Lifan 620 User manual
Foreword
LF620 Service Manual on common treatment of troubles is to help you correctly use and maintain
your love sedan.
This manual, with illustrative figures and easy-going words, thoroughly introduces the structure
features, use and maintenance of LF620 sedan, which will be a good guide for wide users and
maintenance technicians. Meanwhile, LF620 Spare Parts List will also be referred if necessary. For
any questions and doubts, please do not hesitate to contact the service stations of Chongqing Lifan
Passenger Vehicle Co., Ltd.
The figures, notes, specifications etc contained in the manual will take effect as of the date of printing,
which can be modified and terminated at any moment by Chongqing Lifan Passenger Vehicle Co., Ltd.
without any notice in advance.
Any comment on any thing improper in the manual shall be preferred, and no responsibility on any
thing improper shall be undertaken by Chongqing Lifan Passenger Vehicle Co., Ltd.
Without a permit from Chongqing Lifan Passenger Vehicle Co., Ltd., any unit or individual shall not be
allowed to duplicate, store, and distribute any part of the manual in any form or by any method.
Great appreciation for your support!
Compiled by: Chai Lichao
Du Tianchuan
October, 2008
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Content
Foreword 1
Content 2-3
Part 1 Introduction 4-19
Part 2 System Repair 20-362
Chapter I Electronic Injection System 20-102
Section I Introduction 21-21
Section II Principle of controlling and actuating components 22-37
Section III Steps for Trouble Diagnosis with DTC 38-65
Section IV Steps for Trouble Diagnosis Based on Engine Symptom 66-101
Section V Security Items for System Maintenance 102-102
Chapter II Chassis System 103-158
Section I Suspension and Axle 103-115
Section II Steering System 116-130
Section III Brake System 131-151
Section IV Fuel System 152-153
Section V Engine Cooling System 154-156
Section VI Intake and Exhaust System 157-158
Chapter III ABS System 159-190
Section I Function and Composition of ABS 159-159
Section II Principle of ABS 160-162
Section III Removal and Installation ofABS 163-166
Section IV Fault Diagnosis and Troubleshooting 167-190
Chapter IV Electrical System 191-269
General Rules Trouble Shooting 191-195
Section I Instrument Cluster 196-208
Section II Power Window 209-215
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Section III BCM Central Lock, Burglar Alarm System 216-229
Section IV Electric Side Mirror 230-233
Section V Illumination System 234-245
Section VI Wiper and Washer 246-253
Section VII Audio System 254-260
Section VIII Reverse Radar System 261-266
Section IX Power Supply and Other Electrical System 267-269
Chapter V Air Bag System 270-288
Section I Composition, Principle and Safety Rules for Maintenance 270-274
Section II Diagnosis & Fault Clearing 275-282
Section III Diagnosis of Vehicles after Collision 283-284
Section IV Removal and Installation 285-287
Section V Scrapping Tips for Air Bag Mould 288-288
Chapter VI A/C System 289-322
Section I Introduction 289-292
Section II System Layout 293-296
Section III Component Maintenance 297-309
Section IV Fault Diagnosis 310-320
Section V Precautions of Air Conditioning System 321-322
Chapter VII Auxiliary Component System 323-357
Section I Cable 323-323
Section II Windshield 324-327
Section III Safety Belt 328-329
Section IV Front Side Door 330-331
Section V Rear Side Door 332-333
Section VI Seat Assembly 334-341
Section VII Inside & Outside Decorations 342-357
Chapter VIII Vehicle Body Dimension 358-362
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Chapter I Entire Vehicle Overview
LF620 sedans are devised to give expression to the human orientation with features of portable
operation, comfortable ride, spacious inner room, excellent dynamic quality and economical
efficiency. The high tech and low price endow them with the stronger market competition.
I. Engine assembly
1. Either the engine of TRITEC1.6L or LF 481Q3 is adopted, which is a single overhead camshaft
multi-point electronic injection engine with 16 valves.
II. Chassis
1. The McPherson independent suspension is applied in the front suspension; and the dependent
trailing arm suspension is adopted by the rear suspension. It also enjoys the design of the elastic
elements and the shock damper of the front and rear suspensions, director elements and stable
ones of the front sub-frame suspension.
2. Steering gear: The steering column employs the angular adjustable mode.
3. Operation system: Clutch pedal mechanism, hydraulic clutch operating device.
4. Both the front and rear brake gears are the vented disc brakes with reasonable load layout and
the Anti-Lock Brake System, namely ABS safety device. It is used to prevent sliding and dragging
on the road due to locked wheel when the vehicle brakes so as to improve the vehicle’s directional
stability, steering control ability and shorten the braking distance so that the braking will be more
efficient and safer. It greatly promotes the safety and reliability of the vehicle in various road
conditions and the reasonable distribution of the front and rear braking force.
5. 195/60R15 tires are used; the tire rim, 6J.
III. Body:
1. An integral body is adopted which has passed the frontal impact test and qualified by the state
testing institutions. Exterior design is fashionable with excellent aerodynamic performance with
streamline figure.
2. The dash board, exterior trims and lighting equipments employ the novel craftworks and
materials.
3. A/C system: It gives full expression to the ergonomic, after the filtration, offering clean and fresh
air evenly and noiselessly.
IV. Electric equipment
The electric equipment design of LF620 sedans absorbs all the electric options so as to meet
diversified customers’ needs.
1. Engine and electronic fan
The engine is equipped with a starter and a generator. Double electronic fans at two
speed-adjusting levels are arranged.
2. Power start, charging systems
The power start system mainly deals with the model and specs size confirmation of the engine,
battery and generator and voltage regulator, etc.
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3. Ignition and electronic injection system
①Ignition switch: Only the mature products can be employed and the corresponding current is set
to satisfy the functional requirement.
②The engine is the mature product of the TRITEC and the electronic injection system adopts the
multi-point electronic injection system supplied and calibrated by the SUN & TECK or the Delphi.
The key components of this type’s system include the sensor, the engine control unit, the air inlet
pressure temperature sensor, the throttle valve assembly, the knock sensor, the oxygen sensor,
camshaft position sensor, crankshaft position sensor, coolant temperature sensor, weak
acceleration sensor, canCV canister control valve, fuel rail assembly, ignition coil, and the catalytic
converter etc.
4. Warning signal
The design for the control of the circuit system has been devised correspondingly to satisfy the
requirement of the entire vehicle and the state legal regulations.
The warning signal devices are used to warn and hint signals to the surrounding environment,
including the horn, steering indicator, emergent lamp switch, reversing lamp and brake lamp and
switches, front and rear fog light and so on.
5. Instrument assembly
1) Instrument cluster: Instrument cluster of the electronic odometer. The instruments include the
water thermometer, engine tachometer, speed odometer and the fuel gauge.
2）Indicators include: The battery charge indicators, engineer oil pressure indicator, brake fluid
level indicator, engine malfunction detecting indicator, handbrake indicator, safety belt indicator,
fuel warning indicator, instrument lighting light, high beam indicator, steering (emergency) light,
ABS indicator, door ajar indicator. Reverse radar display, fuel flow sensor, engine oil pressure
sensor, vehicle speed sensor, handbrake switch, door lamp switch, brake shoe sensor, safety belt
contact switch, brake fluid level sensor, parking brake (handbrake) switch etc.
6. Auxiliary electrical devices
(1) Front windshield wiper system: controlled by a combination switch handle. The wiper motor
and the connecting rod are collocated in front of the dash panel.
(2) Radio: Four speakers with adjustable high pitch function. CD player, DVD player, and backup
monitor are optional.
(3) Audio system
Single disc CD player and optional DVD on the dash board, six speakers with radio reception, disc
playing and time display functions simultaneously. This novel and nice CD, DVD player own six
interfaces respectively so six disc players are acceptable according to the customers’ needs.
(4) Cigarette lighter: one, installed for convenience, collocated according to the formative
necessity.
(5) Rear defrosting: The heating-type glass is employed for the rear window and controlled by the
switch.
(6) Self-closing four-door window functions: four-door collocation, master control at driver side and
independent control for right doors and windows, the operating switch collocated on the door
armrest.
(7) Central lock: for four doors, unified switch. Remote control, mature products selected
according to the body structure and modeling and adoption of the BCM centralized control.
(8) Electronic anti-theft device: Controlled collectively by the BCM so as to realize the function of
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electronic anti-theft.
(9) A/C system: JSS-120 swinging-vane type compressor with delivery capacity 120ml/r and
excellent refrigerating effect, consisted of the condenser, evaporator, thermostat, sensor, pressure
switch and blower, etc.
7. Safe anti-theft device
(1) Air bag: The electric double air bags are located on the steering wheel and the dash board of
the co-driver room respectively.
(2) The ABS safety device of the Anti-Lock Brake System guarantees the safety and reliability of
the vehicle’s brake system.
(3) Anti-theft device (optional)
The anti-theft system is mainly controlled by the body controller BCM, connected to the engine
ECU by a communication link. When the ignition key is plugged in, if the signal detected is correct,
the ignition system will work normally; otherwise, the engine can not work. This is the anti-theft
system in common use.
8. Other electric devices:
The other electrical devices mainly include the harness, center control box, relay, safety lever,
interface, switch, corresponding fixing bracket and the strapping components.
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Chapter II Main Technical Parameters of Lifan Vehicles
I. Basic performance parameters
1. Complete vehicle basic parameter (Table 1)
2. Complete vehicle performance index (Table 2)
Table 1 Complete Vehicle Main Parameter
Item LF7162 sedan
Type 3 compartments, 4 doors, 5 seats and 2
covers
Drive model Front lateral engine, front-wheel drive
Length mm 4545
Width mm 1705
External dimension
Height (idle load) mm 1495
Wheel base mm 2605
Front track (idle load) mm 1470
Track
Rear track (idle load) mm 1460
Front suspension mm 935
Rear suspension mm 995
Approach angle ( ° ) 20
Departure angle ( ° ) 23
Minimum ground clearance mm 170
Trafficability
characteristic
Minimum turning radius m 10.2
Luggage boot capability L ( 300 )
Complete vehicle weight kg 1150
Axle load distribution
(front/rear) kg 710/440
Full load weight kg 1555
Axle load distribution
(front/rear) kg 810/745
Full load distribution
percentage (front/rear)
﹪51/49
Mass
Mass center height (no/full) mm 593
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Table 2 Complete Vehicle Performance Parameter
Item LF7160
Maximum vehicle speed Km/h ≥180km/h (BMW 1.6) ≥170km/h
(Domestic vehicle 1.6)
Acceleration performance
( 0-100km ) s ＜15.5
Fuel consumption of uniform
speed traveling L/90km 5.64
Performance
parameter
Maximum climbing angle (﹪) ≥35
Number of passengers People 5
II. Structure and Parameter of Main Assemblies
1. Main technical parameters of engine assembly (Table 3, Table 4)
Table 3 Main Performance Parameter of TRITEC1.6L Engine
Item Parameter
Engine type Four-stroke electronic gasoline injection engine
Delivery capacity 1598cc
Engine model 4 cylinders in line
Camshaft model Single overhead camshaft
Rocker arm model Rocker arm shaft with midpoint support , 8mm chain
driven by hydraulic force
Combustion chamber Single cylinder 4 valves
cylinder bore ×stroke 77mm×85.8mm
Compression ratio 10.5 : 1
Supply system Multipoint fuel injection system
Maximum torque 157Nm/4550rpm
Maximum power 87Kw/5600rpm
External dimension 440×564×670
Minimum fuel consumption 248g/Kw.h
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Table 4 Main Performance Parameter of LF481Q3 Engine
Item Unit Model and parameter
Model
Four-stroke, water cooling, 4 cylinders in line,
16 valves, double overhead camshafts and
multipoint electronic injection
Cylinder bore mm 81
Stroke mm 77
Total delivery capacity L 1.6
Compression ratio 9.5:1
Lubricant capacity L 4
Fuel No. 93# unleaded gasoline
Engine oil No. Not lower than SG grade (GB11121-1995)
Starting mode Electric start
Lubricating mode Pressure and splash combined type
Cooling mode
Forced circulating water cooling
Rated rotation speed r/min 6000
Rated power Kw 78
Maximum torque ( 3505000_r/min ) N·m /rmp 137N·m / 3500rmp
Minimum fuel consumption g/kw.h ≤270
Minimum idle load stabilized rotation
speed (idle speed) r/min 800±50
Low idle
speed CO≤0.3%, HC≤80ppm
Emission limit at idle speed
High idle
speed CO≤0.2%, HC≤60ppm
Ignition advance angle (idle speed) 5±3º
Intake valve clearance (cool) 0.20～0.25
Exhaust valve clearance (cool) 0.25～0.30
Without transmission 650×605×640
External
dimension With transmission
mm
1010×605×640
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2. Model and parameter of main assemblies of chassis (Table 5)
Table 5 Model and Parameter of Main Assemblies
Name Structure and parameter
Exhaust system Three-way catalytic converter (one section) and muffler (two sections)
Intake system Intake pipeline and air cleaner
Fuel supply system Including fuel pump, fuel cleaner, pressure regulator, accelerator pedal,
fuel tank
Cooling system Ribbon-tubular radiator and electronic fan
Clutch pedal force ≤140N
Clutch pedal maximum play ≤100mm
Drive shaft Model Tri-pin sliding bush end, Rzeppa fixing end
Front suspension MacPherson independent suspension
Suspension
Rear suspension dependent suspension with a torsion beam
Tire type Radial ply tire
Tire specification 195/60 R15
Rim specification 6J×15
Tire pressure 2.3MPA
Steering gear model Rack and pinion hydraulic power steering
Tire
Steering equipment Pipe angle can be adjusted, steering wheel
external diameter 375mm
Front wheel camber 0°30′±45′(idle load)
Front wheel toe-in -2～2
Kingpin inclination angle 3º±30′(idle load)
Wheel alignment
Kingpin caster 11°15′±45′(idle load)
Structure model Hydraulic dual-pipe, with vacuum booster
and ABS
Driving brake Disc brakes for both front and rear wheels
Brake system
Parking brake Mechanical cable rear wheel rim brake
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3. Vehicle body structure model and parameter (Table 6)
Table 6 Vehicle Body and Inner and Outer Trim
Name Structure and parameter
Vehicle model Integral body, 3 compartments, 4 doors, 2 covers and 5
seats
Body-in-white All metal closed type structure
Door assembly Framed, 4 doors open in regular direction, card lock, with
side bumper
Engine hood Open backward, bent arm hinge
Vehicle
body
Front and rear bumpers Injection molding
Inner trim Injection molding with surface texture
Dash board Injection molding with surface texture
A, B and C pillars and indoor shield Injection molding framework, knitted surface
Windshield Front windshield: laminated glass,
rear window: Toughened glass
Outer rearview mirror: Convex mirror in both left and right,
manual/automatic adjustment
Rearview mirror
Inner rearview mirror: Anti dazzle
Inner and
outer
trims
Seat
Front seat: independent seat, adjustable back and forth
position, backrest angle, headrest and so on; rear seat
with safe belt: dependent seat, unadjusted
Structure model Compressive refrigeration, water heating
Operation
Adjusted with knob to control air flow direction, to control
and adjust air flow speed, temperature and air circulation;
luxurious ones with electric adjustment
A/C
Refrigerant Model R134a, filling 500g ± 50g
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4. Structure and parameter of electrical system (Table 7)
Table 7 Structure and Parameter of Electrical System
Name Structure and parameter
Wire Single wire, negative pole grounded, direct current 12V
Generator Integral type, AC, built-in voltage regulator, specification 14V/80A
Motor solenoid-operated (with generator), power 1.2kw
Electronic fan Without speed regulation single fan
Start
Battery Maintenance-free plumbic acid battery, capacity 60Ah
Front combination lamp
Headlamp (55/55W, white, 2 lamps),
position lamp (0.8W, LED, white),
steering light (21W, amber, 2 lights, both combination switch)
Side steering light 12V, 0.6W, amber, 2 lights
Front and rear fog lights Front fog light (55W, white, 2 lights), rear fog light (3W, LED, red,
combination switch), rear position lamp (1W, LED, red)
Rear combination lamp
Brake lamp (1.2W, red, 2 lamps, contact closed switch),
Reversing lamp (21W, white, 2 lamps), steering light (21W, amber,
2 lamps, combination switch), rear position lamp (0.8W, LED, red)
Rear license plate lamp 5W, white, 2 lamps
High-mounted brake lamp LED, LED, red, 1 lamp
Inner combination roof light 5W, white, 2 lights
Illumination and
signal
Door lamp 6.2W, white, 4 lamps
Instrument cluster Instrument cluster with electronic odometer, including LCD water
thermostat, fuel gauge, vehicle odometer, engine rotation speed
Including battery charge indicator, engine oil pressure indicator, fuel
warning indicator, brake fluid level indicator, engine fault indicator,
handbrake indicator, anti-theft indicator, safe belt indicator,
electronic airbag indicator, instrument illumination light, high beam
indicator, fog light indicator, steering light (emergency lamp)
indicator, ABS indicator, door ajar indicator.
Instrument
system
Indicator
Brake indicator, anti-theft indicator, safe belt indicator, electronic
airbag indicator, instrument illumination light, high beam indicator,
fog light indicator, steering light (emergency lamp) indicator, ABS
indicator, door ajar indicator.
Electric assistant
system
Including CD (or DVD) player, cigar lighter, rear defroster, wiper and
washer, remote door lock, anti-theft system, airbag, window
regulator.
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5. Lubricant, fuel, steering fluid, brake fluid, coolant, refrigerant and capacity
(1) Lubricant
Table 8 Lubricant
Lubricant No. Weight
Bearing and button head pin Lithium base grease 7022 0.34kg
(2) Fuel
Table 9 Fuel No. and Fuel Tank Capacity
Name Performance index
Fuel No. 93# or better unleaded gasoline for vehicle
Fuel tank capacity (L) 58L
(3) Steering fluid, brake fluid, coolant and refrigerant
Table 10 Steering Fluid, Brake Fluid, Coolant and Refrigerant
Name No. Capacity or mass
Power steering fluid ESSO ATED 0.825L
Brake fluid DOT4 0.72L
Coolant Antifreeze G11 8.5L
Refrigerant R134a 500g±50g
Windshield cleaning solvent NFC-60 As necessary
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Chapter III Lifan Vehicle Maintenance Routine
LF620 Maintenance Plan can make the vehicle run stably, safely and economically and
reduce faults. Maintenance interval varies according to the odometer or time interval. Please refer
to the plan. Those items that have exceeded the deadline should also be maintained in the same
interval. Rubber hoses (in cooling and heating system, brake system and fuel system) should be
specially maintained. In case of aging, cracking or damage, replace the hose. Only professional
technician can check the vehicle.
Basic maintenance items:
I. Electric equipments on vehicle body
1. Check all the inner and outer lamps and electric equipments: Instrumentation console indicator,
headlamp, front fog light, rear fog light, front position lamp, rear position lamp, front steering light,
rear steering light, brake lamp, reversing lamp, license plate lamp, luggage boot lamp, cigar lighter,
horn, power window regulator, power exterior rearview mirror and ventilation system.
2. Airbag: Visually check if its surface is damaged.
3. Self-check: Read the fault information of all systems in memorizer with Lifan special diagnostic
tools.
II. Outer vehicle body
1. Door limiter, fixed pin, door lock, engine hood, luggage boot cover hinge and buckle: Check the
function and lubricate.
2. Window: Check the function; clean the lead rail and smear special grease.
3. Wiper/cleaning equipment: Adding washing liquid; adjust the nozzle if necessary when checking
the function.
III. Engine compartment
1. Visually check if there is damage or leak for all parts.
2. Cooling system: Check the antifreeze and refill if necessary. Standard value: -25 (℃-35℃in
cold area)
3. Power steering system: Check if there is any leak; check the steering hydraulic oil level; and
refill if necessary.
4. Brake system: Check if there is any leak in brake pipeline; check the brake fluid level; and refill if
necessary.
5. Replace brake fluid: Every other 2 years or every 50,000km.
6. Air cleaner: Clean the filter element every 7,500km and replace the filter element every
30,000km.
7. Engine cleaner: Replace the element every 7,500km.
8. Gasoline filter: Replace it every 30,000km.
9. Battery: Check if the positive and negative poles of the battery are tightly connected; check the
electric eye.
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IV. Engine and vehicle body bottom
1. Vehicle body bottom: Check if the fuel pipe, brake oil pipe and bottom protection layer are
damaged; check if the exhaust pipe leaks and if fastening is reliable.
2. Steering tie rod: Check the clearance; check if the connection is reliable and if dustproof cover
is damaged.
3. Brake lining: Check the thickness.
4. Parking brake: Check and adjust the length of cable if necessary.
5. Tire (including spare tire): Check the worn condition of tire; check the tire pressure.
6. Wheel alignment: Check with wheel aligner.
7. Wheel fixing bolt: Check according to specified torque.
8. Headlamp: Check and a.
9. Trial run: Check the performance.
Abbreviations in this manual
A
AC Alternating current
ACC Air conditioning clutch
ACMC Air conditioning magnetic clutch
ACT Air charge temperature
A/C Air conditioning
ABDC After bottom dead center
ABS Anti-lock brake system
A/D Aanalog/digit
A/F Air/fuel ratio
AFS Air flow meter (air flow sensor)
A-ELR Automatic/emergency locking retractor (of safety belt)
ATDC After top dead center
API American Petrol Institude
ATF Automatic transmission fluid
ALR Automatic locking retractor (of safety belt)
ASD Automatic switching-over device
A/T Automatic transmission
B
BATT Battery
B＋Battery positive pole
BBDC Before bottom dead center
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BOO Brake on-off
BTDS Before top dead center
C
CAB ABS control unit with electromagnetic coil
CANP Canister Purge exhaust valve
CMP Sensor Camshaft position sensor (crankshaft turning angle sensor)
CO Carbon monoxide
CKT Circuit
CPP Switch Clutch pedal position switch (clutch switch)
CPS Crankshaft position sensor
CPU Central processing unit
CVT Continuously variable transmission
CRS Child restraint system
CTS Coolant temperature sensor
D
DC Direct current
DLC Digit link connector (series data link)
DOHC Double overhead camshaft engine
DOJ Double offset joint
DRL Daytime running light
DTC Diagnostic trouble code, diagnostic code
DS Detonation sensor
E
ECA Electronic control assembly
EBCM Electronic control module (anti-lock brake module)
ECM Engine control module
ECT Engine coolant temperature
ECT Sensor Engine coolant temperature sensor
EFE Heater Early fuel evaporation heater
EFI Electronic fuel injection
EGR Exhaust gas recirculation
EGRT Sensor EGR temperature sensor
EMI Electro magnetic interference
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ELR Emergency locking retractor
EPS Electric power steering
EST Electronic spark timing
EVAP Evaporative system
EVAP Canister Evaporative system canister
F
FP Fuel pump
FPC Fuel pump control ECU
G
GEN Engine
GND Grounding
H
HC Hydrocarbon
HO2S Heated oxygen sensor
HUC Hydraulic unit control with solenoid valve
I
IAC Valve Idle air control valve
IAT Sensor Intake air temperature sensor
ICM Ignition Control Module
ICU Integrated control unit, composed of four parts
IG Ignition
In Inch
ISC Actuator Idle speed control actuator
L
L Left
LH Left hand
LSPV Load sensor proportion valve
M
Max Maximum
MAF Sensor Mass air flow sensor
MAP Sensor Manifold absolute pressure sensor
MFI
Multipoint fuel injection
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Min Minimum
MIL Malfunction indicator light, engine check light
M/T Manual transmission
N
N Neutral
Ne Engine rotation speed, engine efficient power
NOx Nitrogen oxides
O
OBD On-board diagnostics
O/D Over-speed driving
OHC Overhead camshaft
P
P Parking
PCM Power control module
PCV Positive crankcase vent
PDC Power distribution control
PIM Pressure of intake manifold
PNP Park/neutral position
P/N Park/neutral
PSPS Power steering pressure switch
P/S Power steering
PSP Switch Power steering pressure switch
PSW Position of throttle wide-open
PWR Power
R
R Right
RAM Random memorizer
RH Right hand
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Table of contents
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