Changhe FREEDOM CH6390 Series 2005 User manual

CHANGHE FREEDOM SERVICE MANUAL FOREWORD
FOREWORD
This manual contains procedures for diagnosis, maintenance, adjustments, minor service
operations, replacement of components (Service) and for disassembly and assembly of major
components.
Applicable model: CHANGHE FREEDOM (CH6390 series) VEHICLE
The contents are classified into sections each of which is given a section number as indicated in
the Table of Contents on following page. And on the first page of each individual section is an index of
that section. This manual should be kept in a handy place for ready reference of the service work.
When replacing parts or servicing by disassembling, it is recommended to use genuine parts, tools
and service materials as specified in each description.
All information, illustrations and specifications contained in this literature are based on the latest
product information available at the time of publication approval. And used as the main subject of
description is the vehicle of standard specifications among others.
Therefore, note that illustrations may differ from the vehicle being actually serviced.
The right is reserved to make changes at any time without notice.
JIANGXI CHANGHE AUTOMOBILE CO., LTD
© COPYRIGHT: JIANGXI CHANGHE AUTOMOBILE CO., LTD

CHANGHE FREEDOM SERVICE MANUAL INTRODUCTION
INTRODUCTION
The CH6390 series auto is a new generation vehicle developed under own R&D center of JIANGXI
CHANGHE AUTOMOBILE CO., LTD. The CH6390 auto structure is compact, flexible, safe and
comfortable, economic and applied, satisfied with statute of collision, emission and noise. It is a
multifunctional automobile that fits for safety and environment.
The CH6390 series auto is equipped with Electronic Fuel Control Injection Engine. Air bags、alnico
wheel and air condition system is optional. Consumers should verify the true equipment status in using
and service. Consumers, please caution: To your safety and the normal use of vehicle, please
don’t make bold to disassemble the air bag and interrelated. If fault occurs, you should take it to
the franchiser and the maintenance man of service station accredited by our company.
The CH6390 series auto may make changes at any time without notice.
For the mend and perfect of the manual, to service more fine, welcome you bring forward
invaluableness advice, editor will thanks a lot. As the editor’s ability is limited, to the misgivings and
discommodious service of work. Please you comment and amend, we will correct in second version.
If you have the manual, you will not worry the service. The manual will be your good assistant.
EDITOR
December 2005

CHANGHE FREEDOM SERVICE MANUAL IMPORTANT
IMPORTANT
WARNING/CAUTION/NOTE
Please read the manual and follow its
instructions carefully. To emphasize special
information, the words WARNING, CAUTION
and NOTE have special meanings. Pay special
attention to the messages highlighted by these
signal words.
WARNING:
For vehicles equipped with a supplemen-
tal Restraint or Air Bag System:
zWARNING:
Service on and around the air bag system
components or wiring must be performed
only by an authorized JIANGXI CHANGHE
AUTOMOBILE CO., LTD. Please observe all
WARNINGS 、CAUTIONS and NOTES under
“On-
V
ehicle Service” in air bag system
section before performing service on or
around the air bag system components or
wiring. Failure to follow WARNINGS could
result in unintentional activation of the
system or could render the system
inoperative. Either of these two conditions
may result in severe injury.
zIf the air bag system and another ve
-hicle system both need repair, JIANGXI
CHANGHE AUTOMOBILE CO., LTD recomme-
nds that the air bag system be repaired first,
to help avoid unintended air bag system
activation.
zDo not modify the steering wheel, in
-strument panel or any other air bag system
component on or around air bag system
components or wiring. Modifications can
adversely affect air bag system performance
and lead to injury.
zIf the vehicle will be exposed to
temperatures over 93°C (200°F), for example,
during a paint baking process, remove the air
bag system components, that is air bag or
inflator modules, SDM and/or seat belt with
pretensioner, before hand to avoid
component damage or unintended activation.
WARNING:
Indicates a potential hazard that
could result in death or in
j
ur
y
.
CAUTION:
Indicates a potential hazard that
could result in vehicle dama
g
e.
NOTE:
Indicates special information to
make maintenance easier or instru-
cttions clearer.
WARNING:
This service manual is intended
for authorized JIANGXI CHANGHE
AUTOMOBILE CO., LTD and qualify-
ed service technicians only. Inexp-
erienced technicians or technicians
without the proper tools and equip-
ment may not be able to properly
perform the services described in
this manual. Improper repair may
result in injury to the technician and
may render the vehicle unsafe for
the driver and passengers.

CHANGHE FREEDOM SERVICE MANUAL TABLE OF CONTENTS
TABLE OF CONTENTS
THE FIRST PART GENERAL INFORMATION
SECTION 1 GENERAL INFORMATION
............................................................................. 1
SECTION 2 SCHEDULED MAINTENANCE..................................................................... 22
THE SECOND PART ENGINE
SECTION 3 ENGINE
................................................................................................................. 40
SECTION 4 ENGINE MECHANICAL....................................................................................51
SECTION 5 ENGINE COOLING SYSTEM ........................................................................88
SECTION 6 ENGINE LUBRICATE SYSTEM .................................................................102
SECTION 7 ENGINE MANAGE SYSTEM
...................................................................110
THE THIRD PART CLUTCH TRANSMISSION DIFFERENTIAL
SECTION 8 CLUTCH
...............................................................................................................115
SECTION 9 TRANSMISSION
...............................................................................................124
SECTION 10 GEAR SHIFTING CONTROL
....................................................................161
SECTION 11 PROPELLER SHAFT
...................................................................................171
SECTION 12 DIFFERENTIAL
..............................................................................................177
THE FOURTH PART SUSPENSION STEERING BRAKE
SECTION 13 SUSPENSION ...................................................................................................191
SECTION 14 MANUAL RACK AND PINION ..................................................................214
SECTION 15 BRAKES
.............................................................................................................225
THE FIFTH PART BODY AND ELECTRICAL SERVICE
SECTION 16 ELECTRICAL SYSTEM ................................................................................266
SECTION 17 BODY ELECTRICAL SYSTEM. ................................................................282
SECTION 18 BODY SERVICE ..............................................................................................310
THE SIXTH PART HEATER AND AIR CONDITIONING
SECTION 19 HEATER AND COOLING ............................................................................319
SECTION 20 SEAT BELT AND AIR BAG SYSTEM....................................................330

CHANGHE FREEDOM SERVICE MANUAL GENERAL INFORMATION
1
THE FIRST PART GENERAL INFORMATION
SECTION 1 GENERAL INFORMATION
CONTENTS
PRECAUTIONS ........................................................................................................................................... 2
Air Bag System Precautions ..................................................................................................................2
General Precautions ................................................................................................................................4
Precautions for Catalytic Converter ..... ................................................................................................6
Precautions for Electrical Circuit Service. . ..........................................................................................6
Intermittent and Poor Connection Inspection ... ..................................................................................7
IDENTIFICATION INFORMATION ........................................................................................................ 8
VIN ........................................................................................................................................................... 8
Engine Identification Number ............................................................................................................... 8
WARNING, CAUTION AND INFORMATION LABELS ................................................................ 9
VEHCILE LIFTING POINTS.................................................................................................................... 10
When Using floor Jack ........................................................................................................................ 10
When Using Frame Contact Hoist ..................................................................................................... 11
FASTENERS STANDARD INFORMAITON .................................................................................... 12
Metric fasteners measurement standard .......................................................................................... 12
Metric fasteners strength identification.... ......................................................................................... 12
Metric fasteners standard tightening torque .................................................................................... 13
SPECIAL TOOLS ........................................................................................................................................ 14
SERVICE AUXILIARY MATERIAL........................................................................................................ 19

CHANGHE FREEDOM SERVICE MANUAL GENERAL INFORMATION
PRECAUTIONS
AIR BAG SYSTEM PRECAUTIONS
Precautions for Vehicle Equipped with a Supplemental Restrain Air Bag System.
zIf the vehicle will be exposed to temperatures
over 93 °C (200 °F) (for example, during a paint
baking process), remove the air bag system
components before hand to avoid component
damage or unintended air bag system activation.
WARNING：
zThe configuration of air bag system parts are
as shown in the figure. When it is necessary to
service (remove, reinstall and inspect) these parts,
be sure to follow procedures described in section
15. Failure to follow proper procedures could
result in possible air bag system activation,
personal injury, damage to parts or air bag system
being unable to activate when necessary.
zIf the air bag system and another vehicle
system both need repair, we recommend that the
air bag system be repaired first, to help avoid
unintended air bag system activation.
zDo not modify the steering wheel, dashboard,
or any other air bag system components. Modifica-
tions can adversely affect air bag system perfor-
mance and lead to injury.
2

CHANGHE FREEDOM SERVICE MANUAL GENERAL INFORMATION
SERVICING AND HANDLING
Handle the trouble of air bag, follow the procedure of
removal and installation description in section 15.
WARNING：
zFor handling and storage of a live air bag
(inflator) module, select a place where the
ambient temperature below 65 °C (150 °F),
without high humidity and away from electric
noise.
zWhen carrying a live air bag (inflator)
module, make sure the bag opening is pointed
away from you. In case of an accidental
deployment, the bag will then deploy with
minimal chance of injury. Never carry the air bag
(inflator) module by the wires or connector on
the underside of the module. When placing a live
air bag (inflator) module on a bench or other
surface, always face the bag up, away from the
surface. As the live passenger air bag (inflator)
module must be placed with its bag facing up,
this is necessary so that a free space is provided
to allow the air bag to expand in the unlikely
event of accidental deployment. Otherwise,
personal injury may result.
zThe air bag (inflator) module immediately
after deployment is very hot. Wait for at least half
an hour to cool it off before proceeding the work.
zAfter an air bag (inflator) module has been
deployed, the surface of the air bag may contain
a powdery residue. As with many service
procedures, gloves and safety glasses should be
worn.
3

CHANGHE FREEDOM SERVICE MANUAL GENERAL INFORMATION
GENERAL PRECAUTIONS
The WARNING and CAUTION below describe some general precautions that you should observe
when servicing a vehicle. These general precautions apply to many of the service procedures described
in this manual, and they will not necessarily be repeated with each procedure to which they apply.
zNew and used engine oil can be hazardous. Children and pets may be harmed by swallowing new or
used oil. Keep new and used oil and used engine oil filters away from children and pets. Continuous contact
with used engine oil has been found to cause [skin] cancer in laboratory animals. Brief contact with used oil
may irritate skin. To minimize your exposure to used engine oil, wear a long-sleeve shirt and moisture-proof
gloves(such as dishwashing gloves) when changing engine oil. If engine oil contacts your skin, wash
thoroughly with soap and water. Launder any clothing or rags if wet with oil, recycle or properly dispose of
used oil and filters.
zWhen it is necessary to do servicing work with the engine running, make sure that the parking brake is
set fully and the transmission is Neutral(for manual transmission vehicles) or Park(for automatic
transmission), Keep hands ,hair, clothing, tools , etc. away from the fan and belts when the engine is running.
zWhen it is necessary to run the engine indoors, make sure that the exhaust gas is forced outdoors.
zDo not perform service work in areas where combustible materials can come in contact with a hot
exhaust system. When working with toxic or flammable materials(such as gasoline and refrigerant), make
sure that the area you work in is well-ventilated.
zTo avoid getting burned, keep away from hot metal parts such as the radiator, exhaust manifold,
tailpipe, muffler, etc.
WARNING：
zWhenever raising a vehicle for service, be sure to follow the instructions under “VEHICLE LIFTING
POINTS” .
CAUTION：
zWhen performing service to electrical parts that does
not require use of battery power, disconnect the negative
cable of the battery。
zWhen removing the battery, be sure to disconnect the
negative cable first and then the positive cable 。When
reconnecting the battery, connect the positive cable first and
then the negative cable, and replace the terminal cover，
zWhen removing parts that are to be reused, be sure to
keep them arranged in an orderly manner so that they may be
reinstalled in the proper order and position.
4

CHANGHE FREEDOM SERVICE MANUAL GENERAL INFORMATION
zWhenever you use oil seals, gaskets, packing, oil
rings, locking washers, split pins, self-locking nuts, and
certain other parts as specified, be sure to use new ones.
Also, before installing new gaskets, packing, etc., be
sure to remove any residual material form the mating
surfaces.
zMake sure that all parts used in reassembly are
perfectly clean.
zWhen use of a certain type of lubricant, bond or
sealant is specified, be sure to use the specified type.
“A”：Sealant 99000-31150
zBe sure to use special tools when instructed.
Special Tool
（A）：09917-98221
（B）：09916-58210
zWhen disconnecting vacuum hoses, attach at tag
describing the correct installation positions so that the
hoses can be reinstalled correctly.
zAfter servicing fuel oil , coolant, vacuum, exhaust
or brake systems, check all lines related to the system
for leaks.
zFor vehicle equipped with fuel injection systems,
never disconnect the fuel line between the fuel pump
and injector without first releasing the fuel pressure, or
fuel can be sprayed out under pressure.
5

CHANGHE FREEDOM SERVICE MANUAL GENERAL INFORMATION
PRECAUTIONS FOR CATALYTIC CONVERTER
Be must to use unleaded gasoline and be careful not
to let a large amount of unburned gasoline enter the
converter or it can be damaged。
zConduct a spark jump test only when necessary.
zConduct engine compression checks within the
shortest possible time。
zAvoid situations which can result in engine misfire
(e.g. starting the engine when the fuel tank is nearly
empty.)
PRECAUTIONS FOR ELECTRICAL CIRCUIT
SERVICE
zWhen disconnecting and connecting coupler, make
sure to turn ignition switch OFF, or electronic parts may
get damaged.
zBe careful not to touch the electrical terminals of
parts which use microcomputers（e.g. electronic control
unit like as ECM,PCM,P/S controllers, etc），The static
electricity from your body can damage these parts.
zNever connect any tester(voltmeter, ohmmeter, or
whatever)to electronic control unit when its coupler is
disconnected. Attempt to do it may cause damage to it.
zNever connect an ohmmeter to electronic control
unit with its coupler connected to it. Attempt to do it may
cause damage to electronic control unit and sensors.
zBe sure to use a specified voltmeter/ohmmeter.
Otherwise, accurate measurements may not be obtained
or personal injury may result.
zWhen taking measurements at electrical
connectors using at tester probe, be sure to insert the
probe from the wire harness side(backside) of the
connector.
zWhen connecting meter probe from terminal side
of coupler because it can’t be connected from harness
side, use extra care not to bend male terminal of coupler
of force its female terminal open for connection。In case
of such coupler as shown connect probe as shown to
avoid opening female terminal. Never connect probe
where male terminal is supposed to fit.
zWhen checking connection of terminals, check its
male half for bend and female half for excessive opening
and bother locking(looseness), corrosion, dust, etc.
6

CHANGHE FREEDOM SERVICE MANUAL GENERAL INFORMATION
zBefore measuring voltage at each terminal,
check to make sure that battery voltage is 11V or
higher. Such terminal voltage check at low battery
voltage will lead to erroneous diagnosis.
INTERMITTENT AND POOR CONNECTION
Most intermittent are caused by faulty electrical
connections or wiring, although a sticking relay or
solenoid can occasionally be at fault. When checking
it for proper connection, perform careful check of
suspect circuits for:
zPoor mating of connector halves, or terminals
not fully seated in the connector body (backed out).
zDirt or corrosion on the terminals. The
terminals must be clean and free of any foreign
material which could impede proper terminal contact.
However, cleaning the terminal with a sand paper or
the like is prohibited.
zDamaged connector body, exposing the
terminals to moisture and dirt, as well as not
maintaining proper terminal orientation with the
component or mating connector.
zImproperly formed or damaged terminals.
Check each connector terminal in problem
circuits carefully to ensure good contact tension by
using the corresponding mating terminal.
If contact tension is not enough, reform it to
increase contact tension or replace.
zPoor terminal-to-wire connection.
Check each wire harness in problem circuits for
poor connection by shaking it by hand lightly. If any
abnormal condition is found, repair or replace.
zWire insulation which is rubbed through,
causing an intermittent short as the bare area touches
other wiring or parts of the vehicle.
zWiring broken inside the insulation. This
condition could cause continuity check to show a
good circuit, but if only 1 or 2 strands of a
multi-strand-type wire are intact, resistance could be
far too high. If any abnormality is found, repair or
replace.
7

CHANGHE FREEDOM SERVICE MANUAL GENERAL INFORMATION
BODY IDENTIFICATION INFORMATION
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number is located on the left
front panel in the engine room.
ENGINE IDENTIFICATION INFORMATION
The number is punched on the cylinder block.
8

CHANGHE FREEDOM SERVICE MANUAL GENERAL INFORMATION
WARNING, CAUTION AND INFORMATION LABELS
The figure below shows main labels among others that are attached to vehicle component parts.
When servicing and handing parts, refer to WARNING /CAUTION instructions printed on labels. If any
WARNING /CAUTION label is found stained or damaged, clean or replace it as necessary.
Engine oil filter, odometer
maintenance label
Fuel indicator
(The side of cap
of fill fuel)
VIN
9

CHANGHE FREEDOM SERVICE MANUAL GENERAL INFORMATION
VEHICLE LIFTING POINTS
zMake absolutely sure to lock hoist after
vehicle is hoisted up.
zBefore applying hoist to underbody, always
take vehicle balance throughout service into
consideration. Vehicle balance on hoist may
change depending on what part to be removed.
zBefore lifting up the vehicle, check to be
sure that end of hoist arm is not in contact with
brake pipe, fuel pipe, bracket or any other part.
zWhen using frame contact hoist, apply hoist
as shown in figure (right and left at the same
position). Lift up the vehicle till 4 tires are a little
off the ground and make sure that the vehicle will
not fall off by trying to move vehicle body in both
ways. Work can be started only after this
confirmation.
WARNING:
When using floor jack
In raising front or rear vehicle end off the floor by
jacking, be sure to put the jack against the front end of the
engine mounting member or rear axle.
CAUTION:
Never apply jack against suspension parts
(e.g., stabilizer, etc), front bumper or vehicle floor,
otherwise, these parts may get deformed.
To perform service with either front or rear vehicle end
jacked up, be sure to place safety stands under body so
that body is securely supported. And then check to ensure
that body does not slide on safety stands and the vehicle is
held stable for safety's sake.
WARNING:
zIf the vehicle to be jacked up only at the
front or rear end, be sure to block the wheels on
ground in order to ensure safety.
A
fter the vehicle is jacked up, be sure to
support it on stands. It is extremely dangerous to
do any work on the vehicle raised on jack alone.
10

CHANGHE FREEDOM SERVICE MANUAL GENERAL INFORMATION
When Using Frame Contact Hoist
zBefore lifting up the vehicle, check to
be sure that end of hoist arm is not in
contact with brake pipe, fuel pipe, bracket
or any other part.
zWhen using frame contact hoist,
apply hoist as shown (right and left at the
same position). Lift up the vehicle till 4 tires
are a little off the ground and make sure
that the vehicle will not fall off by trying to
move vehicle body in both ways. Work can
be started only after this confirmation.
zBefore applying hoist to underbody,
always take vehicle balance throughout
service into consideration. Vehicle balance
on hoist may change depending on what
part to be removed.
zMake absolutely sure to lock hoist
after vehicle is hoisted up.
WARNING:
ENGINE CYLINDER NUMBER
CAUTION：
These cylinders of the engine are
identified by numbers (figure 0-9); No.1,
No.2, No.3 and No.4 counted from
crankshaft pulley side to flywheel side.
11

CHANGHE FREEDOM SERVICE MANUAL GENERAL INFORMATION
FASTENERS STANDARD INFORMAITON
Metric Fasteners Measurement Standard
Most of the fasteners used for this vehicle are metric，
When replacing any fasteners, it is most important that
replacement fasteners be the correct diameter, thread pitch
and strength.
Metric Fasteners Strength Identification
Most commonly used metric fastener strength property
classes are 4T, 6.8, 7T, 8.8 and radial line with the class
identification embossed on the head of each bolt. Some
metric nuts will be marked with punch, 6 or 8 mark strength
identification on the nut face. Left figure shows the different
strength markings.
Nut strength mark
When replacing metric fasteners, be careful to use bolts and nuts of the same strength or greater
than the original fasteners (the same number marking or higher). It is likewise important to select
replacement fasteners of the correct diameter and thread pitch. Correct replacement bolts and nuts are
available through the parts division.
12

CHANGHE FREEDOM SERVICE MANUAL GENERAL INFORMATION
13
METRIC FASTENERS STANDARD TIGHTENING TORQUE
Each fastener should be tightened to the torque specified in each section of this manual.
If no description or specification is provided, refer to the following tightening torque chart for the
applicable torque for each fastener. When a fastener of greater strength than the original one is used,
however, use the torque specified for the original fastener.
NOTE:
zFor the flanged bolt, flanged nut and self-lock nut of 4T and 7T strength, add 10% to the
tightening torque given in the following chart.
zThe following chart is applicable only where the fastened parts are made of steel light
alloy.
Tightening Torque Table
THREAD
DIAMETER(mm)
STRENGTH
4 5 6 8 10 12 14 16 18
N·m 1.5 3.0 5.5 13 29 45 65 105 160
kg·m 0.15 0.30 0.55 1.3 2.9 4.5 6.5 10.5 16
lb·ft 1.0 2.5 4.0 9.5 21.0 32.5 47.0 76.0 116.0
N·m 2.4 4.7 8.4 20 42 80 125 193 280
kg·m 0.24 0.47 0.84 2.0 4.2 8.0 12.5 19.3 28
l
b·ft 2.0 3.5 6.0 14.5 30.5 58.0 90.5 139.5 202.5
N·m 2.4 4.9 8.8 21 44 84 133 203 298
kg·m 0.24 0.49 0.88 2.1 4.4 8.4 13.3 20.3 29.8
l
b·ft 2.0 3.5 6.5 15.5 32.0 61.0 96.5 147.0 215.5
N·m 2.3 4.5 10 23 50 85 135 210 240
kg·m 0.23 0.45 1.0 2.3 5.0 8.5 13.5 21 24
l
b·ft 2.0 3.5 7.5 17.0 36.5 61.5 98.0 152.0 174.0
N·m 3.1 6.3 11 27 56 105 168 258 373
kg·m 0.31 0.63 1.1 2.7 5.6 10.5 16.8 25.8 37.3
l
b·ft 2.5 4.5 8.0 19.5 40.5 76.0 121.5 187.0 270.0
N·m 3.2 6.5 12 29 59 113 175 270 395
kg·m 0.32 0.65 1.2 2.9 5.9 11.3 17.5 27 39.5
l
b·ft 2.5 5.0 9.0 21.0 43.0 82.0 126.5 195.5 286.0

CHANGHE FREEDOM SERVICE MANUAL GENERAL INFORMATION
SPECIAL TOOLS
The main function of special tools：1）Improve the quality of work；2）Increase the efficiency of
work；3）Protect parts and components from damage . The special tools use by the model are as
follows:
Mass Storage Facility
14

CHANGHE FREEDOM SERVICE MANUAL GENERAL INFORMATION
09900-25002
Pocket tester
09900-20803
Thickness rule
09900-06107
Snap ring pliers
（Opening type）
09900-06108
Snap ring pliers
（Closing type）
9913-65135
T
ransmission gear remover
09913-65210
Tie-rod end remover
09913-80112
Bearing installer
09913-75520A：60.5mm
09913-75510A：70.5mm
Differential front and rear
outer race installer
09913-84510
Bearing installer
09913-85210
Wheel hub installer
09913-85230
Differential end Bearing
remover jig
09915-47310
Oil filter wrench
15

CHANGHE FREEDOM SERVICE MANUAL GENERAL INFORMATION
1.09916-14510
Valve lifter
2.09916-48210
Valve lifter attachment
09916-34520
Reamer（7mm）
09915-64510
Air pressure gauge
09915-67310
Vacuum gauge
09915-77310
Vacuum gauge
09916-34541
Reamer handle
09916-37310
Reamer（12mm）
09916-44511
Vacuum gauge
09916-57321
V
alve guide installer handle
09916-77310
Piston ring compressor
09916-84510
Forceps
09917-47910
Vacuum pump gauge
09917-58010
Bearing remover
（
Input shaft use ）
09917-88210
Valve guide installer
09917-98210
Valve stem seal installer
09921-20200
pinion bearing remover
16