Dongfeng Sokon; C35 Manual

Dongfeng Sokon Mini Automobile
Repair & Maintenance Handbook
维C Series
(C35)

Chapter 1 Use and Maintenance
Unit 1 Main technical Parameter
1.1 Basic Parameter
1.1.1 Basic dimension & Weight Parameter (Form 1-1)
Form 1-1 Basic dimension & Weight Parameter
Items Parameters
1. Dimension (mm)
C35
Total Length
4500
Total Width 1680
C35
Total Height (empty)
2000
C35
Wheelbase (mm)
2515
Fr.Tread (mm) 1435
Rr.Tread (mm) 1435
2. Weight
Mass of the vehicle with bodywork in
running order
C35
948 ~ 980
2、Performance Parameter (Form 1-2)
Form 1-2 Performance Parameters
Items Parameters
Optional Model of Engine DK15-06 SFD12C
（km/h）Max speed 135 105
Max Climbing Capacity 32 30
Time-Needed from Start and then with
continuous gear-swift to accelerate 90km/h
40 48
Economical Fuel Consumption Under Limited
Condition like 50Km/h, etc
≤6.5 ≤6
（50km/h）Brake Distance ≤20
Outside Noise While Speeding up (dB) ≤74
1.2 Structure parameter
1、Main Technical Parameter of Engines (Form 1-3 )
Form 1-3 Main Technical Parameters of Engines
DK15-06 SFD12C
Model
Items

Types
Four Stroke, Water Cooling, Single
Top camshaft, Petrol engine with
electric control fuel jet,16vavles
Four Stroke, Water Cooling, Single
Top camshaft, Petrol engine with
electric control fuel jet
Cylinder Dimension 76 69.6
Piston Stroke 84.5 82
Exhaust 1493 1248
Compression Ratio 9.5:1 8.8:1
Rating Power 60.5 38.5
Max Torque 102 74
Weight 98 97
Fuel Consumption 93 93
（r/min）Idle Emission 750

50 900 50
（r/min ）Max/Mini
Swerving Speed
6000/750

50 5200/900 50
2、Transmission Technical Parameter (Form 1-4)
Form 1-4 Transmission Technical Parameter
DK15-06 AF10-06
GearⅠ4.425 3.652
GearⅡ2.722 1.948
GearⅢ1.792 1.423
GearⅣ1.226 1
GearⅤ1.000 0.795
Diving
Ratio
Gear R 4.722 3.466
Model
Item

Unit 2 Use and Notices
2.1 Basic Knowledge for New Car Use
2.1.1 Checking the new car
In order to ensure safe driving, before using the car, it must be checked as follows:
(1) Check the connection and strength of the key and essential parts to see whether they accord with
requirements, especially on steering devices and braking system. For example, universal joint boot, bed plate,
brake system, wheels, steering tie rod boot, steering boot, transmission and so on.
(2) Check the specification, models and quantity of all the oil and liquid to see whether they accord with
requirements, such as gasoline, lube, cooling liquid, electrolyte, air window washer fluid, brake liquid,
transmission oil, brake oil, steering oil and so on. And also check the car leaks oil and water or not.
(3) Check the working condition of battery voltage, electrical system, lamplight, horn, instrument, pilot lamp
and so on. And also check the installment of fuse wire in driver’s cab.
(4) Check the types, specifications and tread of the tyres to see whether they comply with requirements;
check the tightening torque of the bolt to see whether it comply with the demanding requirement; check each
tyre’s air inflating pressure to see whether it is normal (including spare tyre) and check the installment of inner
valve and the coverings of wheel.
(5) Check the connection and strength of each part, especially the parts of driving, steering, braking,
suspension, wheels and so on.
(6) Check clutch, and free stroke of pedal to see whether they accord with the specified value; check the
brake system and free stroke of braking pedal to ensure that air in the pipeline is exhausted.
(7) Check the cleanliness of the exterior, including: paint, decorating parts and glass; check the cleanliness of
the interior, including: seats, inner decoration parts; check the state of windscreen cleaning device.
(8) Start the engine, warm it up till it reaches the normal temperature, then check it to see whether there is
any leakage of oil, gas, water and electricity.
(9) After running with the gearshift lever in gear, check the working condition of clutch, transmission, hand
braking, foot braking, steering system and so on.
1) Clutch: whether there is a stuck noise or disordering noise.
2) Speeding-up pedal: flexible as well as non-loosening.
3) Transmission: freely changing gear without difficulty or out-of-gear.
4) Odometer: the odometer index is not chattering while running; when speed changes, the index should
waggle stably.
5) Steering control mechanism: we should check whether free stroke of steering wheel is normal, and
whether it can automatically back to its position after turning.
6) Foot braking: when braking at speed of 40km/h, we can feel the braking impact, and stop without
deflection.
7) Hand braking: when we are lifting the handle of hand braking, and driving at low speed of 20km/h,
we can feel the braking impact while transmission getting into neutral position.
8) Air condition: operate buttons and check whether they are in normal working.
9) Judge each part to see whether the sound is normal: when the car is running, especially speeding up
or slowing down, please pay much attention to whether there is obviously disordering sound.
10) Check the car to see whether the tools and required technical materials are complete along with it.
11）The air in the water tank and engine must be brought out first.
2.1.2 Breakingin of the new car
Because of the oversight of processing and assembling, friction resistance between moving parts, at the
beginning of working, is stronger than at the normal occasions. The effect of breakingin during early period of

using car will affect much on its using length of life, its working fiduciary level and economical efficiency.
Therefore, the new car must strictly execute the rules when used.
(1)The rules of breakingin when driving less than 1000km
1) Driving at full speed is absolutely not allowed
2) Drive generally less than 100km/h
3) Avoid driving at high speed in each gear.
(2) The rules of breakingin when driving between 1000km-15000km: gradually drive to the highest speed or
the highest rotation rate which engine allows.
(3) Notices after the period of breakingin.
1) Drive the car with speed indicator. When you get into the accessing high speed gear, no later than the
finger reaches the red indicating area, the highest rotation speed is 5500r/min which engine allows in the short
time. The highest speed which each gear allows is respectively: 20km/h in 1 gear, 30km/h in 2 gear, 50km/h in 3
gear, 70km/h in 4 gear, 80km/h in 5 gear.
2) Avoid engine rotating with unnecessary high speed, and early getting into high speed gear is
favorable to save fuel and reduce noise.
3) When we are driving, the rotation rate can not be too low. Only if engine works hard can low gear be
used.
4) The speed and rotation rate listed in the explanation book is only applicable to engines with normal
temperature. When cooling the car, we should not make engine work with high rotation in neutral position or in
each gear.
5) The new tyre doesn’t have the strongest adhesion at the beginning of use, so it also needs breakingin.
Driving the first 100km should be slow and careful.
6) The new friction wafer of brake also needs breakingin. When we drive the first 200km, there is no
appropriate friction. If the braking works not well during this period, we can properly add pressure on the pedal.
2.2 Driving
Proper driving not only shows the good technical performances of the car, but also ensures safety driving.
Therefore, as a driver, we must do the daily maintenance work before driving, and during driving, we should drive
the car properly according to different roads.
2.2.1．Checking preparation before driving
(1) Check the fuel gauge and judge whether it needs to add fuel.
(2) Check the lube level and examine whether the track on the vemier is between upper limit and lower limit.
If the fuel is not enough, we should add fuel on time; when the fuel is excessive, on most occasions, lubricating
system of engine will be in trouble. Therefore, we should analyze the reasons immediately and solve the troubles.
(3) Check the cooling liquid level to see whether it accords with requirements. If it is not enough, we should
add cooling liquid on time.
(4) Check the braking liquid level to see whether it accords with requirements. If it is not enough, we should
add braking liquid on time.
(5) Check the electrolyte level of battery to see whether it accords with requirements. If it is not enough, we
should add distilled water on time.
(6) Check the tyre’s inflating pressure to see whether it accords with requirements and whether there are
enough spare tyres.
(7) Check whether the lamplight, steering signal lamp and braking signal lamp are in good condition.
(8) Check whether the front and back air window are clean, the angle of back mirror inside and outside of the
car is proper, and whether wiper is in normal work.
(9) Whether the steering wheel height is adjusted to a proper position, and whether the seat and safe belt are
adjusted to a proper position.

(10) Check the performance of tyre’s braking system to see whether it is reliable.
(11) Check whether the moving of each pedal is flexible, whether the free stroke is within the demanding
scope, whether position shift is free, and whether there is stuck.
(12) Check whether tools along with the car are complete, and whether there is an amount of fusing wires
and bulbs.
(13) When driving in a long-distance, we should prepare an amount of lube and cooling liquid.
The key notices of safe driving:
(1) Before each driving, we should wear safe belt and adjust the headrest according to our statures.
(2) We should pay attention that the control of pedal cannot be foreclosed, and things put on the luggage and
rear shelf should be accurately placed.
(3) Do not drive when you are tired. Usually we should have a short rest after two hours’ driving.
(4) Alcohol, narcotics and druggery will reflect the reaction of the driver. So do not keep driving in drank or
distractingly situation. The latest research shows, if driver uses mobile communication equipments during driving,
the result will be worse than in over drank situation. Thus, never use mobile communication equipments while
driving.
(5) At anytime, the speed of the car should fit the road. For example, low down the speed of the car while
driving on the ice or on wet road, or in the crowd road.
(6) For the safe of the driver, do comply with the traffic rules.
2．Start the engine
(1)Manual shifting car
1) Move the gearlever at zero gear，and pull up grip brake.
2) Starts of manual shifting car, step clutch pedal to the bottom, in this way, while the starter work, idle the
engine.
3) Open the switch, start the starter, no need to step the accelerograph.
Remark: Loosen the switch key the moment the starter working, in order to prevent the starter from
passively working.
4) After the engine starting to work, you can drive at once, and there is no need to warm-up.
Remark: Before the temperature of the engine reach the normal level, do not let the engine work fast
or step the accelerograph to the end.
(2) Notices when start the engine.
1) When the engine coldstarts, because the engine of this car is equipped with continual injection equipment,
it can provide oil-gas mixed fuel at any situation. This start-up procedure can not be affected by any outside
environment, before the start-up, please do not trample the accelerograph, if the engine can not be started
immediately, please wait for around 10 seconds, then re-start it again.
2) If the engine is very hot, you can step the accelerograph lightly after starting the engine. If can not be
started immediately, maybe there’s problem with the fuse of the electric fuel pump or the fuse of the engine
operation system (maybe fusing).
3．Driving notice:
In order to exert the technical performance of the car, reduce the fuel consumption as much as possible, and
reduce the blight of exhaust gas and noise, we should pay attention to the followings:
(1) We should avoid trample the speeding-up pedal fiercely, but moderately, this can not only reduce the fuel
consumption, but also reduce the abrasion between pollution and inner spare parts.
(2) Change the gear when it is necessary, we should often drive it with economical gear, and avoid the engine
running at a too high or too low speed.
(3) Try to drive stably, the operation should be prospective, the unnecessary speed-up, brake, start and stop
all increase the fuel consumption rapidly, and avoid sharp curve and urgent brake.

(4) When running into a traffic jam, we should switch off the engine.
(5) Check the tyre’s inflating pressure terminally, when the pressure of the tyre is too low, it will increase the
rolling resistance, speed up tyre wear and distort steel ring.
(6) Clean up the unnecessary things in the luggage on time.
(7) The accessorial electronic apparatus such as warming, air condition, heating device in rear window, front
lamp and so on should only be used when it is necessary.
(8) Do not switch off engine immediately after a long time driving; we should let the engine running two
more minutes at a speed higher than idle speed to cool it.
(9) Check the car and follow the rules of safe driving notice before a long journey.
If we know that the oil change and some other maintenance items are at term beforehand during this long
journey, we should move them up; especially the change of brake liquid is significant to security of driving.
(10) If the car often drives under the conditions such as with full weight, the outside temperature is too high
or too low, full of dust and the poor quality of the fuel; we should adopt some special technical measures
accordingly, for example: we should adopt the lube whose viscosity is tally with the outside temperature (we can
choose the viscosity grade of the lube according to the outside temperature), install air cleaner with specific
function, and the maintenance cycle should be changed accordingly, for example, if the burthen of the engine is
heavy, the cycle of changing the lube should be shorten.
(11) Pay attention to the instrument and pilot lamp when we are driving. In order to make
drivers more convenient, the car adds various alarm units and fault diagnosis pilot lamp of engine
which can reflect the working condition accurately. If there has some hidden trouble, they will
warn us as soon as possible and require the driver to pay attention to it immediately to avoid
accident with mechanical failure, there are some important alarm units we should especial pay
attention to:
1) The pilot lamp alarms when the temperature of the cooling liquid is too high.
2) The pilot lamp alarms when the pressure of the oil is too low.
3) The pilot lamp alarms when the oil liquid level is too low.
4) The pilot lamp alarms when the level of fuel box is too low.
5) The pilot lamp of brake system.
6) The pilot lamp of generator.
(12) When driving through water, we have to move at a crawl and be conscious in case that the water flood
into the engine or soak some electrical system, and consequently lead to some malfunction, so we should resume
the brake system immediately. When the surface gathers water, we cannot go through it by force.
(13) Do not refit the car without permission, or it will affect the car’s normal technical status and the
guarantee.
(14) Strictly follow the rules of the manufacturer to maintain and repair the car.
4．Accurate use of draw gear
There is a towing hook in both the front and rear bumpers, which can tow the other cars and be towed by the
other cars.
(1) When the car tows the other cars or be towed by the other cars, the dragrope and towing handle can only
be put in this towing hook. we should especially avoid forced towing or fierce pulling, or it will be dangerous
because of heavy burden.
(2) Follow the traffic rules about tow, the car is towing and the car is towed both have to light the pilot lamp.
(3) The driver of the towed car should pay attention to the dragrope to keep it taut.
(4) The towed car must open the switch to make the redirector turning freely, and the turning lamp, horn,
windscreen wiper working normally.
(5) The towed car should get into 3 gear or 2 gear before starting.

(6) Once the towed car starts the engine, we should step the clutch and get to neutral position to avoid
bumping to the front car.
2.3 Right Use of Fuel, lubricant & Various Fat Liquid
1．Add fuel correctly
The quality of the fuel influence the performance of driving, engine and its life use, and
fuel additive can ameliorate the performance above, so it is necessary to adopt the fuel with
high quality additive. If we cannot buy the fuel with high quality additive or when the engine
meets something in trouble, such as starting with difficulty, idle speed is not stable or the
power drops, we should add fuel with proper additive. The fuel additive can prevent the engine
from tarnishing and fouling and has the function of clean oil supply system, which can avoid
throttle valve casing freezing at the temperature between 0 and 15. Each service station has
fuel additive with the permission of the company, and workers in the station master the method
of its use and of dealing with the fouling of the engine.
When we add the fuel, we should pay attention that the oil filling port lies on the little cover board behind the
front door and above the side plate, with the capacity of the standard fuel box is 40L. After opening the cover of
the fuel box, we can hang it on the cover board, and when we adding fuel, please use the fuel gun accurately.
Explanation; when taking spare fuel with the car, we must follow the rules of local statute.
For the case of safe, do not take spare fuel with the car to avoid accidents, such as breakage of fuel box,
overflow of petrol, which lead to fire.
2．Accurate use of engine lube
Before leaving the factory, the car had been filled with engine lube with high quality. Except under
extraordinary cold weather, it can be used through the whole year. The engine lube with high quality is the
precondition of engine running without failure and long use. Therefore when we add lube or change lube, we must
use the proper lube with high quality.
(1) When we check the lube level and engine working, the consumption of lube is natural; the consumption
can reach to 0.138L/1000km.So we must check the lube level terminally, and had better check it when
adding fuel every time.
When check the lube level, the car must be held in a horizontal position. After the engine stops, wait for a
few minutes to let the lube back to the lube plate. Then take out the dipstick, clean it with cloth, and put it back to
the bottom, and again take it out to read the number, the fuel level should be between the superscript X and the
subscript X.
The difference of highest fuel level and the lowest fuel level of the engine in the car is about 1.0L.
(2) Fill the engine lube. We should open the filling up cap on the cover of the cylinder, fill with lube, and
check the fuel level with the dipstick.
Notice: the fuel level is not allowed to exceed the highest level; otherwise the lube may be absorbed through
the vent-pipe in crankcase.
After fill the lube, the cover of the fueller should be put away. The dipstick must be put into the bottom, or
the lube may flow out when the engine is running.
(3) Change the engine lube. The burden and aging of the lube during working will change the performance
of engine lube. So the time of changing lube depends on both the using burden and the using time.
Usually when the car has driven 5000km, it needs to change the engine lube.
If the car is always driving on the special road or in the area with capricious weather, we should shorten the
driving mileages of the engine lube to make sure reliable and safe driving during the long journey.
Notice: the engine lube should not be mixed with other materials. The used lube must be disposed strictly
according to the rules, and we must forbid the children to touch it. We cannot let the lube flow into the drainpipe
or the soil under any circumstance.

3．Accurate use of cooling liquid
The cooling system is not need maintenance normally.
When the car left the factory, the cooling system had been put with permanent cooling liquid. This kind of
cooling liquid is unnecessary to change.
The cooling liquid is mixed with half glycol and half water, its anti-freeze capacity is
-35°C and it has an excellent performance of antisepsis. Besides, the additive can prevent scaling, and
increase the boil point of the cooling liquid.
Based on the excellent performance above, this kind of cooling liquid should be used in the cooling system
perennially. Do not add pure water at any time (especially in summer or in some hot area) to avoid decreasing the
consistency of the cooling liquid. In order to make sure the normal function of the cooling liquid, the consistency
of the cooling liquid can not below 40%( volume proportion)
If it is necessary to improve the anti-freeze capacity of the cooling liquid, we can enhance the proportion of
the glycol properly, but the consistency of the cooling liquid can not beyond 60%(volume proportion). At that
time the engine can run normally under -48°C. Otherwise it will reduce the anti-freeze capacity and weaken the
cooling effect.
Extremely cold area(under -50°C), we should make out cold weather protection.
(1) Check the height of the cooling liquid level. The tank of the cooling liquid is located in front clapboard.
The level of the cooling liquid should accord with the rules to fulfill the level when adding the fuel.
In order to check the cooling level accurately, we should closedown the engine and wait until it stops running
before checking. The tank of the cooling liquid is a translucently plastic pot, on which labels max and min, and it
is no need to open the tank to check the level.
When the engine is under cold condition, the cooling liquid level must be between the highest and the lowest
mark. Once it reaches to thermal state, the level may be higher than the highest mark.
Notice: if the cooling liquid appears exceptional loss, it may mean that the cooling system appears the
breakage of leaking, at this period of time, merely depending on adding cooling liquid cannot solve the problem
completely. So do not waste any time, come to the service station of the company right away to check the cooling
system.
(2) Add the cooling liquid. Close down the engine, wait until it becomes cool and lay over the cover of the
cooling liquid tank with a cloth, turn it counter-clock wisely and wait the inside pressure fell down to
take out the cooling liquid tank, then add the cooling liquid.
Notice: when the engine is under thermal state, and when the cooling system is still under thermal and high
pressure state, do not open the cover of the cooling liquid tank in case of being scalded.
Under emergency, if we have to add pure water, we must add cooling additive afterwards as soon as possible
to make the consistency of the cooling liquid back to its normal state.
If the cooling liquid loses a lot, we have to add cooling liquid when the engine is under cold condition to
avoid the breakage of the engine.
When add the cooling liquid, do not add it beyond the highest mark of the cooling liquid tank! Because once
the engine reaches to the thermal state, the excessive cooling liquid will flow out through the limiting valve of the
tank cover under great pressure. After adding the cooling liquid, do screw down the cover tightly.
Notice: both of the cooling liquid and the cooling additive are poisonous! So the additive must be put into the
original container, and strictly forbid the children to touch it. If we have to release the cooling liquid in the system,
we should collect it properly and put it in a safe place. The ejective cooling should not be used again; we must
follow the rules of environment protection law to deal with the used cooling liquid.
4．Accurate use of brake liquid
(1) Check the brake liquid level. The brake liquid tank is on the left of the front clapboard. The brake liquid
level must accord with the rules to meet the need of the brake system.

The level should be between the max and min mark of the tank.
There is a friction facing in the brake system of the car. So when we drive the car, the brake liquid level may
decrease a bit, this phenomenon is natural, do not worry about it. However, if the level of the liquid is apparently
decreased a lot or below the lowest mark, which means that the brake system is in trouble, at this time we should
drive to the service station of the company to repair the brake system immediately.
(2) Change the brake liquid. The brake liquid has the performance of accessibility, which can absorb
moisture in the air when it is used. If the water content of the brake liquid is too heavy, it will rust the
brake system. Moreover, the boiling point of the brake liquid will decrease obviously, which will affect
the impact of brake and safety. Because of these reasons, the brake system must be changed every year.
Notice: if the brake liquid has been used for a long time or it is often been braked, the brake system will
produce steam bubbles, which influence the brake impact and safe driving.
In order to ensure the brake impact and safe driving, please choose the original brake liquid of our company,
and do not use the new brake liquid which have never been used before.
Notice: the brake liquid is poisonous! So do put it in the original sealed container, and do not let the children
to touch it! The brake liquid is also mordant to the paint of the car!
Dealing with the used brake liquid is a professional job; we have to equip special tools, so we had better go
to the service station of the company to change the brake liquid.
5．Check the power steering liquid heights
Whether the power steering liquid heights is right or not, influence the power steering accommodate directly,
so, do check the liquid height regulate. After the engine working 2min, put the front wheel right ahead, stop the
engine, check the liquid level.
Open the cover of the oil ruler, check the liquid level, keep it between the maximum and
minimum mark. If under the minimum mark, add power steering hydraulic oil according the
regulations.
Remark:
(1) Do not mix braking liquid and power steering hydraulic oil. Otherwise, the braking system would not
work.
(2) Power steering hydraulic oil is a kind of lube lubricant, if there is no power steering hydraulic oil in the
system, oil pump will break. So, in the situation, add it immediately, or unload the V belt of the power steering,
drive the vehicle to the maintenance station to add hydraulic oil.
(3) If the power steering component does not work, the vehicle can still turn, but need put more power on
the steering wheel, and examine the power steering system as soon as possible.
6．Right use the shift gear oil
In order to keep the shift working normally, do pay attention to add gear oil properly according to the
stipulation.
(1) The two types of gear oil of the manual shift are GL-4, SAE80W-90 AND GL-4, SAE75W-90. and the
type of GL-4, SAE75W-90 applicable for south and north areas, and for winter & summer. In order to
maintenance the transmission better, change the gear oil annually or droved 50000km.
Notice: after a high speed driving or long time bearing, check the level of oil after a 30 minutes packing at
least. If the level of oil is not enough, add oil or escape oil (the oil bolt is at the lower part of the oil sump of
transmission). The color of the shift oil should be bright red. If it changes to brown or black, which means that
there is quantity of friction material or other impurity in the oil. If it changes to pink or white, which means that
the cooler of the engine radiator leaks the cooling liquid. If this happens, change the shift oil at once.
Under normal situation, we should change the shift gear oil every 50000km. if the condition of the road is not
well, we should shorten the interval of changing the driving miles of shift gear oil to ensure the security and
reliability of the car.

2.4 Use of Body Establishment & Accessory
1．Open and close of the vehicle door
(1) Outside the car, when we open the vehicle door, we should pull the door handle. Both of the front doors
can be opened or locked by keys outside the car.
(2) Inside the car, all the vehicle doors(the left front door must be locked)can be locked through safe cage
knob. Once we press the safe lock, we can not open the door no matter inside or outside the car.
Notice: do not lock the door when the car is driving in order to open the door easily to get help from outside
when we come across emergency.
2．Close the window
(1) Regulator. The inside window can be opened or closed by the handle on the door. When we turn the
handle clock wisely to the left, the window will lower. On the contrary, if we turn the handle clock wisely to the
right, the result will be contrarily.
3．Adjust the angle of back mirror
In order to ensure the best effect, we should adjust the angle of back mirror before driving.
(1) Adjust the angle of back mirror outside the car by hand. The angle of back mirror outside the car should
be adjusted rightly. This position can not only ensure the largest view, but also ensure profound check at anytime.
4．The use and adjustment of safe belt
A lot of facts prove that when the accident happens, the safe belt can provide better protect. So we must wear
safe belt before each driving.
(1) The use of safe belt
1) Three point safe belt. When the car is driving under common condition, the safe belt can be flexed freely
according to the need of the passenger, but if the speed of the car (or some other facts, such as rapid pull
or urgent brake) changed suddenly, the buckle of the safe belt will be locked and maintain proper
contraction force. The safe belt in the car is the kind of combined safe belt.
Notice: the rightly use of safe belt is important to its function.
2) Method of tying the safe belt across the waist. Pull the head of the safe belt from one side to the other side
across the waist, and connect it to the other side until hearing the sound, then pull the belt to see whether the belt
is already locked.
3) Method of tying the safe belt across the shoulder. The safe belt should be pulled across the center of our
shoulder and cling to our body.
(3) The adjustment of the safe belt. The shoulder safe belt can be adjusted according to passengers’ height.
When we adjust the safe belt, we should move the knob up and down to make the safe belt going across
the center of the shoulder. After adjusting the safe belt, we should check it to see whether it is locked.
The method of adjusting the height of safe belt in front row
1) Press the guiding ring on the fixed point of the safe belt by hand, and move up and down, adjust the safe
belt through shoulder and abut against the neck.
2) After adjusting it, we should to check whether the fixed point on the safe belt is firm.
5．Adjustment of seat
(1) Adjust the front seats back and forth. In order to ensure safe driving, the adjustment of driver’s seat can
only be done when the car stops. The back and forth adjustment of the front seats is: pull the tie bar of the seat to
move the seat back and forth.
(2) Adjust the backrest of the front seats, we only have to pitch ourselves and pluck the rod next to the
backrest. Do not make the backrest pitched behind too much when we are driving, otherwise, it will influence the
effect of the safe belt.
(3) Rear row seats. The backrest and the cushion of the rear row is detached, both of which
have the function of turning ahead to enlarge the volume of the luggage. The method of turning

the backrest: we should adjust the front seats to a proper position in case that the front seat
will hit the rear ones. And pull the plastic rod which is on the top of the backrest, then we
can turn the backrest ahead. The method of turning the cushion: firstly pull the plastic drawstring
lightly, and then we can turn it freely.
Unit 3 Maintenance of the car
3.1 Repairing and Maintenance Form
3.1.1 Repairing and Maintenance Form under normal condition
This form lists the repairing and maintenance demand of the car which had been
driven for 80,000km. For the car of driving miles beyond 80,000km should be repaired
and maintained according to the same interval.
(×1，000)
Kilometer 10 20 30 40 50 60 70 80
(×1，000)
mile 6 12 18 24 30 36 42 48
The interval of repairing
and maintenance:
The interval should be
fixed according to the
odometer or the using
months
month 6 12 18 24 30 36 42 48
1．engine
l—1．driving belt — — — ︱— — — R
1—2．Top camshaft timing belt Change it per 100,000kms
l—3．valve clearance — ︱— ︱— ︱— ︱
l—4．(SE／SF／SG／SH／SJ)
engine oil and engine oil filter R R R R R R R R
1—5．Cooling system tube and junction — — — ︱— — — ︱
1—6．Cooling liquid of the engine — — — R — — — R
l—7．exhaust pipe and fabricated section(not
include pipe filter) — — — ︱— — — I&(R)
2．Exhaust control system
2—1．Air hose and junction of crankcase — ︱— ︱— ︱— ︱
2—2．Air flow controller of crankcase — — — ︱— — — ︱
2—3．Exhaust system of fuel evaporation — ︱— ︱— ︱— ︱
2—4．Fuel cut system — — — ︱— — — ︱
3．electrical system
3—1．wiring harness and junction — — — ︱— — — ︱
4．Switch system
Using unleaded
gasoline — R — R — R — R
4—1．spark plug If using leaded gasoline, we should consult the form”
driving under severe condition”
4—2．
Subordinate electronical cover and head — — — ︱— — — ︱
4—3．Switch line — — — ︱— — — R

4—4．Timing switch — — — ︱— — — ︱
4—5．The device of subordinate electronic
adjustment — — — ︱— — — ︱
5．fuel
5—1．— — — ︱— — — ︱
5—2．The proportion of idle speed and rotate
speed of the engine (︱) ︱— ︱— ︱— ︱
5—3．Fuel tank cover — — — ︱— — — R
5—4．Chip of air cleaner ︱︱︱R ︱︱︱R
5—5．oil filler Change it per100,000kms
5—6．Fuel tube and junction/fuel box — — — ︱— — — ︱
6．brake
Brake wheel and gasket(front) ︱— ︱— ︱— ︱—6—1．
Brake drum and block ︱— ︱— ︱— ︱—
6—2．Brake tube and pipe ︱— ︱— ︱— ︱—
6—3．Brake liquid — ︱— R — ︱— R
6-4．Braked pedal — ︱— ︱— ︱— ︱
6—5．brake staff and cable ︱— ︱— ︱— ︱—
7．batholiths and body
7—1．clutch ︱︱︱︱︱︱︱︱
7—2．tyre ︱︱︱︱︱︱︱︱
7—3．tyre turntable ︱︱︱︱︱︱︱︱
7—4．impending shelf setting ︱︱︱︱︱︱︱︱
7—5．transmission shaft — ︱— ︱— ︱— ︱
7—6．manual transmission oil ︱︱︱R ︱︱︱R
7—7．differential gear oil ︱︱︱R ︱︱︱R
7—8．redirector system ︱︱︱︱︱︱︱︱
7—9．gemelandlock
7—10．shift control staff and axis ︱︱︱︱︱︱︱︱
Remark
“R”：Replacing
“︱”：Inspecting, replacing when needed
1—7（R）is used only for installing rubber stuff on exhausting system.
Advice when the car drove under bad condition.
Obey the maintain schedule
2．Codes for bad conditions
A—Repeated short distance running.
B—Driving on uneven or muddy road
C—Driving on dusty roads
D—Driving on cold weather and salty roads
E—Repeat short distance traveling under cold weather
F—using lead oil

Bad condition
code Maintenance Opera -tion Intermittent time for maintenance
︱every 20,000km or 12 months
-BC--- transmission strap
R every40,000km or 24months
A-CDE- generator oil and oil
cleaner R every 5,000kms or 3 months
AB-D-- releasing pipe and
installing stuff ︱every10,000km or 6 months
R every 2,500kms
--C--- Air cleaner core *1
︱every 20,000kms or 12 months
ABC-EF Spark plug
R every 10,000km or 6 months
AB-D-- Transmission shaft
︱every 10,000km or6 months
-B--E- Manual transmission and
differential gear oil R every 20,000km or 12 months
-B---- Bolts & nuts on Chassis
T every 10,000kms or 6 months
ABC---
Brake set and front pad
Brake drum and brake
show(rear)
︱every 10,000kms or 6 months
“R”：Replacing
“︱”：Inspecting when needed
“T”：Screw down
*1：More frequently checking or replacing is needed when traveling on dusty roads.
二、Maintenance
1、engine
Transmission strap
Warning: cut off the cathode of the battery before checking strap’s condition
Water pump strap checking
1）Checking the crack, cut , distortion, wearing as well as its cleanliness, replacing when needed.
2) Check the tensility of the strap. There should be 7-10mm sink when is pressed by 10kg force.
Tensility of the strap “a”: Sink value 7-10mm.

Attention:
The tensility regulation is, when replacing a new strap: press at the middle, a 7-10mm sink
Water pump strap replacing
1) Cutting off the cathode of the battery.
2) Remove the compressor transmission strap, if air conditioner is available(details please as per driving strap of
air conditioner compressor)
3) Replacing water pump strap with a new one.
4) Regulating the strap tensility according to instruction.
5) Turning on the battery cathode.
Check air conditioner compressing transmission strap.
Check wearing, scathe and tensility of the strap. Replacing or adjusting when needed.
Check air conditioner compressing transmission strap.
Check wearing, scathe and tensility of the strap. Replacing or adjusting when needed.
The tensility of air conditioner’s transmission strap:
Pressing at the middle with a 10kg force, there will be a 8-11mm sink.
Replacing air conditioner’s compressing transmission strap
1) Cut the cathode of the battery.
2) Release the strain of the old belt, and change the new one instead.
3) Change the pump belt by the new belt.
4) Adjust the strain of the belt according to the demand of technology.
5) Connect the cathode of the accumulator.
Notice:
When we change the new belt, the strain should be adjusted to: press the middle heavily, there will be a
8-9mm sink.
The timing belt of camshaft
Check
1) Put off the inspection port plug from the timing belt.
2) Examine the abrasion, crack, hurt, oil stain of the timing belt
with lamp and appropriative mirror according stipulation.
3) Install the inspection port plug.
The gap of valve
Check
1) Unload the crankcase soft pipe on the cover of the cylinder, and the warmer soft pipe
2) Unload the cover of the cylinder head.
3) Check the gap of the intake and exhaust valve, and if need, adjust it.
See the second chapter to check it.
1. Pully of camshaft
2. Adjusting bolt.
3. Valve rod
4. Lockin
g
nut for ad
j
ustin
g
bolt.

Cold engine
Coolant temperature
15—25°C
Hot Engine
Coolant temperature
60—68°C
Intake 0.13—0.17mm 0.23—0.27mm
The gap of
the valve
(gap “a”)
Required tech
Exhaust 0.15—0.18mm 0.25—0.28mm
4) Install the cover of the cylinder head, screw down bolt according the technical requirement.
5) Link the ventilative soft pipe to crankcase.
Oil of engine and cleaner of engine oil
Change
Suggest using engine oil of SE, SF, SG, SH OR SJ grade.
Choose right engine oil viscidity according to the picture on the
left.
It is better to change the oil and the oil cleaner after driving on a
dusty road. Details please as per the user manual.
Before drain out the engine oil, please check the leakage of the
engine oil. If leaked, change the bad part before falling to
working.
1) Remove the oil plug, drain out the engine oil.
2) After draining out the oil, clean the drain out plug. Then
install it, and screw tight as per the following requirements.
Tightening toque:
(a）：35N·m
3) Loosen the oil filter with appropriative spanner.
Appropriative tools
(A):09915-47340
4) Put engine oil on the “o” ring of new oil filter
5) Screw the new oil filter on the holder of it by hand, screw it until
the surface contacted the “o” ring
Attention
In order to screw the oil filter properly, please find the
exactitude joint place of the “o” ring and the surface.
6) After contacting the surface of holder, screw the oil filter with spanner (turn 3~4 circles).
Appropriative tools
(A):09915-47340
Tightening torque:
(a）：35N·m
7) Filling up oil to the full mark on the fuel level gauge (dipstick).
8) Before checking the level of the oil, idle running the engine for 3mins. Then stop it, check the oil level after
5mins. If necessary, add oil to the maximum mark on the fuel level gauge.
Notice：
The stipulation of the oil level please refer to the following table.
Table of Engine oil viscidity
1. Oil sump.
2. Drain out plug.
3. Engine oil filte
r
1. Engine oil filte
r

However, according to different situations (temperature, viscidity, etc.), please be noted that
the real oil level may be not the same as the figures showed in the right form.
9) Check whether the oil filter and drain out plug leak oil.
Oil level of the engine
Oil mass of the oil sump About 3.0L
Oil mass of the oil cleaner About 0.2L
Other About 0.3L
Total oil mass About 3.5L
Soft pipe of cooling system and the tie-in
Check
1) Eye-evaluating whether there are leaks, cracks on the cooling system,
check whether the soft pipe is broken, whether the pipe clamp screwed
tight.
2) Change any soft pipes with leaks, cracks, or other defects.
Change all the pipe clamps which can not keep proper tight
3) Clean the front part of the radiator core.
4) Text the cooling system and the radiator head, the pressure should be
110kPa. If necessary, change the radiator produced for this vehicle.
5)Check the level and concentration of the cooling liquid. See the
processes from the second chapter.
Cooling liquid of engine
Warning:
When the engine and the radiator are still thermal, we can not put the cover of the radiator down to avoid danger.
If we put the cover of the radiator down at once, the hot water and steam will spurt out by pressure.
change
Notice: never put down the cover of thermostat.
1) Don’t remove the radiator cover, until the engine cool down.
2) Screw out radiator drain-out plug to drain out the coolant.
3) Remove the liquid storing kettle, and drain out coolant.
4) Screw on the drain-out plug, install the liquid storing kettle.
5) Add a certain amount of coolant to radiator (refer to chapter
2 VI) exhaust air from cooling system, idle running the engine
for 2-3 minutes, then stop. Re-inject coolant till the level rose
to radiator fluid mouth. Install radiator cover.
6) Inject coolant into liquid storing kettle, till the level up to the mark “Full”
(Full Level), then install tank cap, make markers on tank and cover align.
Notice:
When change coolant of engine, you should use coolant which is
mixed with 50% water and 50% glycol while the temperature is lower
than -16 , and use coolant which is mixed with 70% of water and 30% glycol while the temperature is℃
higher than -16 .℃
Even temperature is above freezing, in the purpose of lubricating and anticorrosion, coolant with 70%of
water and 30% of glycol is required.
Refer to chapter 2 VI- coolant quantity
Exhaust pipe and install components
1. Full liquid level mark
2.Low liquid level mark
1. Full mark; 2. Low mark
3. Cap 4. align mark

Warming:
Don’t touches exhaust system when it is still heat, to avoid scalded. Any maintenance work should be
done after the exhaust system has cool down.
Inspection
When repair or other regular maintenance as following steps,
inspect exhaust system firstly.
·Check whether there are damages or wears on rubber components.
·Check whether there are leakages, joints loose, dimple and
damage in exhaust system.
If the bolt or nut is loose, it should be lighted enough under
technical requirements.
· Check that if there are any damage or dislocation with bad
elements near the exhaust system, or something may result in the
emission of smoke into the slit vehicles, holes, loose joints or other damage.
· Ensure there are enough space between exhaust system components and body soleplate, to avoid floor carpeting
because of overheating.
· If there are any damage in components, should be repaired immediately.
2、Exhaust pollution control systems
Crankcase ventilation tube and joints
Check
Check whether crankcase ventilation tubes contain leak and cracks, any damages should be repaired or replaced.
Check and ensure the hose joints remain fastened.
Crankcase ventilation valve
1) Continued to cast cylinder head of the crankcase ventilation valve, and then
plug the hole and stuffed it into his cast cylinder head.
2) Idle running engine
3) Put hand on the end of the crankcase ventilation valve control switch to
check whether there are any vacuum. If there is no vacuum, it should check
valve plug. If necessary, change it.
4) Checking the vacuum, stop running the engine, removed the crankcase
ventilation valve. Shake this valve, listen if there’s any “Ka Ta” voice from the valve needle.
5) After the inspection, remove the stopper, and then install the crankcase ventilation valve.
Fuel evaporation pollutant control system
1)Check hoses whether there any defects, cracks or excessive
bending. Check whether the tube is damaged and the location is
appropriate.
2) Any damage should be repaired or replaced.
3) Check evaporation containers, as per chapter 3 section
6.Inspect evaporation containers in vehicle maintenance steps.
3、Electrical system
Harness and joints
Check
1) Visually check all engine components whether there are any signs of
damage. Check the insulation (crank), all clamps should be tightened.
2) Replace all damaged and bad harness.
4、Ignition system
1. Crankcase ventilation valve

Spark plug
Replacement
1) Remove the dust on the cylinder head around spark plug.
2) Cut the high damping line of spark plugs. Note you only can pull the spark plugs cover.
3) Use spark plug wrench, loosen spark plugs and then remove it.
4) Install new spark plugs
Notes:
Ensure the new spark plugs comply with the required heating degree and size.
6) Tighten torque spark plugs.
Tighten the spark plug with the rated tightening torque:
Tightening torque：15N·m（465）23－28N·m（474）
7) While connecting the spark plug high damping lines, please don’t push the
high-voltage wire, just push the shield.
Ignition system circuit (high damping line)
Check
Check whether there’re cracks of the high damping line and the resistance of the
joints; Resistance data and the measurement steps as per section 7 in chapter 3.
Changed when it’s damaged.
Notice:
Do inspection to ensure that every high damping line and resistance are already firmly connected, and insert
into the complementary components totally. Change every burnout joint.
1) Disconnect the damping line and the ignition coil.
2) Link with new damping line and clip it tightly. Don’t pull the damping line joint but only pull the cover.
Ignition time
Check
Use fault decoder to check and be sure whether the ignition time is appropriate while it is rotating. If it can not
meet the requirement, please check the valve timing or electronic control system.
5．Fuel
Engine idle speed and exhaust gas mixture
Check
Check engine idle speed and exhaust gas mixture. Adjust it when it’s necessary. Detail requirements for checking
idle speed/ gas mixture please as per chapter 3.
Fuel tank cover
Inspection
Measure the gasket of fuel case, please change it if damaged.
Caution:
The new cover should be the same in order to avoid
working inappropriately.
Air filter core
Replacement
Caution:
Under dusty conditions, change it more frequently. Ask the local service providers for more details
about the change of the core. Please as per section 5 in chapter 3 for the steps of the changing the air
cleaner core.
Check and cleanness
1) Visually check air filter whether it is over dirty, damaged or contains too much oil.
2) Clean filter core through the air filter by compressing the air.
1. Pressure resistance; 2: Cap
1. High voltage damping
line;
2. OHMmeter
1. Fuel filling up cap
2. Bush
1.Air filter outer cove
r
2.Clamp

Notice:
If the car is driving on dusty road very often, clean or replace the filter every 2,500 kms.
Fuel filter
Replacement
Warning:
Keep off from fire when changing the fuel filter and in a place with good ventilation.
Fuel filter is above the fuel tank, including the fuel pump assembly.
Change fuel filter interval. Refer to chapter three for detail knock down and installment.
Fuel pipe and fuel case
Check
Check if there’s any leakage, crack, or damage of the fuel tank, fuel pipes, and
connectors, make sure that all clips are tightly fixed.
Replace the connectors when it’s leaking. Also change when there’re
cracks or damages.
6．Arrester
1. Fuel pump; 5. Drain out valve
2. Fuel pump filter; 6.Two-way single valve
3. Fuel filter; 7. Fuel disconnecting valve
4. Fuel ruler 8. Fuel pump assy