (HIRAIN RBCM)
Next page
Print
Return

△ Hint:
83
Front body control system (HIRAIN FBCM) LIFAN Dedicated\Chongqing Lifan\V5.0\
Clear fault code (g). Read and record the displayed diagnostic DTCs.
ECU reset
Next page
Print
Return
LIFAN AUTO
Information
OK
Cancel
2. Clearing of DTCs
Front body control system (HIRAIN FBCM) LIFAN Dedicated\Chongqing Lifan\V5.0\
Clear fault code
ECU reset Next page
Print
Return
Information
OK
Cancel
LIFAN AUTO

Attention:

(DTC)
• Front left door window motor circuit

Front left door window motor has short-
B104011 • Front left door window motor
circuit.
• Front left door control unit
• Front left door window motor circuit

Front left door window motor has open-
B104015 • Front left door window motor
circuit.
• Front left door control unit
• Front right door window motor circuit

Front right door window motor has short-
B104111 • Front right door window motor
circuit.
• Front right door control unit
• Front right door window motor circuit

Front right door window motor has open-
B104115 • Front right door window motor
circuit.
• Front right door control unit
• Rear left door window motor circuit

Rear left door window motor has short-
B104211 • Rear left door window motor
circuit.
• Rear left door control unit
• Rear left door window motor circuit

Rear left door window motor has open-
B104215 • Rear left door window motor
circuit.
• Rear left door control unit
• Rear right door window motor circuit

Rear right door window motor has short-
B104311 • Rear right door window motor
circuit.
• Rear right door control unit
• Rear right door window motor circuit

Rear right door window motor has open-
B104315 • Rear right door window motor
circuit.
• Rear right door control unit
83
LIFAN AUTO

these parts.
1. Fuse (burned out) Replace.

All power windows do not
work 2. Power circuit (open circuit or short
circuit)
2. Power rearview mirror controller

Neither of power rearview Replace.
(damaged)
mirrors on both sides works
3. Power rearview mirror power
supply and grounding wire (open Repair or replace the harness or connector
circuit or short circuit)

Replace.
(damaged)
Left rearview mirror does
not work
2. Wire harness (open circuit or short
circuit)

Replace.
(damaged)
Right rearview mirror does
not work
circuit)

Replace.
(damaged)
not work in up/down 2. Motor (damaged) Replace rearview mirror assembly
direction
circuit)

Replace.
(damaged)
not work in left/right 2. Motor (damaged) Replace rearview mirror assembly
direction
circuit)

Replace.
(damaged)
Right rearview mirror
does not work in up/down 2. Motor (damaged) Replace rearview mirror assembly
direction
circuit)

Replace.
(damaged)
Right rearview mirror
does not work in left/right 2. Motor (damaged) Replace rearview mirror assembly
direction
circuit)
LIFAN AUTO
B104011 - Front left door window motor has short-circuit.

B104015 - Front left door window motor has open-circuit.
Check system
1 To Step 2
• Pull Front left door window lifter switch, and inspect whether Front left door window
motor works normally.
Check for broken circuit

• Disconnect front left door window motor connector D06, front left door control unit
2 connector D05. To Step 3 To Step 7
and No.2terminals of D06, and No.10 and No.9 terminals of D05 is less than 2Ω.
Check for short circuit

• Disconnect Front left door window motor connector D06.
and No.2terminals of connector D06 and grounding is more than 1MΩ.
Inspect front left door window motor.

• Disconnect Front left door window motor connector D06.
• Connect positive and negative poles of battery respectively to No.1 and No.2terminals of
Front left door window motor, and observe whether Front left door window motor works
normally.
Replace front left door control unit.

5 • Refer to repair procedures specified in repair manual to replace front left door glass lifter To Step 8
main switch.
Replace front left door window motor.

6 • Refer to repair procedures specified in repair manual to replace front left door window To Step 8
motor.

7 To Step 8
B104111- Front right door window motor has short-circuit. 83

B104115 - Front right door window motor has open-circuit.
Check system
1 To Step 2
• Pull Front right door window lifter switch, and inspect whether Front right door window

• Disconnect Front right door window motor connector K01, Front right door control unit
2 connector K04. To Step 3 To Step 7
and No.2terminals of K01, and No.10 and No.9 terminals of K04 is less than 2Ω.

• Disconnect Front left door window motor connector K01.
and No.2terminal of K01 and grounding is more than 1MΩ.
LIFAN AUTO
Inspect front right door window motor.

• Disconnect Front right door window motor connector K01.
• Connect positive and negative poles of battery respectively to No.1 and No.2terminals
of Front right door window motor, and observe whether Front right door window motor
works normally.
Replace front right door control unit.

5 • Refer to repair procedures specified in repair manual to replace Front right door glass To Step 8
lifter switch.
Replace front right door window motor.

6 • Refer to repair procedures specified in repair manual to replace Front right door window To Step 8
motor.

7 To Step 8
B104211 - Rear left door window motor has short-circuit.

B104215 - Rear left door window motor has open-circuit.
Check system
1 To Step 2
• Pull Rear left door window lifter switch, and inspect whether Rear left door window

• Disconnect rear left door window motor connector M01, rear left door control unit
2 connector M04. To Step 3 To Step 7
and No.2terminals of M01 and No.10 and No.9 terminals of M04 is less than 2Ω.

• Disconnect rear left door window motor connector M01.
• Use a digital multimeter resistance scale to check whether No.1 and No.2 terminals of
M01 and grounding is more than 1MΩ.
Inspect rear left door window motor.

• Disconnect rear left door window motor connector M01.
• Connect positive and negative poles of battery respectively to No.1 and No.2terminals of
Rear left door window motor, and observe whether Rear left door window motor works
normally.
Replace rear left door control unit.

5 • Refer to repair procedures specified in repair manual to replace rear left door glass lifter To Step 8
switch.
Replace rear left door window motor.

6 • Refer to repair procedures specified in repair manual to replace rear left door window To Step 8
motor.

7 To Step 8
LIFAN AUTO
B104311 - Rear left door window motor has short-circuit.

B104315 - Rear left door window motor has open-circuit.
Check system
1 To Step 2
• Pull Rear right door window lifter switch, and inspect whether rear right door window

• Disconnect Rear right door window motor connector N01, rear right door control unit
2 connector N04. To Step 3 To Step 7
• Use a digital diameter resistance scale to check whether the resistance between No.1 and
No.2terminals of N01, and No.10 and No.9 terminals of N04 is less than 2Ω.

• Disconnect rear right door window motor connector N01.
and No.2terminals of N01 and grounding is more than 1MΩ.
Inspect rear right door window motor.

• Disconnect rear right door window motor connector N01.
• Connect positive and negative poles of battery respectively to No.1 and No.2terminals
of Rear right door window motor, and observe whether rear right door window motor
works normally.
Replace rear right door lock unit.

5 • Refer to repair procedures specified in repair manual to replace rear right door window To Step 8
glass lifter switch.
Replace rear right door window motor.

6 • Refer to repair procedures specified in repair manual to replace rear right door window To Step 8
motor.

7 To Step 8
83
LIFAN AUTO
All power windows do not work

Check all power windows

1 To Step 2
• Operate power window switch, and inspect whether power window has lifting and
descending actions.
Check power window fuse

• Inspect whether power window fuse FS15 is burned out.
Inspect power window power supply circuit.

• According to wiring diagram, inspect whether power window wire harness has open-
circuit or short-circuit.
3 To Step 4
Hint:
For how to check the harnesses for short circuit s or opens according to the electrical wiring
diagrams, See Chapter 91 Circuits--Description of Diagnosis and Repair Methods
Neither of power rearview mirrors on both sides works

Check power rearview mirror

1 To Step 2
• Turn power rearview mirror controller to check if left and right rearview mirrors rotate
flexibly.
Check power rearview mirror fuse

• Inspect whether power window fuse FS36 is burned out.
Check power rearview mirror power supply circuit

• Dismantle power rearview mirror switch, and disconnect power rearview mirror switch
connector.
3 To Step 4
• Use a multimeter voltage scale to check whether No.3 terminal of I04 has voltage.
• Use a multimeter resistance scale to check whether No.1 terminal of I04 and grounding
is connected.
Left rearview mirror does not work

Check left power rearview mirror

1 • Turn the ignition switch to ON. To Step 2
• Turn on left power rearview mirror controller, check if left rearview rotates flexibly.
LIFAN AUTO
Check left power rearview mirror controller

• Disconnect power rearview mirror switch connector.
• Turn on the left power rearview mirror controller.
• Turn on left adjustment switch of power rearview mirror, and use a multimeter resistance
scale to inspect whether No.3 and No.5 terminals of connector I04 are connected.
2 • Turn on right adjustment switch of power rearview mirror, and use a multimeter To Step 3 To Step 4
resistance scale to inspect whether No.3 and No.2terminals of connector I04 are
connected.
• Turn on up adjustment switch of power rearview mirror, and use a multimeter resistance
• Turn on down adjustment switch of power rearview mirror, and use a multimeter
connected.
Check left power rearview mirror motor circuit

• Dismantle alt speaker assembly, and disconnect left power rearview mirror connector.
• Turn on left-adjusting switch of power rearview mirror.
• Use a multimeter voltage scale to check whether No.1 terminal of connector D01 and
grounding has battery voltage.
• Use a multimeter resistance scale to check whether No.5 terminal of connector D01 and
grounding are connected.
• Turn on up-adjusting switch of power rearview mirror.
3 To Step 4
• Turn on down-adjusting switch of power rearview mirror.
83
Right rearview mirror does not work
Check right power rearview mirror

1 To Step 2
• Turn on right power rearview mirror controller to check if right rearview mirror rotates
flexible.
LIFAN AUTO
Check right power rearview mirror controller

• Turn on right power rearview mirror controller.
• Turn on left adjustment switch of power rearview mirror, and use a multimeter resistance
2 • Turn on right adjustment switch of power rearview mirror, and use a multimeter To Step 3 To Step 4
resistance scale to inspect whether No.1 and No.10 terminals of connector I04 are
connected.
• Turn on up adjustment switch of power rearview mirror, and use a multimeter resistance
connected.
Check right power rearview mirror motor circuit

• Dismantle alt speaker assembly, and disconnect right power rearview mirror connector.
• Use a multimeter voltage scale to check whether No.1 terminal of connector K06 and
• Use a multimeter resistance scale to check whether No.5 terminal of connector K06 and
3 To Step 4
Left power rearview mirror can't work in UP/DOWN directions.


1 To Step 2
• Turn on left power rearview mirror controller to check if left rearview mirror can be
adjusted up/down.
LIFAN AUTO
Check up/down-adjusting switches of left power rearview mirror.

2 • Turn on up adjustment switch of power rearview mirror, and use a multimeter resistance To Step 3 To Step 5
connected.
Check up/down-adjusting motor of left power rearview mirror.

• Disconnect left power rearview mirror connector.
• Use a multimeter resistance scale to inspect whether No.4 and No.5 terminals of left
power rearview mirror motor connector D01 are connected.
Check up/down-adjusting motor circuit of left power rearview mirror

4 To Step 5
• Turn on down-adjusting switch of power rearview mirror.
Left rearview mirror does not work in left/right direction


1 To Step 2
• Turn on left power rearview mirror controller, check if left rearview mirror can be
adjusted to the left/right.
Check left/right-adjusting switches of the left power rearview mirror

83
2 • Turn on left adjustment switch of power rearview mirror, and use a multimeter resistance To Step 3 To Step 4
• Turn on right adjustment switch of power rearview mirror, and use a multimeter
connected.
Check left/right-adjusting motor of left power rearview mirror

• Disconnect left power rearview mirror connector.
• Use a multimeter resistance scale to inspect whether No.1 and No.5 terminals of left
power rearview mirror motor connector D01 are connected.
LIFAN AUTO
Check left/right-adjusting motor circuit of the left power rearview mirror

4 To Step 5
Right rearview mirror does not work in up/down direction


1 To Step 2
• Turn on right power rearview mirror controller, and then check if right rearview mirror
can be adjusted up/down.
Check up/down-adjusting switches of right power rearview mirror

2 • Turn on up adjustment switch of power rearview mirror, and use a multimeter resistance To Step 3 To Step 4
connected.
Check up/down-adjusting motors of right power rearview mirror

• Disconnect right power rearview mirror motor connector.
• Use a multimeter resistance scale to inspect whether No.4 and No.5 terminals of right
power rearview mirror motor connector K06 are connected.
Check up/down-adjusting motor circuits of right power rearview mirror

4 To Step 5
LIFAN AUTO
Right rearview mirror does not work in left/right direction


1 To Step 2
• Turn on right power rearview mirror controller, check if right rearview can be adjusted
to the left/right.
Check left/right-adjusting switches of right power rearview mirror

2 • Turn on left adjustment switch of power rearview mirror, and use a multimeter resistance To Step 3 To Step 4
• Turn on right adjustment switch of power rearview mirror, and use a multimeter
connected.
Check left/right-adjusting motors of right power rearview mirror

• Disconnect right power rearview mirror motor connector.
• Use a multimeter resistance scale to inspect whether No.1 and No.5 terminals of right
power rearview mirror motor connector K06 are connected.
Check left/right-adjusting motor circuits of right power rearview mirror

4 To Step 5
83
LIFAN AUTO
83-26 Power Window and Rearview Mirror-Front power window
Front power window

Components diagram
1 Front door guide way 4 Hexagon bolt with flange
2 Hexagon bolt with flange 5 Front door glass regulator assembly
3 Front door glass assembly
LIFAN AUTO
Power Window and Rearview Mirror-Front power window 83-27
Replace
1. Remove front power window
Trim - Front Door Inner Trim Panel, Replacement).
(b). Connect front door glass lifter control box wire harness
connector, and connect negative cable connector of battery.
(c). Lower glass to proper position, unfold trim seal, and
disconnect two fixed bolts of glass and glass lifter.
(d). Disconnect negative cable connector of battery, and
disconnect front door glass lifter control box wire harness
connector.
(e). Rotate glass and take out glass by pressing upwards.
(f). Dismantle fixed bolts of glass lifter.

(g). Take out glass lifter assembly.
83
LIFAN AUTO
(h). Dismantle fixed screws of glass lifter motor, and remove

glass lifter motor.
(i). Dismantle fixed bolts of door guide way, and remove door
guide way.
2. Install front power window

(a). Place the door guideway in position.
(b). Tighten the door guideway fixed bolt.
LIFAN AUTO
Power Window and Rearview Mirror-Front power window 83-29
(c). Place the glass lifter motor in position. Tighten the fixed
bolt.
Torque: 4N•m
△ Hint:
• Before installing glass lifter motor, it is necessary to inspect
whether glass lifter tooth is damaged. If it is, replace it.
• Uniformly apply lubricating oil to sliding and rotating
section of glass lifter assembly.
(d). Install glass lifter onto mounting position, and pre-tighten

glass lifter fixed bolts.
(e). Adjust the glass lifter position. Install the glass, matching
the glass lifter.
(f). Install fixed bolts of connection section glass and glass lifter 83
and tighten them.
LIFAN AUTO
(g). Tighten fixed bolts of glass lifter.

△ Hint:
After tightening fixed bolts of glass lifter, connect front door glass
lifter control box wire harness connector. After glass lifts freely,
conduct the following steps.
(h). Install front door trim seal.

(j). Install front door trim panel (See Chapter 81 Vehicle Trim -
Front Door Trim Panel, Replacement).
LIFAN AUTO
Power Window and Rearview Mirror-Rear power window 83-31
Rear power window

Components diagram
1 Rear door triangle window 5 Cross recessed countersunk head screw 83

2 Sealing strips of rear triangle window 6 Rear door glass assembly
3 Hexagon bolt with flange 7 Hexagon flange bolt
4 Rear door guide rail 8 Rear door window regulator assembly
LIFAN AUTO
83-32 Power Window and Rearview Mirror-Rear power window
Replace
1. Dismantling of rear power window.

(a). Dismantle rear door trim panel (See Chapter 81 Vehicle
Trim - Rear Door Trim Panel, Replacement).
(b). Connect rear door glass lifter control box wire harness
connector, and negative cable connector of battery.
(c). Lower or lift glass to proper position, and unfold trim seal,
and disconnect two fixed bolts of door guide way.
(d). Disconnect battery negative cable connector, and rear door
glass lifter control box wire harness connector.
(e). Dismantle fixed screws on the top of door guide way, and
remove glass guide way.
LIFAN AUTO
(f). Remove quarter glass.
(g). Rotate the glass and disengage the glass run and window
regulator, then take out the glass.
(h). Dismantle fixed bolts of glass lifter.

(i). Remove glass lifter assembly.
83
LIFAN AUTO
83-34 Power Window and Rearview Mirror-Rear power window
(j). Dismantle fixed bolts of glass lifter motor, and remove glass
lifter motor.
2. Install rear power window

(a). Install glass lifer motor to mounting position.
(b). Install fixed screws of glass lifter motor and tighten them.
Torque: 5 ~ 7N•m
(c). Place the glass lifter assembly in position.

(d). Tighten the glass lifter assembly fixed bolt.
LIFAN AUTO
(e). Install glass onto mounting position, rotate glass, and install
glass lifter sliding block into glass sliding groove.
(e). Install rear door quarter glass onto mounting position.
(f). Install rear door glass guide way onto mounting position,
and tighten fixed bolts of glass guide way.
△ Hint:
When install rear door glass, tighten fixed screws/ bolts according
to up, middle, low sequence.
83
(h). Install rear door rain-proof curtain.

(i). Install rear door trim panel (See Chapter 81 Vehicle Trim -
Rear Door Trim Panel, Replacement).
LIFAN AUTO
83-36 Power Window and Rearview Mirror-Interior rearview mirror
Interior rearview mirror

Components diagram
1 Hexagon bolt with flange 4 Cross recessed screw
2 Right exterior rearview mirror assembly 5 Left exterior rearview mirror assembly
3 Interior rearview mirror assembly
LIFAN AUTO
Power Window and Rearview Mirror-Interior rearview mirror 83-37
Adjustment
1. Adjust interior rearview mirror
(a). Manually adjust the interior rearview mirror angle.
(b). Adjust view angle of interior rearview mirror finely through

fine-adjusting handle.
83
LIFAN AUTO
83-38 Power Window and Rearview Mirror-Interior rearview mirror
Replace
1. Replace interior rearview mirror

(a). Remove the interior rearview mirror assembly retaining
screw.
(b). Remove the interior rearview mirror assembly.
(c). Install the interior rearview mirror in place.
(d). Tighten the interior rearview mirror assembly retaining
screw.
Torque: 5 ~ 7N•m
LIFAN AUTO
Power Window and Rearview Mirror-Exterior rearview mirror 83-39
Exterior rearview mirror

Adjustment
1. Adjust exterior rearview mirror
(a). Adjust view angle of interior rearview mirror through
adjusting switch of exterior rearview mirror.
Replace
1. Remove exterior rearview mirror
(b). Remove alt speaker assembly.
83
LIFAN AUTO
83-40 Power Window and Rearview Mirror-Exterior rearview mirror
(c). Disconnect exterior rearview mirror connector.
(b). Remove the exterior rearview mirror fixed nut. Remove the
exterior rearview mirror.
2. Install exterior rearview mirror

(a). Place the exterior rearview mirror assembly in position.
(b). Tighten the exterior rearview mirror assembly fixed nut.
LIFAN AUTO
Power Window and Rearview Mirror-Exterior rearview mirror 83-41
(c). Connect exterior rearview mirror connector.
(d). Install alt speaker assembly.

(e). Install front door inner trim panel (See Chapter 81 Vehicle
83
LIFAN AUTO
• Memo •
LIFAN AUTO
Seats
Seats............................................................................. 84-1
Components diagram(front seat)............................ 84-2
Components diagram(rear seat)............................. 84-3
Determination of seat noise:................................... 84-4
Seat heating system doesn't work........................... 84-4
Driver seat................................................................... 84-5
Adjustment............................................................. 84-5
Replace................................................................... 84-7
Front passenger's seat.............................................. 84-11
Adjustment........................................................... 84-11
Replace................................................................. 84-11
Rear seat................................................................... 84-12
Adjustment........................................................... 84-12
Replace................................................................. 84-12
84
LIFAN AUTO
Seats-Seats 84-1
Seats
Item N•m
Front seat fixed bolt 45~55
Rear seat back fixed bolt 45~55
Rear seat back hinge fixed bolt 45~55
84
LIFAN AUTO
84-2 Seats-Seats
Components diagram(front seat)
1 Headrest of front seat 8 Front seat back tilt adjuster
2 Headrest connecting pipe A 9 Hexagon bolt with flange
3 Headrest connecting pipe B 10 Front seat track assembly
4 Front seat assembly 11 Rear right foot cover of front seat
5 Front seat height adjuster handle 12 Rear left foot cover of front seat
6 Semicircular protective cover 13 Big protective cover
7 Front seat tilt adjuster handle
LIFAN AUTO
Seats-Seats 84-3
Components diagram(rear seat)
1 Rear seat headrest on two ends 11 Hexagon bolt with flange 84
2 Rear seat backrest unlock knob 12 Central armrest assembly
3 Rear seat backrest unlock knob seat 13 Rear seat right back
4 Rear seat middle headrest 14 Rear seat backrest middle hinge
5 Headrest connecting pipe A 15 Hexagon bolt with flange
6 Headrest connecting pipe B 16 Rear seat left back
7 Rear seat right side backrest 17 Rear seat left backrest left hinge
8 Hexagon bolt with flange 18 Rear seat left side backrest
9 Rear seat right backrest right hinge 19 Plastic clamp
10 Hexagon bolt with flange 20 Rear seat cushion
LIFAN AUTO
84-4 Seats-Troubleshooting
Troubleshooting
Determination of seat noise:
When isolating the seat noise, pay more attention to the seat position and the articles on the seat when the seat
producing noise. When determining and isolating noise, make such conditions recur.
Potential causes of seat noise include:
1. Headrest push rod and bracket
2. Seat bolster and seat frame
3. Rear-row seat back lock and bracket
To make noises recur, move or hold the suspicious components to isolate such noises. You can reset the component or
use polyurethane adhesive tapes in the contact field to troubleshoot most faults.
Seat heating system doesn't work

the reasons that seat heating system doesn’t work include:
1. The fuse FS39 is damaged
2. The switch of the system (central console)is damaged
3. The seat heater assemnly is damaged.
4. The wire harness has short circuit
LIFAN AUTO
Seats-Driver seat 84-5
Driver seat
Adjustment
1. Adjust driver seat in forward/rearward direction
(a). Holding up the driver seat adjusting lever in front of the
seat, move the seat in forward/rearward direction to a proper
position, then release the adjusting lever.
2. Adjust driver seat back angle

(a). Pull and hold the adjuster handle of driver's seat upward.
Adjust the backrest to a proper location, and release the
handle.
84
3. Adjustment of driver's seat height

(a). If the driver's seat height is low, you can pull upwards the
seat height adjuster handle back and forth to lift the seat up
to its desired position.
LIFAN AUTO
84-6 Seats-Driver seat
(b). If the driver's seat height is high, you can pull downwards
the seat height adjuster handle back and forth to drop the
seat down to its desired position.
4. Adjustment of driver's seat headrest

(a). Press the clip for the headrest left insert, then move the
headrest in vertical direction to a proper position.
LIFAN AUTO
Replace
1. Remove driver seat
(a). Disconnect negative cable connector of battery.
(b). Disconnect the connector of the driver’s seat belt indicator
lamp.
(c). Disconnect the connector of driver’s seat heater.(Only for
the vehicle with seat heater）
(d). Adjust the driver’s seat to make it move backwards to the

extreme position so as to expose the fixed bolts at the front
end of the seat .
84
(e). Unscrew the fixed bolts at the front end of the seat with a
wrench.
LIFAN AUTO
(f). Adjust the driver's seat to make it move forwards to the

extreme position so as to expose the fixed bolts at the rear
end of the seat .
(g). Unlock the rear foot cover of the seat. Unscrew the fixed
bolts at the rear end of the seat with a wrench.
(h). Remove the four fixed bolts from the front and rear ends of
the seat and put them at the specified place to prevent them
from being lost.
(i). Adjust the seat back to its desired position in order to

remove the seat.
LIFAN AUTO
(j). Remove the driver's seat.

Attention:
Be careful when moving out the seat. Do not damage the paint
on surface of vehicle.
(2). Install driver seat

(a). Adjust the seat back to its desired position in order to
introduce the seat.
(b). Introduce the driver's seat.

84
LIFAN AUTO
(c). Adjust the driver's seat to make it move forwards to the

extreme position so as to make the mounting holes of the
fixed bolts at the rear end of the seat be in alignment with
the mounting holes of the bolts of the body .
(d). Install the fixed bolts at the rear end of the seat and pre-
tighten them.
(e). Adjust the seat to make it move backwards to the extreme

position so as to make the mounting holes of the fixed
bolts at the front end of the seat be in alignment with the
mounting holes of the bolts of the body .
LIFAN AUTO
Seats-Front passenger's seat 84-11
(f). Install the fixed bolts at the front end of the seat and pre-
tighten them.
(g). Tighten the four fixed bolts of the seat to the specified
torque with a torque wrench, and install the rear foot cover
of the seat.
(h). Install the connector of the seat belt indicator lamp.

(i). Install the connector of driver’s seat heater. (Only for the
vehicle with seat heater）
(j). Install the connector of the battery negative cable.
Front passenger's seat 84

Adjustment
△ Hint:
Adjustment and steps of front passenger seat are the same as those of driver seat (See Chapter 84 Seat - Driver Seat,
Adjustment).
Replace
△ Hint:
Replacement and steps of front passenger seat are the same as those of driver seat (See Chapter 84 Seat - Driver Seat,
Replacement).
LIFAN AUTO
84-12 Seats-3rd row seat
Rear seat
Adjustment
1. Adjustment of rear-row seat headrest

(a). Press the clip for the headrest left insert, then move the
headrest in vertical direction to a proper position.
Replace
1. Remove rear seat
(a). Remove the seat cushion.
• Raise the seat cushion upwards to disconnect it from its
snap-fits.
• Pull seat cushion outwards, and take out seat cushion.
LIFAN AUTO
Seats-3rd row seat 84-13
(b). Removal of seat right back

• Pull up seat right headrest unlock knob; meanwhile pull
seat right backrest to proper position.
• Dismantle two fixed bolts of seat right backrest, and
place them to the specified position to avoid missing.
• Remove the right back of the seat.
(c). Removal of seat left back

• Pull up seat left headrest unlock knob; meanwhile pull
seat left backrest to proper position.
• Dismantle two fixed bolts of seat left backrest, and place
it to the specified position to avoid missing.
• Remove the left back of the seat.
(d). Dismantle seat side backrest.

84
• Dismantle lower fixed bolts of seat side backrest, and
place them to the specified position to avoid missing.
• First pull up seat side backrest, and then pull seat side
backrest outwards.
LIFAN AUTO
84-14 Seats-3rd row seat
2. Install rear seat

(a). Install seat side backrest.
• Put the protruded section on the upper of seat side
backrest onto mounting position, and then install it to
proper position.
• Install lower fixed bolts of side backrest, and tighten
them to the specified tightening torque.
(b). Install seat backrest.

• Put the left back of the seat at its mounting position, and
install the fixed bolts and tighten them to the specified
torque.
• Put the right back of the seat at its mounting position,
and install the fixed bolts and tighten them to the
specified torque.
• Press the position under seat left and right backrest
unlock knob until "tick" sound is produced.
(c). Install seat cushion.

• Insert U frame at the rear of seat cushion into the hook
of middle hinge.
△ Hint:
Pull the seat belt out before pushing the seat cushion.
LIFAN AUTO
Dashboard and console
Dashboard and console.............................................. 85-1

Precautions............................................................. 85-1
Components diagram(dashboard).......................... 85-2
Components diagram(console)............................... 85-3
Lower left panel of the dashboard............................ 85-4
Replace................................................................... 85-4
Lower right panel of the dashboard......................... 85-9
Replace................................................................... 85-9
Glove box.................................................................. 85-17
Replace................................................................. 85-17
Dashboard................................................................. 85-18
Replace................................................................. 85-18
Console...................................................................... 85-24
Replace................................................................. 85-24
85
LIFAN AUTO
Dashboard and Console-Dashboard and console 85-1
Dashboard and console

Item N•m
Fixed screw of instrument cluster panel 5~6
Fixed bolts of lower left panel of the dashboard 8~9
Fixed bolts of lower right panel of the dashboard 8~9
Fixed bolts of dashboard 8~9
Fixed screws of radio/CD player body 5~6
Fixed bolts of console handrail box 8~9
Fixed bolts of console front end 8~9
Fixed bolts of ashtray assembly 5~6
Precautions
1. Do not remove the dashboard and console using any sharp tool. If you have to use a sharp tool, wrap it with a
piece of cloth.
3. If the clip of a part is damaged, it is recommended to replace the part.
4. Do not rudely remove the guard board. Remove it after removing all the fixed bolts.
85
LIFAN AUTO
85-2 Dashboard and Console-Dashboard and console
Components diagram(dashboard)
1 Right end cover plate of the dashboard 12 Instrument cluster cover
2 Hexagon bolt with flange 13 Left trim component of the dashboard
3 Right air distribution vent assembly 14 A type spring nut
4 Plastic clamp 15 Spring nut
5 Lower right panel assembly 16 Lower left panel body of the dashboard
6 Right lining of glove box lock hole 17 Notes box
7 Left lining of glove box lock hole 18 Cushion
8 Right trim strip component of the dashboard 19 Left air distribution vent assembly
9 Intermediate vent assembly 20 Left end cover plate of the dashboard
10 Glove box 21 Dashboard upper panel
11 Lower right panel body of the dashboard
LIFAN AUTO
Dashboard and Console-Dashboard and console 85-3
Components diagram(console)
85
1 Gear shifting panel body 10 Console trim frame component
2 Gear shifting leather sheath 11 Console front right panel
3 Pressing ring of gear shifting leather sheath 12 Console handrail box assembly
4 Console front left panel 13 Console glove box bottom gasket
5 Hexagon bolt with flange 14 Console glove box bottom cover plate
6 Plastic snap-fit 15 Cross-recess pan-head self-tapping screw
7 Fixed sleeve for leather sheath 16 Rear ashtray assembly
8 Cross-recess pan-head self-tapping screw 17 Console end cover plate
9 Front ashtray assembly 18 Console
LIFAN AUTO
85-4 Dashboard and Console-Lower left panel of the dashboard
Lower left panel of the dashboard

Replace
1. Dismantle opening handle of engine cable
(a). Press the engine compartment bracing cable handle
forcibly while moving it upwards to make it disengage the
dashboard left lower panel.
2. Dismantle diagnosis interface connector
3. Dismantle left end cover plate of the dashboard

(a). Pry up left end cover plate of the dashboard with a flat-
blade screwdriver.
Attention:
(b). Remove left end cover plate of the dashboard.
4. Dismantle dashboard cover

(a). Remove two fixed screws of lower dashboard covers with a
short screwdriver.
(b). Pry up dashboard cover with a flat-blade screwdriver.
Attention:
(c). Remove dashboard cover.
LIFAN AUTO
Dashboard and Console-Lower left panel of the dashboard 85-5
5. Dismantle left A-Pillar lower panel assembly

(a). Dismantle left A-Pillar lower panel assembly (See Chapter
81 Interiors and Exteriors - A-Pillar Panel , Replacement).
6. Dismantle lower left panel assembly of the dashboard

(a). Dismantle fixed bolts of lower left panel of the dashboard.
85
(b). Pry up plastic snap-fit of lower left panel with a flat-blade
screwdriver, and take out lower left panel assembly of the
dashboard.
LIFAN AUTO
(c). Turn over lower panel assembly of the dashboard, and

disconnect power rearview mirror and lamp adjustment
control wire harness connector.
(d). Take out lower left panel assembly of the dashboard.
7. Install lower left panel assembly of the dashboard

(a). Connect power rearview mirror and lamp adjustment
control wire harness connector.
Attention:
connected in place.
(b). Fasten lower left panel assembly of the dashboard.

△ Hint:
Please exert force on each snap-fit position of lower left panel of
the dashboard.
LIFAN AUTO
Dashboard and Console-Lower left panel of the dashboard 85-7
(c). Install fixed bolts of dashboard lower left panel.

Torque: 8 ~ 9N•m
8. Install left A-Pillar lower panel assembly

(a). Dismantle left A-Pillar lower panel assembly (See Chapter
81 Interiors and Exteriors - A-Pillar Panel , Replacement).
85
9. Install instrument cover plate
(a). Install dashboard panel (see Chapter 75 Driver Information
System – Instrument Cluster, Replacement).
LIFAN AUTO
10. Install left end cover plate of the dashboard

(a). Close left end cover plate of the dashboard.
△ Hint:
Please exert force at each snap-fit position of left end cover plate
of the dashboard.
11. Install opening handle of engine hood cable

(a). Install opening handle of engine hood cable.
12. Install diagnosis interface connector
LIFAN AUTO
Dashboard and Console-Lower right panel of the dashboard 85-9
Lower right panel of the dashboard

Replace
1. Dismantle middle air outlet assembly of the dashboard

Attention:
(c). Remove middle air outlet panel outwards.
△ Hint:
Place middle air outlet panel stably or disconnect the connector to
remove the panel.
85
2. Dismantle A/C control panel assembly

(a). Remove fixed screws of radio /CD player body.
△ Hint:
Radio/CD player body and central panel integrated control switch
component are fastened by common screws.
LIFAN AUTO
85-10 Dashboard and Console-Lower right panel of the dashboard
(b). Take out central panel integrated control switch component

and radio/CD player body assembly.
△ Hint:
Place central panel integrated control switch component and radio/
CD player body assembly stably.
3. Dismantle right end cover plate of the dashboard

(a). Pry up right end cover plate of the dashboard with a flat-
blade screwdriver.
Attention:
(b). Remove right end cover plate of the dashboard.

(a). Dismantle lower left panel assembly of the dashboard (see
Chapter 85 Dashboard and Console - Lower Left Panel of
the Dashboard, Replacement).
LIFAN AUTO
5. Dismantle console panel assembly

(a). Dismantle console assembly (See Chapter 85 Dashboard
6. Remove the glove box

(a). Dismantle glove box (See Chapter 85 Dashboard and
85
7. Dismantle lower right panel assembly of the dashboard
(a). Dismantle right trim strip component of the dashboard.
LIFAN AUTO
(b). Dismantle fixed bolts of lower right panel of the dashboard.
(c). Pry up plastic snap-fits of lower left panel with a flat-blade

screwdriver, and take out lower right panel assembly of the
dashboard.
8. Install lower right panel assembly of the dashboard

(a). Fasten lower right panel assembly of the dashboard.
△ Hint:
Please exert force on each buckle position of lower right panel of
the dashboard.
LIFAN AUTO
(b). Install fixed bolts of lower right panel of the dashboard.

Torque: 8 ~ 9N•m
(c). Install right trim strip component of the dashboard.
85
9. Install console panel assembly
(a). Install the console panel assembly (See Chapter 85
Dashboard and Console--Console, Replacement).
LIFAN AUTO

(a). Install lower left panel assembly of the dashboard (see
Chapter 85 Dashboard and Console - Dashboard Lower Left
Panel, Replacement).
11. Install right end cover plate of the dashboard

(a). Close right end cover plate of the dashboard.
△ Hint:
Please exert force at each buckle position of left end cover plate of
the dashboard.
12. Install A/C control panel assembly

(a). Place central panel integrated control switch component and
radio/CD player body into mounting position.
LIFAN AUTO
(b). Install fixed screws of radio/CD player body.

Torque: 5 ~ 6N•m
13. Install middle air outlet assembly of the dashboard

(a). Install middle air outlet panel.
85
(b). Install fixed screws of middle air outlet panel.
Torque: 5 ~ 6N•m
LIFAN AUTO
14. Install the glove box

(a). Install glove box (See Chapter 85 Dashboard and Dashboard
Console - Glove Box, Replacement)
LIFAN AUTO
Dashboard and Console-Glove box 85-17
Glove box
Replace
1. Remove the glove box
(a). Open the glove box.
(b). Grasp both sides of the glove box and draw it outward, and
then remove the glove box.
85
2. Install the glove box

(a). Grasp two sides of glove box to align mounting hole to
install the glove box.
(b). Close the glove box.
LIFAN AUTO
85-18 Dashboard and Console-Dashboard
Dashboard
Replace
1. Dismantle A-Pillar upper panel
(a). Dismantle A-Pillar upper panel on both side of the
dashboard (See Chapter 81 Interiors and Exteriors - A-Pillar
Panel, Replacement) .
2. Dismantle console assembly

(a). Dismantle front left and right panel of the console.
(b). Dismantle panel assembly of the console(see Chapter 85
Dashboard and Console - Console, Replacement).

(a). Disconnect opening handle cable of engine hood cable.
(b). Dismantle left end cover plate of the dashboard.
(c). Dismantle lower left panel assembly of dashboard (see
Chapter 85 Dashboard and Console-Dashboard Lower Left
Panel, Replacement) .
LIFAN AUTO
Dashboard and Console-Dashboard 85-19
4. Dismantle middle air outlet panel assembly of the

dashboard
(a). Dismantle fixed bolts of middle air outlet panel of the
dashboard.
(b). Pry up middle air outlet panel assembly of the dashboard,
disconnect the connector.
(c). Remove middle air outlet panel assembly of the dashboard.
5. Dismantle radio /CD player and A/C panel assembly

(a). Dismantle fixed bolts of radio /CD player and A/C
assembly.
(b). Take out radio /CD player and A/C panel assembly,
disconnect all connectors of the assembly.
(c). Take out radio /CD player and A/C panel assembly.
85
6. Dismantle lower right panel assembly of the dashboard
(a). Dismantle lower right panel assembly of the dashboard (see
Chapter 85 Dashboard and Console - Lower Right Panel
Assembly of the Dashboard, Replacement).
LIFAN AUTO
7. Dismantle A/C air outlet panel of the dashboard

(a). Dismantle left A/C air outlet panel of the dashboard.
(b). Dismantle right A/C air outlet panel of the dashboard.
8. Remove dashboard
(a). Dismantle fixed bolts of the dashboard.
(b). With the help of an assistance, remove the dashboard.
LIFAN AUTO
9. Install dashboard.
(a). Clean the area below the dashboard. Tidy the instrument
harnesses.
(b). Place the dashboard assembly in position.
(c). Tighten the dashboard assembly fixed bolt.
Torque: 8 ~ 9N•m
10. Install A/C air outlet panel of the dashboard

(a). Install left A/C air outlet panel of the dashboard.
(b). Install right A/C air outlet panel of the dashboard.
85
11. Install lower right panel assembly of the dashboard
(a). Install lower right panel assembly of the dashboard (see
Chapter 85 Dashboard and Console - Lower Right Panel
Assembly of the Dashboard, Replacement).
LIFAN AUTO
12. Install radio /CD player and A/C panel assembly

(a). Connect radio /CD player and A/C assembly connector.
(b). Install fixed screws of radio /CD player and A/C assembly.
Torque: 5 ~ 6N•m
13. Install middle air outlet panel assembly of the dashboard

(a). Connect middle air outlet panel connector of the dashboard,
close middle air outlet panel assembly of the dashboard.
(b). Install fixed screws of middle air outlet panel of the
dashboard.
Torque: 5 ~ 6N•m

(a). Install lower left panel assembly of the dashboard (see
Chapter 85 Dashboard and Console - Dashboard Lower Left
Panel, Replacement).
(b). Install left end cover plate of the dashboard.
(c). Connect opening handle cable of engine cable.
LIFAN AUTO
15. Install console assembly

(a). Install console panel assembly (see Chapter 85 Dashboard
(b). Install front left/right panel of the console.
16. Install A-Pillar upper panel

(a). Install A-Pillar upper panel on both sides of dashboard
(See Chapter 81 Interiors and Exteriors - A-Pillar Panel,
Replacement).
85
LIFAN AUTO
85-24 Dashboard and Console-Console
Console
Replace
1. Dismantle front panel of console
(a). Dismantle front left panel of the console.
(b). Dismantle front right panel of the console.
△ Hint:
Please exert force at snap-fit position of panel, open console panel
directly by hand.
2. Dismantle console assembly

(a). Dismantle left and right fixed bolts on the front end of
console.
(b). Turn on console handrail box assembly and take out console
glove box bottom gasket and cover plate.
(c). Dismantle fixed bolts in console handrail box.
LIFAN AUTO
Dashboard and Console-Console 85-25
(d). Place parking brake handle to the highest position.

(e). Move console assembly to rear end of the vehicle until it
cannot be moved.
(f). Dismantle gear shifting lever knob.

• Pressing the fixture for the dust boot of shift lever, pull
the knob off the shift lever.
85
(g). Dismantle gear shifting panel assembly.
• Pry up gear shifting panel assembly with a flat-blade
screwdriver and take it out.
Attention:
Wind one end of a flat-blade screwdriver by adhesive tape to
avoid damaging console panel.
LIFAN AUTO
(h). Dismantle front ashtray assembly.

• Pry up console trim frame component with a flat-blade
screwdriver and take it out.
• Dismantle fixed bolts of front ashtray assembly.

• Pull up front ashtray assembly.
• Disconnect front cigarette lighter connector, remove

front ashtray assembly.
LIFAN AUTO
(i). Dismantle backup power.

• Pry up backup power assembly with a flat-blade
screwdriver.
• Disconnect backup power connector and data joint and

remove backup power assembly.
(j). Remove console assembly.
△ Hint:
When taking console assembly, according to actual conditions,
adjust the height of parking brake handle grip to remove console
assembly at any time.
85
3. Install console assembly
(a). Clean the position for installing the console.
(b). Place the console in position.
(c). Install backup power assembly.
• Connect backup power connector and data joint, and
close backup power assembly.
LIFAN AUTO
(d). Install front ashtray assembly.

• Connect front cigarette connector.
Attention:
connected in place.
• Install fixed bolts of front ashtray assembly, and tighten

them.
Torque: 5 ~ 6N•m
• Install console trim frame component.
LIFAN AUTO
(e). Push front end of console assembly forwards to connect

console assembly and dashboard assembly.
(f). Install fixed bolts in console handrail box.

Torque: 8 ~ 9N•m
85
(g). Install left and right fixed bolts on front end of console.
Torque: 8 ~ 9N•m
LIFAN AUTO
(h). Install gear shifting panel assembly.
(i). Install gear shifting lever knob.

△ Hint:
Press down gear shifting lever knob to the lowest point. At the
same time, place gear shifting panel sleeve.
4. Install front panel of the console

(a). Install front left panel of the console.
(b). Install front right panel of the console.
Attention:
Please exert force at snap-fit position of panel to make sure the
buckle is installed in place.
LIFAN AUTO
Wiper and washer system
Wiper and washer system.......................................... 86-1

Preparation............................................................. 86-1
Precautions............................................................. 86-2
Wiring diagram....................................................... 86-4
On-Vehicle check................................................... 86-7
The whole front wiper and washing system does not
work...................................................................... 86-10
Only front wiper HI position does not work........ 86-11
Only front wiper LO position does not work....... 86-11
Only front wiper washing position does not
work.. ..................................................... 86-12
Wiper arm cannot reset or the position is not correct
(windshield wiper is turned off)........................... 86-13
Wiping result is poor............................................ 86-13
Washing fluid is not injected or injected weakly.. 86-14
Injecting area of washing fluid is not correct....... 86-14
Wiper......................................................................... 86-15
Replace................................................................. 86-15
Wiper link assembly ............................................... 86-18
Replacement......................................................... 86-18
Windshield washer fluid reservoir.......................... 86-23 86
Replace................................................................. 86-23
Wiper Blade.............................................................. 86-27
Replace................................................................. 86-27
Nozzle........................................................................ 86-28
Adjustment........................................................... 86-28
Replace................................................................. 86-28
Rear window defroster............................................ 86-30
Inspection............................................................. 86-30
LIFAN AUTO
Wiper and Washer System-Wiper and washer system 86-1
Wiper and washer system

Preparation
Measure the voltage,

1 Digital multimeter resistance, current and the
circuit
Remove and install pipe

3 Screwdriver
clamps
86
Quick-action wrench
bolts
extension rods
LIFAN AUTO
86-2 Wiper and Washer System-Wiper and washer system
Item N•m
Fixed nuts of wiper linkage and motor assembly 8~12
Wiper motor fixed bolt 8~12
Fixed bolts of windshield washer fluid reservoir 8~12
Wiper arm fixed nut 20~26
Fixed bolts of filling port for windshield washer fluid reservoir 8~12
Precautions
1. Before dismantling connection wire of electrical equipment, dismantle the battery negative electrode and wait for
at least 1min. Otherwise, it may cause personal hurt.
2. During the course of using, if the wiper is blocked unexpectedly, shut off the power immediately to prevent
wiper motor from being burnt out. Now, it is not enough to turn wiper switch to OFF. First disconnect the battery
negative electrode cable, then pull out the plug on wiper motor of the socket on combination lever.
3. Keep the wiper close to window glass during the course of using. No clearance is allowed to ensure the wiper
function.
4. Dry wiping is forbidden, for fear of damage of wiper. When triggering the wiper switch accidently, turn it off in
time. Clean and maintain the windshield and wipers, so as to prevent dust accumulation.
5. After the wiper is used for 1000h, dismantle and maintain wiper motor, clean the commutator. Grind electric
brush mark on the commutator with double-zero paper or replace electric brush.
6. The washer may not operate for a long duration. The duration of each operation should not exceed 5 seconds The
interval between two operations may not be less than 10 seconds. Do not operate the washer without fluid.
7. The spray hose should be securely fixed. It is strictly prohibited to randomly move the spray hose. When washing
your vehicle, do not aim the water jet at the spray hose joint for a long duration. This helps prevent corrosion and
ageing.
8. In chilly regions, be sure to use the corresponding washer fluid.
9. Do not use engine antifreeze or another fluid as a substitute, to avoid damaging the window glass or vehicle body
paint.
LIFAN AUTO
Components diagram
86
1 Auxiliary wiper blade 7 Wiper motor
2 Auxiliary wiper arm 8 Washing nozzle
3 Main wiper blade 9 Washer hose assembly
4 Wiper cap 10 Hexagon bolt with flange

5 Main wiper arm 11
washer
6 Wiper linkage 12 Washer fluid reservoir assembly
LIFAN AUTO
Front wiper washer
Wiper switch signal Regulator switch signal Wiper return signal Wiper low speed Wiper high speed Washing
Wiper and Washer System-Wiper and washer system
LIFAN AUTO
Wiper
regulator
Combination Front wiper Front washer
Front washer lever motor motor
switch
Wiring diagram
86-4
Terminal definition
U15 to Front wiper motor U18 to front wiper washing

No.
No. 1 BrY Washing motor (+)
1 BrW Wiper return signal 2 B Washer motor (-)
2 - -
3 BrR Wiper low speed (+)
4 B Wiper motor(-)
5 BrG Wiper high speed (+)
I20 to Front BCM
Terminal Terminal
No. No.
1 R Width lamp /turn signal lamp power supply 14 YG Right turn signal lamp 86
2 YW Front width lamp, backlight 15 YR Left turn signal lamp
3 BrO Key aperture 16 GBl High beam lamp control
4 WY Solar sensor input 17 GY Low beam lamp control
5 GB Simulating switch grounding 18 GW Front fog lamp control
6 - - 19 - -
7 GW Dimming switch 20 - -
8 OR Light control switch 21 GV Wiper speed regulation switch
9 GY Fog lamp combination lever 22 GBl Wiper switch
10 GBr Steering combination lever 23 GGr Rear wiper switch
11 BrY Front wiper washer 24 BrR Front wiper motor low speed
12 - - 25 BrG Front wiper motor high speed
13 RW Wiper/washing power 26 B Simulating ground
LIFAN AUTO
I05 to Combination lever I19 to Front BCM

No.
Terminal
1 - - Color Function
No.
2 - - 1 - -
3 GBl Wiper switch signal 2 - -
4 GR Rear wiper switch signal 3 - -
5 GV Wiper speed regulation switch signal 4 WBl Reverse light switch
6 GB Combination lever grounding 5 VR Front right door stopper switch
7 OR Lamp switch signal 6 VB Front left door stopper switch
8 GW Dimming switch signal 7 WR Clutch switch
9 - - 8 BrW Wiper motor return signal
10 - - 9 - -
11 - - 10 - -
12 GBr Turn signal lamp switch signal 11 WG Engine hood switch
13 GY Fog lamp switch signal 12 W Emergency lamp switch
14 - - 13 VG Rear right door stopper switch
15 - - 14 VW Rear left door switch
16 - - 15 - -
16 - -
LIFAN AUTO
On-Vehicle check
1. Check windshield wiper and washer switch
(a). Connect two pointers of the resistance position of a digital
multimeter with 3 and No.6 terminals of wiper switch
connector I05, respectively.
(b). Turn the switch to WASHING, HI, LO, INT, OFF, MIST,
and then read corresponding resistance value. The resistance
value shall increase progressively. In addition, the resistance
value at LO and MIST shall be equal.
(c). Connect two pointers of the resistance position of a digital
multimeter with No.5 and No.6 terminals of wiper switch
connector I05.
(d). Turn wiper speed regulation to 1, 2, 3, 4, read corresponding
resistance value. The resistance value shall decrease in turn.
If the resistance value does not conform to requirements,
replace with a new combination lever assembly.
2. Check washing pump assembly

(a). Connect the battery positive electrode (+) with No.2
terminal of washing pump.
(b). Connect the battery negative electrode (-)No.1 terminal of
washing pump.
(c). Check if washing fluid flows from water outlet of washing
pump assembly. If no washing fluid flows out, replace with
86
a new washing pump assembly.
Attention:
This operation shall be completed in a short time to avoid
damaging washing pump assembly. If necessary, add a proper
amount of fluid into the reservoir.
LIFAN AUTO
3. Check wiper motor assembly

(a). Check working conditions at low speed.
Connect the battery positive electrode with No.3 terminal of
wiper motor, the negative electrode with No.4 terminal, the
motor shall run at low speed.
(b). Check working conditions at high speed.

Connect the battery positive electrode with No.5 terminal of
wiper motor, the negative electrode with No.4 terminal, the
motor shall run at high speed.
(c). Check that the wiper stops automatically

• Connect the battery positive electrode with No.3
terminal of wiper motor, the negative electrode with
No.4 terminal. Wiper blade stops at any other position
except automatic stop position.
• Connect wire with No.3 and No.4 terminals of wiper
motor, the battery positive and No.1 terminal of wiper
motor, wiper motor shall go on running at low speed.
Wiper blade shall stop at automatic stop position.
LIFAN AUTO
Wiper and Washer System-Troubleshooting 86-9
Troubleshooting
these parts.

Wiper and washer system circuit)
does not operate
3. Combination lever (damaged) Replace.
4. FBCM (damaged) Replace.

circuit)
Only front wiper HI position
does not work 2. Front wiper motor (damaged) Replace.

circuit)
Only front wiper LO
position does not work 2. Front wiper motor (damaged) Replace.

circuit)
Only front wiper washing
Position does not work 2. Front washing motor (damaged) Replace.

circuit)
Wiper arm cannot reset or
the position is not correct
(windshield wiper is turned
2. Front wiper motor (damaged) Replace. 86
off) 3. FBCM (damaged) Replace.
4. Wiper arm (installation is incorrect) Reinstall them.
1. Wo r m ( r u s t o r i n s u f f i c i e n t
Replace windshield wiper assembly
lubrication)
Abnormal noise of wiper 2. Connecting rod (worn or deformed) Replace windshield wiper linkage assembly
3. Wi p e r b l a d e ( r u b b e r a g e d o r
Replace wiper blade assembly
cracked)
1. Windscreen (oil stain or wax) Wiper off
2. Washing fluid ( poor quality) Replace high quality washing fluid
3. Wiper blade ( wrong model) Replace the same type of wiper blade assembly
Wiping result is poor
4. Wi p e r b l a d e ( r u b b e r a g e d o r
Replace wiper blade assembly
cracked)
5. Wiper arm (deformed or damaged) Replace.
6. Wiper arm (spring force decreases) Replace.
LIFAN AUTO
86-10 Wiper and Washer System-Troubleshooting
1. Washing fluid (insufficient) Fill washing fluid
2. Washing fluid (frozen)
Washing fluid is not injected 3. Washing fluid hose (damaged or

Dredge or replace it
or injected weakly blocked)
4. Nozzle (blocked) Dredge or replace it
5. washing pump assembly (damaged) Replace.
Injecting area of washing Adjustment (See Chapter 86 Wiper and Washing System-
1. Nozzle (adjustment required)
fluid is not correct Nozzle, Adjustment)
The whole front wiper and washing system does not work
Check system
• Turn ignition switch to ON and check if wiper and washing system works normally.
Check fuse
• Examine the fuse FS13 of wiper, to see whether it is broken.
Check power source for broken circuit

3 • Disconnect FBCM connector I20, central control box connector I1F of the cab. To Step 4 To Step 10
• Check if the resistance between 1No.3 terminal of I20 and 1No.3 terminal of I1F is less
Check if power supply circuit is short

4 • Disconnect FBCM connector I20. To Step 5 To Step 10
• Check if the resistance between 1No.3 terminal of I20 and the grounding is more than
1MΩ with the resistance position of a digital multimeter.

5 • Refer to check method of combination lever in check on the vehicle to check if To Step 6 To Step 8
combination lever works normally.
Replace FBCM
6 To Step 10
Replace fuse

8 To Step 10
Check harness
9 To Step 10
LIFAN AUTO
Only front wiper HI position does not work

Check system
1 To Step 2
• Turn ignition switch to ON, turn wiper switch to HI position, and check if the wiper runs
at high speed.
Check Harness for broken circuit

• Disconnect front wiper motor connector U15, FBCM connector I20.
• Check if the resistance between No.5 terminal of U15 and 2No.5 terminal of I20 is less
Check Harness for short circuit

• Disconnect front wiper motor connector U15.
• Check if the resistance between No.5 terminal of U15 and the grounding more than 1MΩ
Check wiper motor

4 • Refer to the on-vehicle Check on wiper operation at high speed. Check whether the front To Step 5 To Step 7
wiper motor operates normally at high speed.
Replace FBCM
5 To Step 8
Check harness
6 To Step 8
Replace front wiper motor

7 To Step 8
• Referring to the repair manual, replace the wiper motor.
Only front wiper LO position does not work 86
Check system
1 To Step 2
• Turn ignition switch to ON, turn wiper switch to LO position to check if the wiper runs
at low speed.

• Check if the resistance between No.3 terminal of U15 and 2No.4 terminal of I20 is less

• Check if the resistance between No.3 terminal of U15 and the grounding is more than
1MΩ with the resistance position of a digital multimeter.
Check front wiper motor

4 • Refer to the on-vehicle Checkion on wiper operation at low speed. Check whether the To Step 5 To Step 7
wiper motor operates normally at low speed.
LIFAN AUTO
Replace FBCM
5 To Step 8
Check Harness
6 To Step 8

7 To Step 8
Only front wiper washing position does not work

Check system
1 To Step 2
• Turn ignition switch to On and windshield wiper to washing position and check if
washing motor works normally.

• Disconnect front washing motor connector U18, FBCM connector I20.
• Check if the resistance between No.2 of U18 and 1No.1 terminal of I20 less than 2Ω

• Disconnect front washing motor connector U18.
• Check if the resistance between No.2 of U18 and the grounding is more than 1MΩ with
the resistance position of a digital multimeter.

• Disconnect front washing motor connector U18.
• Check if the resistance between No.1 of U18 and the grounding is less than 2Ω with the
Check front washing motor

5 • Refer to check method of working conditions for front washing motor in check on the To Step 6 To Step 8
vehicle to check if front washing motor works normally.
Replace FBCM
6 To Step 9
Check harness
7 To Step 9
Replace front washing motor

8 To Step 9
• Referring to the repair manual, replace the washer motor.
LIFAN AUTO
Wiper arm cannot reset or the position is not correct (windshield wiper is
turned off)
Check wiper arm Reinstall

1 To Step 2
• Check if wiper arm is installed properly. them.

• Check if the resistance between No.1 of U15 and No.8 terminal of I19 is less than 2Ω

• Check if the resistance between No.1 of U15 and the grounding is more than 1MΩ with
the resistance position of a digital multimeter.
Check front wiper motor

Repeat the
4 • Refer to check method of working conditions for wiper automation stop in check on the To Step 6
above steps
vehicle to check if automatic stop function of front wiper motor works normally.
Check harness
5 To Step 7

6 To Step 7
Wiping result is poor

Check windshield 86
• Check if the windshield has oil stain or wax.
Check washing fluid

• Check if there is impurity or oil in washing fluid.
Check wiper blade

3 • Check if wiper blade model matches with the windshield. To Step 5 To Step 4
• Check if wiper blade rubber is aged or cracked.
Check wiper arm

4 • Check if wiper arm is deformed or damaged. To Step 5
• Check if wiper arm spring force decreases.
LIFAN AUTO
Washing fluid is not injected or injected weakly

Check washing fluid

1 • Check if washing fluid in washer fluid reservoir is insufficient. To Step 4 To Step 2
• Check if washing fluid in washer fluid reservoir is frozen.
Check washing hose

• Check if washing hose is damaged or blocked.
Check nozzle
3 To Step 4
• Check if nozzle is blocked.
Injecting area of washing fluid is not correct

Check nozzle
1 • Check if the direction of nozzle spraying is wrong. To Step 2
• Check if nozzle is blocked.
LIFAN AUTO
Wiper and Washer System-Wiper 86-15
Wiper
Replace
1. Remove wiper arm assembly
(a). Turn on windshield wiper to INT / LO / HI positions to
swing wiper assembly.
Warning:
Do not turn on windshield wiper when front windshield
assembly is dry to avoid damaging front windshield assembly.
△ Hint:
Refer to Operation Manual for LIFAN 720 vehicle.
(b). Turn windshield wiper to OFF position to make wiper
assembly reset automatically.
(c). Remove wiper cap.
86
(d). Remove the wiper arm fixed nut.
LIFAN AUTO
86-16 Wiper and Washer System-Wiper
(e). Remove the wiper arm and blade assembly.

△ Hint:
Turn up wiper arm assembly. Shake wiper arm to remove it.
2. Install wiper arm assembly

(a). Clean the splined hole of wiper arm with a round file or
equivalent.
(b). Using a steel wire, clean the spline shaft of the wiper link.
(c). Place the wiper arm and blade assembly in position.

△ Hint:
• The left wiper blade assembly shall be located on lower
edge of front windshield assembly.
• Turn up the wiper arm and blade assembly, then place it in
position.
LIFAN AUTO
Wiper and Washer System-Wiper 86-17
(d). Tighten the wiper arm fixed nut to the specified torque.
(e). Install wiper blade cap.

△ Hint:
• After installing, turn down the left wiper arm and wiper
blade assembly.
• Confirm wiper blade assembly is located on the lower edge
of front windshield assembly.
86
(f). Make sure the left wiper assembly of wiper returns

automatically.
• Turn on windshield wiper to INT / LO / HI positions to
swing wiper blade assembly.
Warning:
Do not turn on windshield wiper when front windshield
assembly is dry to avoid damaging front windshield assembly.
• Turn off windshield wiper to OFF position to return wiper
blade assembly automatically.
• Check if the left wiper blade assembly is located on lower
edge of front windshield assembly.
LIFAN AUTO
86-18 Wiper and Washer System-Wiper link assembly
Wiper link assembly

Replacement
1. Remove wiper link with motor assembly
(a). The wiper assembly returns automatically to OFF position.
(b). Open engine hood and use a support bar to support it.
(d). Dismantle main and auxiliary wiper arm and wiper blade
assembly.
(e). Dismantle cover plates on both sides of cowl top grille.
(f). Dismantle fixed snap-fits of cowl top grill and remove it

away.
LIFAN AUTO
Wiper and Washer System-Wiper link assembly 86-19
(g). Disconnect wiper motor assembly wire harness connector.
(h). Dismantle fixed bolts of wiper linkage and motor assembly.
86
(i). Remove wiper linkage and motor assembly.

Attention:
Handle and store wiper motor assembly with care. Do not
move wiper linkage assembly at random.
LIFAN AUTO
2. Disassemble wiper linkage and motor assembly

(a). Dismantle fixed nuts of wiper motor and connecting rod
swing arm.
(b). Dismantle fixed bolts of wiper motor and connecting rod.
(c). Remove wiper motor assembly.
3. Install wiper linkage and motor assembly

(a). Install fixed bolts of wiper motor and connecting rod.
Torque: 8 ~ 12N•m
(b). Install fixed nuts of wiper motor and connecting rod swing
arm.
Torque: 8 ~ 12N•m
LIFAN AUTO
Wiper and Washer System-Wiper link assembly 86-21
4. Install wiper linkage and motor assembly

(a). Install wiper linkage assembly.
(b). Install fixed bolts of wiper linkage and motor assembly.

Torque: 8 ~ 12N•m
86
(c). Connect wiper motor assembly wire harness connector.

Attention:
connected in place.
LIFAN AUTO
(d). Install front cowl top grille and fixing snap-fit.

(e). Install main and auxiliary wiper arm and wiper blade
assembly.
(g). Check automatic return of wiper assembly.
(h). Install cover plates on both sides of front cowl top grille
LIFAN AUTO
Wiper and Washer System-Windshield washer fluid reservoir 86-23
Windshield washer fluid reservoir

Replace
1. Dismantle windshield washer assembly
(b). Dismantle right front wheel mudguard (See Chapter 81
Interiors and Exteriors – Mudguard, Replacement).
(c). Disconnect washer fluid reservoir assembly connector.
(d). Pull down water outlet pipe of washing pump.
86
(e). Dismantle fixed bolts of windshield washer fluid reservoir

assembly.
LIFAN AUTO
86-24 Wiper and Washer System-Windshield washer fluid reservoir
(f). Dismantle fixed bolts of filling port for windshield washer

fluid reservoir.
(g). Remove windshield washer fluid reservoir assembly.
(h). Remove washing pump.
LIFAN AUTO
Wiper and Washer System-Windshield washer fluid reservoir 86-25
2. Install windshield washer fluid reservoir assembly

(a). Install windshield washer fluid reservoir assembly and fixed
bolts, tighten them to specified torque.
Torque: 8 ~ 12N•m
(b). Install fixed bolts of filling port for windshield washer fluid
reservoir; tighten them to specified torque.
Torque: 8 ~ 12N•m
Attention:
When installing, apply antifreeze solution on filling port seal
ring of washer fluid reservoir to prevent damaging filling port
seal ring of washer fluid reservoir.
86
(c). Install washing pump assembly.
LIFAN AUTO
86-26 Wiper and Washer System-Windshield washer fluid reservoir
(d). Connect washing pump assembly wire harness connector.

Attention:
connected in place.
(e). Install water outlet pipe of washing pump.

(f). Install right front wheel mudguard (See Chapter 81 Interiors
and Exteriors- Mudguard, Replacement).
(g). Install the battery negative electrode cable.
LIFAN AUTO
Wiper and Washer System-Wiper blade 86-27
Wiper Blade
Replace
1. Remove wiper blade
(a). Turn up the wiper arm assembly.
(b). Rotate the wiper blade. Push out the wiper arm connecting
part. Remove the wiper blade assembly.
86
2. Install wiper blade

(a). Install wiper blade assembly.
△ Hint:
If you hear a click, it means the wiper blade assembly is installed
in place.
(b). Turn down the wiper arm assembly.
LIFAN AUTO
86-28 Wiper and Washer System-Nozzle
Nozzle
Adjustment
1. Check nozzle spray range

(a). Turn on the front washer switch. Check whether fluid is
sprayed at the specified position on windscreen.
△ Hint:
2. Adjust the working range of nozzle assembly
(a). Use a needle or similar object to insert water injection
nozzle to keep it smooth until the nozzle sprays smoothly.
(b). Adjust up nozzle assembly position by hand until spraying
range conforms to the standard.
Nozzle of driver’s side Nozzle of front passenger’s side
Replace
1. Remove washer nozzle

(b). Pull out washing nozzle.
LIFAN AUTO
Wiper and Washer System-Nozzle 86-29
(c). Disconnect the nozzle and washing hose.

(d). Remove the nozzle.
2. Install washer nozzle

(a). Connect the nozzle and washing hose.
(b). Install the washer nozzle.
86
LIFAN AUTO
Rear window defroster

Inspection
1. Check method
Wind tinfoil on the side of a multimeter test probe to
prevent damaging heater strip. Press the tinfoil by hand,
move it along grille line to check if there is open circuit.
Test probe
Tinfoil
Heating wire
2. Check heating wire of rear window defroster

(a). Turn on defroster switch and measure the voltage of each
heating wire at the middle of the glass with a multimeter.
If the voltage is about 6V, it means heating wire of rear
window is normal.
(b). If there is open circuit between central point and positive

electrode, the voltage will be displayed as 12V.
LIFAN AUTO
Wiper and Washer System-Nozzle 86-31
(c). If there is open circuit between central point and negative

electrode, the voltage will be displayed as 0V.
(d). After it is confirmed which side has open circuit, you can
move test probe along this direction until you find that
voltage occurs or the voltage changes to 0V at a certain
point. This point is open circuit point.
86
(e). Measure the resistance between the terminal and grille

wire center, the terminal and adjacent heating wire with
an ohmmeter. The resistance of the circuit with breaking
point is twice of other circuit resistance. Move test probe on
affected part until the resistance at a certain point changes
sharply.
LIFAN AUTO
3. Repair heating wire of rear window defroster

(a). Prepare repairing materials:
Conductor paint, paint thinner, masking tape, silicon resin remover.
(b). Repairing method:
Use a fine brush to remove the glass near heating strip with breaking point; clean it with silicon resin remover
and attach masking tape as shown in the Fig. Shake conducting paint container to mix conducting paint
uniformly, brush it once every 15min. Brush three times totally. Before power on, tear down the tape and ensure
the paint becomes dry. It is better to use a knife to scrape off excessive sediment (about 24h) after the paint
become dry completely.
Attention:
After repairing, dry and soft cloth is used to clean the glass or wipe along grille wire direction with a wet cloth.
LIFAN AUTO
01
Index
(Arranged in alphabetical order)...
Complete vehicle
A B104011 (Troubleshooting) …………………… 83-17
B104015 (Troubleshooting) …………………… 83-17
ABS artificial exhaust (Anti-lock braking system) 53-28 B104115 (Troubleshooting) …………………… 83-17
ABS diagnostic description (Troubleshooting) … 53-10 B104211 (Troubleshooting) …………………… 83-18
ABS indicator light stays constantly bright or fails to B104215 (Troubleshooting) …………………… 83-18
illuminate (Troubleshooting) …………………… 53-22
Adjustment (Brake pedal) ……………………… 51-11
Adjustment (Door lock buckle) ………………… 82-13
Adjustment (Door) ……………………………… 82-4
Adjustment (Driver seat)………………………… 84-5
Adjustment (Engine hood) ……………………… 82-29
Adjustment (Exterior rearview mirror) ………… 83-39
Adjustment (Front fog lamp) …………………… 77-63
Adjustment (Front headlamp) …………………… 77-48
Adjustment (Front passenger's seat) …………… 84-11
Adjustment (Interior rearview mirror) ………… 83-37
Adjustment (Nozzle) …………………………… 86-28
Adjustment (Parking brake control) …………… 52-12
Adjustment (Rear seat) ………………………… 84-12
Adjustment (Steering wheel) …………………… 62-6
All center control locks don't work.
(Troubleshooting) ………………………………73-14
All power windows do not work (Troubleshooting) 83-20
B
LIFAN AUTO
02
B190800 (Troubleshooting) …………………… 71-46 Check (Horn switch) …………………………… 78-13

B190900 (Troubleshooting) …………………… 71-47 Check (License lamp) …………………………… 77-83
Basic check (Troubleshooting) ………………… 75-11 Check (Rear ceiling light) ……………………… 77-77
Brake lamp does not come on (Troubleshooting) 77-46 Check (Tail lamp) ……………………………… 77-57
Brake system fault warning lamp cannot be illuminated / Check (Rear right door locking device) ………… 73-21
stays on. (Troubleshooting)……………………… 75-21
Check (Rear Seat belt) ………………………… 72-53
Check (Rear trunk lid locking device) ………… 73-22
C Check (Rear window defroster) ………………… 86-30
Check (Rear-mounted speaker) ………………… 74-26
Check (Reverse radar sensor) …………………… 76-18
C001004,C001104,C001404,C001504,C001804,
Check (Reversing switch) ……………………… 76-16
C001904,C001C04,C001D04,C109504,C007208
(Troubleshooting) ……………………………… 53-18 Check (Rear left door locking device) ………… 73-20
C002004 (Troubleshooting) …………………… 53-19 Check (Side turn signal lamp)…………………… 77-68
C003108,C00A900,C003408,C00AA00, Check (Step lamp) ……………………………… 77-70
C003200,C00A000,C00A100,C00A900,C03500, Check (Trunk light) ……………………………… 77-81
C00A200,C00A300,C00AA00,C003800, Cigarette lighter does not operate
C00A400,C00A500,C00AB00,C003B00, (Troubleshooting) …………………………… 78-19
C00A600,C00A700,C00AC00,C109904
Components diagram (brake control ) (Service
brake) ……………………………………………51-5
C003708,C00AB00, C003A08,C00AC00,C006B06
Components diagram (A/C System) …………… 71-6
Components diagram (Audio entertainment
C100004,C101008 (Troubleshooting) ………… 53-21
system) ……………………………………… 74-3
C109904 (Troubleshooting) …………………… 53-20
Components diagram (Brake line) (Service brake) 51-4
C190004,C190104 (Troubleshooting) ………… 53-18
Components diagram (Cigarette lighter and standby power
CD cannot be inserted or pop up after inserting. supply)…………………………………………… 78-15
Components diagram (Console)) (Dashboard and
CD cannot be taken out (Troubleshooting) ……… 74-13 console) ………………………………………… 85-3
CD skipping (Troubleshooting) ………………… 74-13 Components diagram (dashboard) (Dashboard and
console) ………………………………………… 85-2
Check (Parking brake control) ………………… 52-5
Components diagram (Driver information system) 75-6
Check (Refrigerant) …………………………… 71-49
Components diagram (Front brake) …………… 51-22
Check (Steering pipe column) ………………… 62-12
Components diagram (front lamps) (Lighting
Check (Alt speaker horn) ……………………… 74-20
system) …………………………………………77-4
Check (Antenna) ………………………………… 74-28
Components diagram (Front power window) …… 83-26
Check (Compound horn)………………………… 78-10
Components diagram (Front seat) (Seats) ……… 84-2
Check (Front ceiling light) ……………………… 77-73
Components diagram (Horn system) …………… 78-2
Check (Front fog lamp) ………………………… 77-63
Components diagram (Interior rearview mirror) 83-36
Check (Headlamp) ……………………………… 77-49
Components diagram (Parking brake) ………… 52-2
Check (Front left door lockout mechanism) …… 73-18
Components diagram (Power steering) ………… 61-3
Check (Front right door lockout mechanism) …… 73-19
Components diagram (Rear brake) ……………… 51-29
Check (Front Seat belt) ………………………… 72-47
Components diagram (rear lamps) (Lighting
Check (Front speaker) …………………………… 74-23 system) ……………………………………… 77-5
Check (High-mounted brake lamp) …………… 77-80 Components diagram (Rear power window) …… 83-31
LIFAN AUTO
03
Components diagram (Rear seat) (Seats) ……… 84-3 Front ceiling lamp is lit but rear ceiling lamp is not lit
Components diagram (Remote control central lock
system) ………………………………………… 73-4 front ceiling lamp is not lit but rear ceiling lamp is lit
Components diagram (Reversing radar system) … 76-4
Front fog lamp and rear fog lamp are not lit
Components diagram (Seat belt)………………… 72-45
Components diagram (Steering mechanism) …… 62-3
Front fog lamp is lit but rear fog lamp is not lit
Components diagram (Wiper and washer system) 86-3 (Troubleshooting) ……………………………… 77-44
Cross validation (ABS hydraulic regulator) …… 53-26 Front fog lamp on one side is not lit
Fuel gauge malfunction (Troubleshooting)……… 75-19
D
H
Description (Driver information system ………… 75-3
Determination of seat noise (Troubleshooting) … 84-4
High beam on one side is not lit (Troubleshooting) 77-37
Diagnostic Steps (Troubleshooting) …………… 53-10
Horn does not sound (Troubleshooting) ………… 78-6
Diagnostic Steps (Troubleshooting) …………… 77-23
Horn stays on (Troubleshooting) ……………… 78-8
Dipped headlight on one side is not lit
(Troubleshooting) ……………………………… 77-39 Hydraulic schematic diagram (Anti-lock braking
system) …………………………………………53-4
Display doesn't show or show incorrectly.
Disposal (Driver airbag) ………………………… 72-31 I
Disposal (Passenger airbag) …………………… 72-38
Distribution map (Airbag) ……………………… 72-6
Drain (Brake fluid) ……………………………… 51-20 Initial Check. (Anti-lock braking system) ……… 53-8
DTC (DTC) list (Troubleshooting) ……………… 53-14 Injecting area of washing fluid is not correct
Instrument background lighting lamp does not come on.
Interior dimming lamp is not lit (Troubleshooting) 77-39
Interior lamps do not light (Troubleshooting)…… 77-40
L
E
Left brake lamp is lit but right brake lamp is not lit
Exhaust (Brake fluid) …………………………… 51-21 (Troubleshooting) ……………………………… 77-46
Left rearview mirror does not work in left/right direction
F
Left rearview mirror does not work
Fasten-front-passenger-seat-belt warning lamp cannot be

illuminated/stays on. (Troubleshooting) ………… 75-22
LIFAN AUTO
04
N On-Vehicle check (Steering mechanism) ……… 62-4

On-Vehicle check (Wiper and washer system) … 86-7
Operating principle (A/C System) ……………… 71-8
Neither high beam lamp comes on Overhaul (Air-conditioning Compressor) ……… 71-65
Overhaul (Condenser and drying tank assembly) 71-71
Neither low beam lamp comes on
Overhaul (Radio) ……………………………… 74-15
Neither of power rearview mirrors on both sides works
(Troubleshooting) ……………………………… 83-20 P
None instrument operates (Troubleshooting) …… 75-17
O Parking brake indicator lamp does not come on or stay on

Parts identification (A/C System) ……………… 71-19
Passenger Seat belt indicator doesn't light up/ constantly
Oil pressure warning lamp cannot be illuminated / stays
lights up (Troubleshooting) ……………………… 75-23
on. (Troubleshooting) …………………………… 75-20
Play CD with poor tone quality (Troubleshooting) 74-9
Only front left door central lock is invalid
(Troubleshooting) ……………………………… 73-15 Play radio with poor tone quality (Troubleshooting) 74-10
Only front right door central lock is invalid Precautions (A/C System) ……………………… 71-4
Precautions (Airbag) …………………………… 72-4
Only front wiper HI position does not work
Precautions (Anti-lock braking system) ………… 53-2
Precautions (Audio system) …………………… 74-2
Only front wiper LO position does not work
(Troubleshooting) ……………………………… 86-11 Precautions (Dashboard and console) …………… 85-1
Only front wiper washing Position does not work Precautions (Door and lock) …………………… 82-2
(Troubleshooting) ……………………………… 86-12 Precautions (Interior and exterior trims) ………… 81-2
Only rear right door central lock is invalid Precautions (Lighting system) ………………… 77-3
Precautions (Parking brake) …………………… 52-1
Only Right left door central lock is invalid
(Troubleshooting) ……………………………… 73-16 Precautions (Power steering) …………………… 61-2
Only the bass horn is soundless. (Troubleshooting) 78-9 Precautions (Power window and rearview mirror) 83-1
Only the tweeter is soundless. (Troubleshooting) 78-8 Precautions (Remote control central lock system) 73-3
On-Vehicle check (A/C System) ………………… 71-23 Precautions (Reversing radar system) …………… 76-3
On-Vehicle check (Airbag) ……………………… 72-11 Precautions (Seat belt) ………………………… 72-44
On-Vehicle check (Audio system) ……………… 74-7 Precautions (Service brake) …………………… 51-3
On-Vehicle check (Cigarette lighter and standby power Precautions (Steering mechanism) ……………… 62-2
supply)…………………………………………… 78-18 Precautions (Wiper and washer system) ………… 86-2
On-Vehicle check (Horn system) ……………… 78-5 Pre-check (Troubleshooting) …………………… 72-14
On-Vehicle check (Lighting system) …………… 77-21 Preparation (A/C System) ……………………… 71-1
On-Vehicle check (Parking brake) ……………… 52-3 Preparation (Airbag) …………………………… 72-1
On-Vehicle check (Power steering) …………… 61-5 Preparation (Anti-lock braking system) ………… 53-1
On-Vehicle check (Remote control central lock Preparation (Audio system) …………………… 74-1
system) …………………………………………73-12
Preparation (Cigarette lighter and standby power
On-Vehicle check (Reversing radar system) …… 76-8 supply) ………………………………………… 78-14
On-Vehicle check (Service brake) ……………… 51-6
LIFAN AUTO
05
Preparation (Door and lock) …………………… 82-1 Rear left-view mirror can't work in UP/DOWN directions.
Preparation (Driver information system) ……… 75-1
Refilling (Brake fluid)…………………………… 51-20
Preparation (Horn system) ……………………… 78-1
Repair Specifications (Airbag) ………………… 72-3
Preparation (Interior and exterior trims) ………… 81-1
Repair Specifications (Anti-lock braking system) 53-1
Preparation (Lighting system)…………………… 77-1
Repair specifications (Audio system) …… 74-1
Preparation (Parking brake) …………………… 52-1
Repair Specifications (Cigarette lighter and standby power
Preparation (Power steering) …………………… 61-1
supply)…………………………………………… 78-14
Preparation (Power window and rearview mirror) 83-1
Repair Specifications (Dashboard and console) … 85-1
Preparation (Remote control central lock system) 73-1
Repair Specifications (Door and Lock) ………… 82-2
Preparation (Reversing radar system) …………… 76-1
Repair Specifications (Driver Information System) 75-2
Preparation (Seat belt)…………………………… 72-43
Repair Specifications (Horn system) …………… 78-1
Preparation (Service brake)……………………… 51-1
Repair Specifications (Interior and exterior trims) 81-2
Preparation (Steering mechanism) ……………… 62-1
Repair Specifications (Lighting system)………… 77-2
Preparation (Wiper and washer system) ………… 86-1
Repair Specifications (Power steering) ………… 61-2
Problem Symptoms Table (Troubleshooting) …… 53-17
Repair Specifications (Power window and rearview
Problem Symptoms Table (Troubleshooting) …… 62-5 mirror) …………………………………………… 83-1
Problem Symptoms Table (Troubleshooting) …… 71-38 Repair Specifications (Remote control central lock
system) ………………………………………… 73-2
Repair Specifications (Reversing radar system) … 76-2
Repair Specifications (Seat belt) ………………… 72-44
Repair Specifications (Seats) …………………… 84-1
Repair Specifications (Service brake) …………… 51-2
Repair Specifications (Steering mechanism) …… 62-2
Repair Specifications (Wiper and washer system) 86-2
Replace (A-pillar panel) ………………………… 81-7
Replace (ABS hydraulic regulator) ……………… 53-26
Replace (Airbag ECU) ………………………… 72-25
Replace (Alt speaker horn) ……………………… 74-21
Replace (Antenna) ……………………………… 74-29
Replace (B-pillar panel) ………………………… 81-9
Replace (Brake line) …………………………… 51-38
Replace (Brake master cylinder) ………………… 51-14
Replace (Brake pedal) …………………………… 51-12
R
Replace (C-pillar panel) ………………………… 81-13
Replace (Carpet) ………………………………… 81-31
Replace (Central display) ……………………… 75-28
Read and clear DTCs (Troubleshooting) ……… 53-10
Replace (Cigarette lighter) ……………………… 78-21
Replace (Clock spring) ………………………… 72-39
Replace (Combination lever) …………………… 62-9
Replace (Compound horn) ……………………… 78-11
Replace (Console) ……………………………… 85-24
LIFAN AUTO
06
Replace (dashboard) …………………………… 85-18 Replace (Tail lamp) ……………………………… 77-58

Replace (Door hinge and check) ………………… 82-9 Replace (Rear compartment door lock) ………… 82-33
Replace (Door lock buckle) …………………… 82-14 Replace (Rear door inside guard board) ………… 81-20
Replace (Door) ………………………………… 82-5 Replace (Rear door lock) ……………………… 82-22
Replace (Driver airbag) ………………………… 72-28 Replace (Rear doorsill trim panel) ……………… 81-6
Replace (Driver seat) …………………………… 84-7 Replace (Rear power window) ………………… 83-32
Replace (Exterior rearview mirror) ……………… 83-39 Replace (Rear right door locking device) ……… 73-21
Replace (Front brake) …………………………… 51-23 Replace (Rear seat belt) ………………………… 72-53
Replace (Front bumper) ………………………… 81-45 Replace (Rear seat) ……………………………… 84-12
Replace (Front ceiling light) …………………… 77-73 Replace (Rear trunk lid locking device) ………… 73-22
Replace (Front compartment door lock) ………… 82-31 Replace (Rear trunk lid) ………………………… 82-32
Replace (Front door inside guard board) ……… 81-16 Replace (Rear windshield) ……………………… 81-42
Replace (Front door lock) ……………………… 82-15 Replace (Rear-mounted speaker) ……………… 74-26
Replace (Front doorsill trim panel) ……………… 81-5 Replace (Refrigerant) …………………………… 71-53
Replace (Front fog lamp) ……………………… 77-64 Replace (Reverse radar sensor) ………………… 76-19
Replace (Front headlamp) ……………………… 77-50 Replace (Reversing switch) …………………… 76-16
Replace (Front left door lockout mechanism) … 73-18 Replace (Right left door locking device) ……… 73-20
Replace (Front passenger's seat) ………………… 84-11 Replace (Safety handle and roof) ……………… 81-24
Replace (Front power window) ………………… 83-27 Replace (Side turn signal lamp) ………………… 77-68
Replace (Front right door lockout mechanism) … 73-19 Replace (Standby power supply) ……………… 78-24
Replace (Front seat belt) ………………………… 72-49 Replace (Steering gear) ………………………… 61-12
Replace (Front speaker) ………………………… 74-24 Replace (Steering pipe column) ………………… 62-12
Replace (Fuel filler cap) ………………………… 81-50 Replace (Steering wheel) ……………………… 62-6
Replace (Glove box) …………………………… 85-17 Replace (Step lamp) …………………………… 77-70
Replace (High-mounted brake lamp) …………… 77-80 Replace (Sunvisor) ……………………………… 81-3
Replace (Horn switch) ………………………… 78-13 Replace (Trunk light) …………………………… 77-81
Replace (HVAC assembly) ……………………… 71-58 Replace (Vacuum booster) ……………………… 51-17
Replace (Instrument assembly) ………………… 75-25 Replace (Wheel speed sensors) ………………… 53-23
Replace (Interior rearview mirror) ……………… 83-38 Replace (Windscreen) …………………………… 81-37
Replace (License lamp) ………………………… 77-83 Replace (Windshield washer fluid reservoir) …… 86-23
Replace (Lower left panel of the dashboard) …… 85-4 Replace (Wiper blade) ………………………… 86-27
Replace (Lower right panel of the dashboard) … 85-9 Replace (Wiper link assembly) ………………… 86-18
Replace (Mudguard) …………………………… 81-49 Replace (Wiper) ………………………………… 86-15
Replace (Nozzle) ………………………………… 86-28 Right rearview mirror does not work in left/right direction
Replace (Parking brake control) ………………… 52-5
Right rearview mirror does not work in up/down direction
Replace (Passenger airbag) ……………………… 72-35
Replace (Power steering oil pump) ……………… 61-10
Right rearview mirror does not work
Replace (Rear brake) …………………………… 51-30 (Troubleshooting) ………………………………83-21
Replace (Rear bumper) ………………………… 81-47
Replace (Rear ceiling light) …………………… 77-77
LIFAN AUTO
07
S The system will work without shifting to Reverse

Position. (Troubleshooting) …………………… 76-13
The system won't work completely.
Speaker is mute (All speakers are mute)
The whole front wiper and washing system does not work
Speaker is mute (Individual speaker is mute)
Trunk light do not lighting (Troubleshooting) … 77-42
Standby power supply doesn't work.
(Troubleshooting) ………………………………78-20 U
System components (Anti-lock braking system) 53-3
System Description (Airbag) …………………… 72-10
System Description (Anti-lock braking system) … 53-8 U000500,U000700,C100104,U000104,
System Description (Parking brake) …………… 52-3 U100104 (Troubleshooting) …………………… 53-21
System Description (Power steering) …………… 61-4 Unable to receive radio broadcast
System Description (Reversing radar system) … 76-5
System Description (Service brake) …………… 51-6
System Description (Steering mechanism) ……… 62-4 V
System fault diagnosis (Troubleshooting) ……… 71-32
System Maintenance (A/C System) …………… 71-18
Volume of sound is small in all modes
T
Terminal definition (A/C System) ……………… 71-14

Terminal definition (Airbag) …………………… 72-8
Washing fluid is not injected or injected weakly
Terminal definition (Anti-lock braking system) … 53-7 (Troubleshooting) ……………………………… 86-14
Terminal definition (Audio system) …………… 74-6 When shifting to reverse position, the system will not
work (Troubleshooting) ………………………… 76-14
Terminal definition (Cigarette lighter and standby power
supply)…………………………………………… 78-17 Width lamp and license plate lamp are not lit
Terminal definition (Driver information system) 75-10
Wiper arm cannot reset or the position is not correct
Terminal definition (Horn system) ……………… 78-4
(windshield wiper is turned off) (Troubleshooting) 86-13
Terminal definition (Power window and rearview
Wiping result is poor (Troubleshooting) ………… 86-13
mirror) …………………………………………… 83-8
Wiring diagram (A/C System) ………………… 71-11
Terminal definition (Remote control central lock
system) ………………………………………… 73-10 Wiring diagram (Airbag) ……………………… 72-7
Terminal definition (Reversing radar system) … 76-7 Wiring diagram (Anti-lock braking system) …… 53-5
Terminal definition (Wiper and washer system) … 86-5 Wiring diagram (Audio Entertainment System) … 74-4
The display indicates and buzzes abnormally. Wiring diagram (Cigarette lighter and standby power
(Troubleshooting) ……………………………… 76-15 supply)…………………………………………… 78-16
The self-checking system is abnormal. Wiring diagram (Driver Information System) … 75-7
Wiring diagram (Horn system) ………………… 78-3
The system does not work (Troubleshooting)…… 74-9
Wiring diagram (Lighting system) ……………… 77-6
LIFAN AUTO
08
Wiring diagram (Power window and rearview

mirror) …………………………………………83-2
Wiring diagram (Remote control central lock
system) …………………………………………73-5
Wiring diagram (Reversing radar system) ……… 76-6
Wiring diagram (Wiper and washer system) …… 86-4
LIFAN AUTO

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Service Manual

LIFAN INDUSTRY(GROUP) IMP&EXP CO.,LTD

without incurring any obligation whatsoever.

CLIFAN INDUSTRY(GROUP) IMP&EXP CO.,LTD

How to use this manual

Parts assembly relationship

Differential front bearing cover Differential gear

"Warning", "Hint", and "Attention"

Warning • Cause serious injury to the technicians.

System of international units (SI)

2. Engine model and factory number

Driving type Front-engine, front wheel drive

Overall dimensions Length × Width × Height (no load): 4700×1765×1490mm

Front wheel track 1520mm

Rear wheel track 1520mm

Front overhang 960mm

Rear overhang 1040mm

Trunk volume 620L (estimated)

Passenger number 5 people

Approach angle 19° (full load) 22° (no load)

Departure angle 15° (full load) 24° (no load)

Minimum ground clearance 130mm (full load) 170mm (no load)

Minimum turning radius 5.5m

Curb mass 1265kg

Axle load mass (front/ rear) 765/500kg

Full load mass 1690kg

Axle load mass (front/ rear) 900/790kg

Full-load axle load percentage (front/

2. Vehicle basic performance parameters

Maximum speed 180km/h

Acceleration performance (0~100km) 17s

Total fuel consumption per 100 km. 7.9L/100km

Max. grade ability % 30%

3. Engine characteristic parameters

Type In-line four-cylinder 16-valve, water cooling, double overhead camshaft

Total displacement 1794ml

Bore × stroke 79×91.5mm

Maximum power 98kW(6000r/min)

Maximum torque 168N•m(4400r/min)

Fuel supply mode Multipoint electronic-control fuel injection

Ignition type Double coil no-distributor ignition

4. Types and parameters of engine accessories and chassis main assemblies

Exhaust system Two three-way catalytic converters and 2 mufflers

Air Intake System Air intake pipeline, air filter

Cooling System Tube type radiator, electric fan

Clutch Single piece, dry, film spring

Type Five-speed manual transmission, mechanical flexible shaft operation

Gear ratio (1st) 3.182

Gear ratio (2nd gear) 1.895

Gear ratio (3rd gear) 1.250

Gear ratio (4th gear) 0.969

Gear ratio (5th gear) 0.784

Gear ratio (reversing gear) 3.133

Type Sliding bush is three-fork type, fixed end is ball type.

Speed ratio 4.308

Front suspension McPherson independent suspension

Rear suspension Torque beam non-independent suspension

Tires and wheels 01