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Engine suspension
1. Overview…………………………………………………………....………………………………….………2
2. Engine suspension specification…………………………………………………………………..……………2
3. Engine suspension removal, re-installation………………………………………………………..……………3
4. Engine suspension fault handling……………………………………………………………………….………4
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1. Review
Powertrain is central vertical with 3-point rubber suspension. There are fasteners including suspension beam
assembly, transmission hanging assembly, etc.
2. Engine suspension specification
1
2
3
4
5
6
3
4
5
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7
8
9
10
9
No. Part Number Name Quantity Remarks
1 1001010W5000 suspension beam assembly 1
2 Q33010F62 All-metal hexagonal flange locking nut 4
3 Q401B12F62 Flat washer 4
4 Q40312F62 spring washer 4
5 Q151C1230TF62 Hexagon bolt-closely-pitched 4
6 Q146B1030F62 Hexagon bolt, spring washers and flat washer assembly 4
7 1001020W5000 T ransmission hanging assembly 1
8 Q33110F62_1.25 All-metal hexagonal flange locking nut 4
9 Q33112F62_1.25 All-metal hexagonal flange locking nut 2
10 1001691U1510 Rear Suspension bolts 2
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3. Engine suspension removal, re-installation
Removal suspension beam assembly
(1)Remove 2 hexagon bolts, spring washers, flat
washer assembly and hexagon flange locking nut on
left side of engine suspension
(2)Remove 2 hexagon bolts, spring washers, flat
washer assembly and hexagon flange locking nut on
right side of engine suspension
(3)Remove 2 rear suspension bolts and hexagon
flange locking nut
Caution:
Before remove powertrain fixing components, m ake
sure the related harness connected to power are
disconnected; After removing fasteners, should use
professional lifter or suspension devices shift the
power assembly to secure site.
(4) Remove 4 hexagon bolts, spring washer and flat
washer connecting suspension beam, remove the
suspension beam assembly
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Transmission hanging assembly removal
Remove four hexagon flange locking nuts connecting
the transmission hanging assembly and remove the
transmission hanging assembly.
Re-installation
Re-installation is in the opposite direction of removal.
Fasteners re-installation torque summary
No. Description Torque values (N *
m)
Remarks
1
Hexagon bolts and hexagon flange locking nuts on both sides
of engine suspension
41～51
2
Rear suspension connecting bolts and hexagon flange locking
nuts
73～89
3
Connecting suspension beam assembly and hexagon screws of
car frame
73～89
4
Hexagon flange locking nuts connecting the transmission
hanging assembly
41～51
4. Engine suspension fault handling
(1) When removing the engine suspension device, check if there is obvious mechanical damage on each
component, must be replaced if there is any d amage.
(2) While removing or re-installation engine suspension, pay attention to prevent water, Corrosive solvents
into parts, otherwise, it will influence life of parts.
(3) If there is engine or power vibration and sounds while using vehicle, check if there are any desoldering
or rubber cracking on suspension beam assembly and transmission hanging assembly, prepare corresponding
replacement or dealing with to dismiss problem.
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Speed drive device
1. Instruction of speed drive device………………………………………………2
2. Specifications and related parameters………………………………………… 2
3. Removal and re-installation of speed drive device……………………………3
4. Cautions of speed drive device………………………………………..………5
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1. Instruction of speed drive device
Speed drive device is composed by accelerator pedal, pedal bracket, accelerator cable, etc., accelerator
pedal bracket connects with body floor and front panel, accelerator pedal is fixed to the accelerator pedal
bracket, one end of accelerator cable is connected with accelerator pedal, and the other end to the engine throttle
arm.
2. Specifications and related
No.
part no.
Name
Quantity Remarks
1
1108020W5000
Accelerator pedal bracket assembly
1
2
Q32006F62
Hexagonal flange nut
3
3
1108010W5000
Accelerator pedal assembly
1
4
Q146B0616F71
Hexagon bolt, spring washer and flat
washer assembly
4
5
1108030W5000
Accelerator cable assembly
1
6
1108035W5000
ribbon I
3
7
1108036W5000
ribbon II
1
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Device explosion drawing
3. Removal and re-installation o f speed drive device
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Accelerator pedal bracket removal
1. Remove 4 screws off accelerator pedal bracket
from the body floor and front mold.
2. Remove 3 nuts connecting accelerator pedal
bracket and accelerator pedal to remove the throttle
pedal
Accelerator cable removal
1. Loosen the screw connecting the cable and pedal
to separate buckle of pedal and cable
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2. Twist the steel wire rope, making it parallel with
gaps, to pull out steel cable terminal in the direction
of arrow
3. In the engine side, repeat steps 1 and 2, loosen
the nut, separate the stringing and buckle, and then
rotate the steel wire rope paralleled with gaps, push
out steel wire rope connector
4. Remove the ribbon and washer connecting
stringing and car body to remove the throttle
stringing.
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Re-installation of the speed drive system
The order of re-installation is opposite to the disassembly order. When fastening throttle cable, direction
must be same as original, do not circle, and ribbon must be blocked in the original hole. Tightening torque is in
the following table:
Part Number Name The torque (N • M)
Q32006F62
Hexagonal flange nut
7.5～10.5
Q146B0616F71
Hexagon bolt, spring washer and flat
washer assembly
8～11
4. Caution of speed drive device
Check if the rubber guard of throttle cable is in place, being badly sealed could lead to excessive matter and
dust, now it is necessary to replace throttle cable with a new one, then it may cause pedal force too much or
does not return to original, which influences road safety.
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Fuel System
1. Instruction of Fuel System……………………………………………………….
2. Specifications and related parameters……………………………………………
3. Fuel System Removal and re-installation ………………………………………....
4. Cautions of Fuel System…………………………………………………………
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1. Instruction of Fuel System
Fuel system is composed by oil filling pipe, fuel tank, fuel supply and return pipes, fuel filter, fuel tank is
in HDPE plastic parts, with a fuel sensor inside, and is fixed by a steel band clamps to the frame. Fuel pipe is
composed by rubber pipe and steel pipe, closely connected by steel band clamps, inlet pipe and the return pipe
is fixed by plastic tube and tube clip to the frame, and connected with the engine inlet port, return port
individually. Fuel filter is installed with a hand pump in upper side, drainage lower side and with electrical
heating.
3. Specifications and related parameters
Parts List
No.
part no. Name Quantit
y
Remarks
1
BTH126A
SteelbelttypeRingClamp
8
2
1104060W5000
The inlet hose components IV
1
3
1104016W5000
Oil return Hose III
1
4
BTH111A
SteelbelttypeRingClamp
6
5
Q146B0616F71
Hexagon bolt, spring washer and flat washer
assembly
3
6
1104030W5000
The pipe clip assembly I
1
7
1104032W5000
pipe clip I
3
8
1104019W5000
oil return steel pipe II
1
9
1104040W5000
Hose assemblyⅡ
1
10
1104015W5000
Oil return Hose II
1
11
1104018W5000
Oil return steel pipe I
1
12
1104014W5000
Oil return Hose I
1
13
1101120W5000
Oil pump bracket with sensor assembly
1
14
1104011W5000
Oil inlet hose I
1
15
1104017W5000
The oil inlet steel pipe I
1
16
1104012W5000
Oil inlet hose II
1
17
1104020W5000
The oil inlet steel pipe II
1
18
1104013W5000
Oil inlet hose II
1
19
1105010W5000
Diesel oil Filter
1
20
1105030W5000
Diesel oil Filter bracket assembly
1
21
Q40310F61
spring washer
2
22
Q151C1030F61
Hexagon bolt-closely-pitched
2
23
Q33008F62
All-metal hexagonal flange locking nut
2
24
1101030W5000
Fuel tank vent tube assembly
1
25
BTH202A
SteelbelttypeRingClamp
2
26
1101100W5000
Fuel Tank Assembly
1
27
Q1840820F61
Hexagonal flange screw
2
28
1103020W5000
oil filler cap assembly
1
29
1101010W5000
oil filler pipe assembly
1
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30
1101031W5000
Oil filler hose
1
31
Q67570
A type transmission hose strap
2
32
1101070W5000
Fuel tank clamp I assembly
1
33
1101080W5000
Fuel tank clamp II assembly
1
34
Q401B10F62
Flat washer
4
35
Q40310F62
spring washer
4
36
Q151C1035F62
Hexagon bolt-closely-pitched
4
Fuel System explosion drawing
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3. Fuel System Removal and re-installation
1. Remove 2 screws connecting oil filler tube and
car body.
2. Remove steel band clamps in the connection of
fuel tank and and its ventilation hose
3. Remove the strap connecting the oil fuel hose and
the fuel tank, then remove the fuel filler tube
assembly.
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Remove fuel tank
Remove the oil filler components
1. Remove two steel clamps connecting the steel
pipe and hose near fuel tank
2. Remove two screws connecting the fuel tank
clamp and car frame out of fuel tank
3. Remove two screws connecting the fuel tank
clamp and car frame out of fuel tank, take off 2
fuel tank clamp and fuel tank.
Note: After removing screws here, remove drive
shaft Protection Architecture first, then remove
fuel tank.
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Fuel Filter removal
1. Remove two band clamps connecting hose of fuel
filter , separating the filter and hose
2. Remove two screws connecting the Fuel Filter
and its bracket to remove the fuel filter.
Fuel pipe removal
1. Remove steel clamps connecting fuel pipe and
engine in cabin floor to separate the oil inlet/return
line and engine.
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2. Remove bolts connecting pipe clamp assembly
and car frame.
3. Remove bolts connecting the other pipe clamp
assembly and the car frame to separate fuel pipe and
the car frame.
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3. Fuel System re-i nstallation
The order of re-installation is opposite to the disassembly order. After re-installation, make sure the Fuel
Supply System Pipe is sealed, drain air from oil pipe after filling oil to fuel system. Fastener torque refer to the
following table:
Part Number Name The torque (N • M)
Q146B0616F71
Hexagon bolt, spring washer and flat
washer assembly
9～11
Q151C1030F61
Hexagon bolt-closely-pitched
41～51
Q1840820F61
Hexagonal flange screw
21～25
Q67570
A type transmission hose strap
6～10
Q151C1035F62
Hexagon bolt-closely-pitched
41～51
Q33008F62
All-metal hexagonal flange locking
nut
21～25
4. Cautions of Fuel System
When removing fuel system, check if there is obvious mechanical or electrical damage on each component,
must be replaced if there is any damage.
Water and debris should be prevented from entering while fuel system removal or re-installation;
When removing be ready to deal with fuel spillage timely, complying with fuel handling procedures.
Otherwise it may cause burn and may lead to personal injury.
When removing or re-installing, it's prohibited to smoke or carry any type of tobacco or kindling.
Intake system
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1. Instruction of intake System…………………………………….……………….2
2. Specification and related parameters…………………………………….………2
3. Removal and re-installation of intake system……………………………………4
4. Cautions of intake system………………………………………….….…………9
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1. Instruction of intake System
The air intake system is composed by air intake, air filter, inter cooler, and pipes connecting those
components, and the air intake is in front of car body to intake enough air, the air filter is in right front of car
frame, easy to remove and clean filter element. Engine is equipped with turbo system, so there is inter cooler in
intake system Outlet pipe of air intake is equipped with resonant cavity, reducing intake noise.
2. Specifications and related parameters
Parts List
1. Intake system (from intake passage to turbo intake part)
No. part no. Name Quantit
y
Remarks
1
1109200W5000
Intake passage assembly
1
2
1109100W5000
air filter assembly
1
3
1109901W5000
Intake protection cover
1
4
1109050W5000
resonant cavity assembly
1
5
1109401W5000
Air filter outlet hose
1
6
1109402W5000
Supercharger air inflow rigid tube
1
7
1109403W5000
Supercharger air inflow hose
1
8
Q402B06F62
Big washer
6
9
Q1420635F62
Hexagon bolt and spring washer assembly
6
10
Q67590
A type transmission hose strap
3
11
Q402B08F62
Big washer
2
12
Q1420835F62
Hexagon bolt and spring washer assembly
2
13
Q1420620F62
Hexagon bolt and spring washer assembly
4
14
Q402B06F62
Big washer
4
15
Q67580
A type transmission hose strap
2
16
Q67570
A type transmission hose strap
1
Intake system (from intake passage to turbo intake)
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2. The air intake system (Turbocharger outlet to the engine air intake)
No. part no. Name
Quantit
y
Remarks
1 1109300W5000
Inter cooler assembly
1
2 1109405W5000
Inter cooler air inflow hose
1
3 1109520W5000
The inter cooler air intake steel tube assembly
1
4 1109404W5000
Supercharger outlet hose
1
5 1109406W5000
Inter cooler outlet hose
1
6 1109540W5000
Inter cooler outlet steel tube assembly
1
7 1109407W5000
Engine air intake hose
1
8 1109550W5000
Engine air intake steel tube assembly
1
9 Q32208F61
Hexagon nut and tapered elastic washer
combination.
2
10 Q1420835F61
Hexagon bolt and spring washer assembly
2
11 Q402B08F61
Big washer
2
12 RQ67765
T-clamp
3
13 RQ67760
T-clamp
5
14 Q402B08F62
Big washer
2
15 Q1420835F62
Hexagon bolt and spring washer assembly
2
16 Q1840816F62
Hexagonal flange screw
2
The air intake system explosion drawing (Turbocharger outlet to the engine air intake)
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3. Removal and re-installation of intake system
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Intake protection cover removal
1. Remove 4 screws from air intake shield in the
bottom of front frame, 2 of which are connected to
front bumper, the other 2 screws are connected to
the body front mold, now remove the air intake
shield.
Intake passage removal
1. Remove 3 screws connecting the air intake and
front body mold
2. Remove the clamp connecting air intake passage
and air filter to remove the air intake passage
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Remove air intake
1. Remove the clamp connecting air filter and its
outlet hose to separate them.
2. Remove 2 screws connecting supercharger intake
rigid tube and car body.
3. Remove two hoses' clamps connected to engine
turbocharger. You can remove the tube from air
filter to turbocharger.
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4. Remove two screws connecting the inter cooler
air intake steel pipe and the frame
5. Remove two clamps connecting the air inlet and
outlet hose, then remove tube from turbocharger to
inter cooler.
6. Remove two screws connecting the inter cooler
air outlet steel pipe and the frame
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7. Remove two nuts connecting engine and its air
intake steel pipe, then remove the tube from inter
cooler to engine
Remove air filter
1. Remove 3 screws connecting the air filter and
frame to remove the air filter
2. Air filter disassemble is showed in the figure.
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Remove the inter cooler
1. Remove 2 nuts and 2 screws connecting inter
cooler and frame to remove the inter cooler.
Re-installation of intake system
The order of re-installation is opposite to the disassembly order. Fix inter cooler, air filter, then fix the rigid
tube, and finally install the hose. Hose must be installed firmly when re-installing hose: insertion depth arrives
to the tube mark. The tube and hose must also be aligned with the arrow mark.
Thetubemark
T ightening torque is in the following table:
Arrow mark
Part Number Name The torque (N • M)
Q1420635F62
Hexagon bolt and spring washer
assembly
8.5～9.5
Q67590
A type transmission hose strap
3
Q1420620F62
Hexagon bolt and spring washer
assembly
8.5～9.5
Q67580
A type transmission hose strap
3
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Q67570
A type transmission hose strap
3
Q32208F61
Hexagon nut and tapered elastic
washer combination.
21～25
Q1420835F61
Hexagon bolt and spring washer
assembly
21～25
RQ67765
T-clamp
5.5～7.5
RQ67760
T-clamp
5.5～7.5
Q1420835F62
Hexagon bolt and spring washer
assembly
21～25
Q1840816F62
Hexagonal flange screw
21～25
4. Cautions of intake system
1. Air filter element has little dust, vehicles travels first 3000Km to deal with, then clean every 5000 km. after
13000 km replace new filter element; Reduce the maintenance mileage under harsh environments or heavy dust
environment, refer to automobile maintenance manual for more details.
2. Seal of pipe: test if tube clamp is tight enough or not, and watch with eyes if the insertion depth is up to
requirement or not: hoses are required be insert to the tube mark.
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Exhaust system
1. Instruction of exhaust system …………………………………………………...2
2. Specification and related parameters …………………………………………... 2
3. Removal and re-installation of intake system……………………………………3
4. Cautions of exhaust system………………………………………………………5
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1. Instruction of exhaust system
Exhaust system includes: front exhaust pipe, muffler, muffler hanging, exhaust tail pipe, exhaust tube
brackets, rubber hanging, and so on.
2. Specifications and related parameters
Parts List
No. part no. Name Quantity Remarks
1 1203010W5000
The front exhaust tube
assembly
1
2 1201100W5 000 Muffler assembly 1
3 1203020W5000 Exhaust tail pipe assembly 1
4 1201200W5000 muffler hanging assembly 1
5 1203071W5000 Exhaust pipe rubber hanging 2
6 Q32310F61 Hexagonal flange nut 4
7 28764-28020 sealing pad 2
8 1203072W5000 The muffler rubber hanging 2
9 Q401B08 Flat washer 1
10 Q40308 spring washer 1
11 Q150B0830 Hexagon head bolt 1
Exhaust system explosion drawing
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3. Removal and re-installation of exhaust system
Remove front exhaust tube
(1) Remove two screws connecting engine exhaust
manifold and front exhaust pipe
(2) Remove rubber hanging from hooks and remove
front exhaust tube
Remove muffler assembly
(1) Use ratchet wrench to remove 2 nuts connecting
the muffler and front exhaust pipe.
(2) Remove rubber hanging from hooks and remove
muffler assembly
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Remove exhaust tail pipe
(1) Use ratchet wrench to remove 2 nuts connecting
the muffler and exhaust tail pipe.
(2) Remove rubber hanging from hooks and remove
exhaust tail tube
Re-installation of exhaust system
Place the front exhaust pipe and the muffler and exhaust tail pipe to the correct location of frame, and then tighten the
nut, tighten all nuts for some laps, tightening torque is in the table below.
Part Number Name Tightening torque (N·m)
Q32310F61 Hexagonal flange nut
45～55
5. Cautions of exhaust system
There are some easily damaged parts in exhaust system, such as seals, rubber hanging, bellows, and so on. These
parts need to be checked regularly. Change damaged parts timely.
Exhaust system leaks, please check if the seal pad of exhaust system flanged connection is damaged, if welding of
corrugated pipe and exhaust pipe snaps.
Exhaust System jitters abnormally, please check the muffler rubber hanging, front exhaust pipe rubber hanging, exhaust
tail pipe rubber hanging is abnormally worn or not. If it is worn, replace timely. See more in explosion drawing. Part 2,
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part 5 and part 11 are rubber hanging, which are easy to be worn, leading to severe vibration, should be replaced timely.
Sealing gasket should be installed between front exhaust pipe and the muffler, between muffler and exhaust tail pipe,
part 4 and part 8 is seal. Pay attention that seal gasket needs to be replaced each time after removing exhaust
system. .
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III. Cooling system
1. Review
Cooling system is comprised of radiator, cooling fan, compensation tank, etc., which are general components of
cooling system. Its function is to maintain engine at normal temperature while working ensuring its working
environment is relatively stable.
(1) cross self tapping screw (2) Liquid storage pot cover (3) hexagon screws, spring washer, big washer (4)
Plastic fastening belts (5) Liquid storage pot cap assembly (6) hose assemblies (7) plastic buckle I (8) hexagon
screws, spring washers, big washers (9)radiator (10) radiator mounted with hose (11) hexagon head with cross
bolts, spring washer, flat washer
(12) steel-Flex hoops I (13) steel-Flex hoops II (14) radiator outlet pipe (15) radiator inlet pipe (16) steel-Flex
hoops III (17) the wind hood (18) Tank Cover Assembly
2. Specification
Radiator wind shield
diameter
Φ474mm
radiator stripe number 60
1
2
5
3
4
6
7
8
1
1
1
1
9
1
1
1
1
1
1
8
1
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radiator radiating area 15.4 m2
Water Tank Cover
pressure
1.1 KPa
Radiator, water outlet
diameter.
Φ36mm
3. Disassembling and re-installation
Disassemble
Disassembling Order
(1) Liquid storage pot cover (2) Liquid storage pot cap assembly (3) Liquid storage pot hose Assembly (4) radiator
assembly (5) radiator mounted with soft pads below (6) radiator outlet pipe (7) wind hood (8) radiator inlet pipe (9)
water tank cover assembly
2
1
3
8
7
6
4
5
9
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Preparations
Before disassembling, clean the cooling system to
avoid greasy dirt and mud, pull the parking brake
control handle to the braking position, remove cab
and open its front hood.
Important operations - disassembly
1. Liquid storage pot cover assembly
(1) Remove the mounting bolts above and below the
the expansion tank with ratchet wrench.
(2) Remove four self-tapping screws fixing liquid
storage pot and remove its shield.
2. Liquid storage pot hose assembly
Remove four hose clamps fixing hose assembly
3. Radiator assembly
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(1) Loosen flexible strap with slip-joint pliers,
remove the outlet pipe from the engine outlet, and
then remove inlet with the same method.
(2) Remove 2 mounting bolts off radiator assembly
and remove the radiator.
(3) A Loosen flexible strap with slip-joint pliers and
remove inlet and outlet.
(4) Remove 5 cross bolts fixing the wind hood,
remove the wind hood.
Inspection and repair
In the course of the inspection, if excessive wear or
damage is found, it is necessary to repair or replace
parts.
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Visual check
Visually check to find the damage or failure and
replace them.
Re-installation
The order of re-installation is opposite to the disassembly order
No. Item T ightening torque (N·m)
(3) Hexagon
bolt-closely-pitched( Q151C0616F61)
9-11
(8) Hexagon
bolt-closely-pitched( Q151C0835F61)
21-25
(11) Hexagon cross bolts ( Q174B0616F61) 3.6
