Mag International T-MAG XC Series, Owner'S Manual

Page 1: ...Mag International Inc Owner s Manual T MAG XC Mini Truck Series With 4WD Operating Instructions ...

Page 2: ...he vehicle Any direct or indirect loss caused by the above mentioned refitting or modification with additional equipment will be assumed at the owners expense Our policy is to continually upgrade and improve our product therefore we reserve the right to make changes on specific structural features at any time without any given notice However a new and revised manual will become available in the ev...

Page 3: ...CIFICATIONS 1 1 Performance 1 2 Mass Data 1 3 Dimensions 1 4 Engine Data 1 5 Name Plate 1 6 Engine Number 1 7 Vehicle Identification Number VIN 2 VEHICLE LAYOUTS 2 1 Outside 2 2 Instruments and Controls 2 3 Interior 2 4 Engine ...

Page 4: ...nd Sun Visor 3 3 Seats and Headrests Regulation 3 4 Seat Belts 3 5 Switches 3 6 Indication Lights and Dome Lights 3 7 Instruments 3 8 Rear Window Defogger 3 9 Cigarette Lighter and Ashtray 3 10 Air Conditioner 3 11 Glove Box 3 12 Radio and Tape Player 3 13 Parking Brake Lever 3 14 4WD Operating Instructions ...

Page 5: ... 4 3 Vehicle Driving Notice 4 4 Engine Starting 4 5 Operation of Transmission 4 6 Braking 4 7 Clutch Brake and Accelerator 4 8 New Vehicle Driving 4 9 High Speed Driving 4 10 Driving on the Special Road 4 11 Cargo and Towing 5 EMERGENCY MANAGEMENT 5 1 Engine Overheat 5 2 Towing of Vehicle 5 3 Emergency Assistance ...

Page 6: ...lacement of Light Bulbs 7 INSPECTION AND MAINTENANCE 7 1 Safety Notes About Inspection and Maintenance 7 2 Daily Check and Maintenance 7 3 Periodic Inspection and Maintenance Schedule 7 4 Simple Inspection and Maintenance Items 8 LUBRICATION AND ANTI CORROSION 8 1 Maintenance of Interior 8 2 Maintenance of Exterior 8 3 Anti Corrosion of Vehicle ...

Page 7: ...tion of 100km at constant speed L 100km 5 5 Minimum turning diameter m 9 5 Minimum ground clearance mm 155 Wheel camber 1 30 30 Wheel kingpin inclination 9 30 30 Wheel caster 3 00 30 Wheel toe in mm 2 5 Approach angle Departure angle 31 30 Main spring leaf thickness 3 7 7 6 Auxiliary spring leaf thickness 1 13 ...

Page 8: ...1610 1560 Seating capacity persons 2 1 3 Dimensions Data Item T MAG XC Overall length mm 3745 3760 Overall width mm 1505 Overall height mm 1925 Wheel base mm 2370 Front 1300 Track mm Rear 1310 Front overhang mm 690 Rear overhang mm 685 700 Note Data with indicates the dimension with skirt ...

Page 9: ... injection Cylinder bore mm 65 5 Stroke mm 72 Total displacement ml 970 Compression ratio 8 8 Rated output kW r min 35 5 5000 Maximum torque Nm r min 74 3000 3500 Minimum fuel consumption g kWh 275 Fuel Unleaded gasoline Item Quantity Item Quantity Engine oil 2 8 Liters Transmission fluid 1 3 Liters Coolant 4 5 Liters Fuel tank 36 Liters ...

Page 10: ...et of wiper 1 6 Engine Number The engine number is stamped on the engine cylinder of the inlet manifold side 1 7 Vehicle Identification Number VIN The Vehicle Identification Number VIN is stamped on the upper surface of the right plate in the engine cabin ...

Page 11: ...ar view mirrors Side windows Antenna Front fog lights Headlights Position lights Turn signal lights Reversing lights Stop lights Position lights Turn signal lights Hazard lights Door lock License plate lights Rear fog lights Tires Note Equipment may vary with each vehicle ...

Page 12: ...shield wiper and washer switch 5 Selection dial 6 N A 7 Mode selection dials 8 Temperature control dials 9 N A 10 Glove box 11 Loud speaker cover 12 Side defogger 13 Front fog light switch 14 N A 15 Rear fog light switch 16 Hood release lever 17 Horn 18 Shift knob 19 Cigarette lighter 20 Parking brake lever 21 A C switch 22 Cap holder 23 Ashtray 24 Radio player 25 N A ...

Page 13: ...13 2 3 Interior 1 Inside rear view mirror 2 Steering wheel 3 Sun visors 4 Driver s seat 2 4 Engine 1 Oil Filter 2 Engine 3 Ignition coil 4 Battery ...

Page 14: ...k the front doors they are as follows I Close the door insert the key and turn it toward rear of the vehicle II Press the inside door lock button down while pulling the outside handle up close the door b To unlock the front door turn the key toward front of vehicle c Operation from inside the vehicle Press the inside door lock button down to lock the door pull up the door lock button to unlock the...

Page 15: ...t is up b Pull up the control handle of the hood latch located on the lower left of the instrument panel The hood may bounce c Put your hand in the gap between the hood and the body counter rotate the handle on the hood latch support to open Support the hood by inserting the support bar in its slot WARNING ONLY OPEN THE HOOD WHEN THE WIPERS ARE IN THE DOWN POSITION FAILURE TO DO SO MAY CAUSE PAINT...

Page 16: ...LIPPING OUT AND LEAD TO AN ACCIDENT 2 To Close a Support the hood release the support bar Then secure the support bar to the clips located on the body b Slowly lower the hood to a position 300mm above the closed position and then let it drop c Confirm that the hood is completely locked WARNING KEEP HANDS AND OBJECTS AWAY WHILE CLOSING THE HOOD BEFORE DRIVING MAKE SURE THAT THE HOOD IS SECURELY LOC...

Page 17: ...s a Manual windows Turn the window crank clockwise to roll window down turn counter clockwise to roll window up 2 Rearview mirror a Outside rearview mirror The outside rearview mirror can be turned upward downward left and right to adjust to a suitable position ...

Page 18: ...rned upward downward left and right to a suitable position Please adjust the knob under the mirror to prevent the light of the rear vehicle from blinding the driver eyes while driving at night 3 Sun visor a To be used to shelter sunlight not only from front but also from the side when moved away from the hook ...

Page 19: ...19 b The clip to hold the visor is located on the reverse side of the sun visor on driver s side c A mirror dressing is located at the back of the sun visor on the passenger side ...

Page 20: ... Proper use of seat belt should be adhered to at all times Neck should be positioned at headrest level WARNING DUE TO OPERATION INFLUENCING DRIVING SEAT ADJUSTMENTS MUST BE CARRIED OUT BEFORE OPERATING THE VEHICLE ACCIDENTS MAY OCCUR IF SEAT IS ADJUSTED WHILE OPERATING THE VEHICLE ALWAYS ENSURE THE SEAT IS FIRMLY SET TO AVOID A POTENTIAL ACCIDENT SERIOUS INJURY MAY BE CAUSED IF THE SEATBACK IS REC...

Page 21: ...seat After regulating make sure that the seat is fixed firmly by shaking the seat gently in moving direction b Adjust the angle of seatback Lift the handle to regulate angle of seatback After regulating make sure that the seat is fixed firmly by shaking the seatback gently ...

Page 22: ...position While pressing the fixing button continuously draw the headrest upward and remove it To install the headrest press the fixing button continuously and insert the headrest into the hole on the seatback WARNING LIFT LEVER AND PUSH THE SEATBACK TO APPROPRIATE ANGLE BY GUIDING SEAT WITH HAND ASSURING THE SEATBACK WILL NOT RESULT IN INJURY TO PASSENGER AS IT RETURNS TO THE ORIGINAL POSITION ...

Page 23: ...VERS SAFETY DO NOT OPERATE VEHICLE IF HEADREST HAS BEEN REMOVE 2 Regulation of rear seat The regulation of seatback and headrest is the same with that of front seats 3 4 Seat Belts 1 Seat belts Cross the seat belt over your body and press the lock buckle into the socket until a click sound is heard Press the button on the socket to release the seat belt The length of the belt can be adjusted autom...

Page 24: ...E BELT WHEN WORN DIRTY OR DAMAGED THE SEAT BELT FOR EACH SEAT IS DESIGNED ONLY FOR ONE PASSENGER MODIFICATIONS ARE PROHIBITED BY LAW 3 5 Switches 1 Ignition switch The four locations of the ignition switch WARNING DO NOT PLACE HANDS THROUGH STEERING WHEEL WHILE OPERATING THE IGNITION ...

Page 25: ...nother position clockwise If you have the trouble unlocking the Ignition switch turn steering wheel to left or right side gently z ACC When the key is rotated to this position the power of accessories such as the radio will be on but not engine power z ON This is the normal position for operation When the key is rotated to this position all electric systems will be on z START When the key is rotat...

Page 26: ...TH KEY IN IGNITION WARNING IF ENGINE CAN T BE STARTED WITHIN 5 SECONDS EACH TIME THEN START IT FOR SECOND TIME AFTER 10 SECONDS OTHERWISE STARTER WILL BE DAMAGED IF ENGINE DOES NOT OPERATE DO NOT HOLD THE IGNITION SWITCH AT ON POSITION THIS COULD DAMAGE THE BATTERY 2 Headlights Lights Lighting switch is on the left of the steering column pipe The operation is as follows ...

Page 27: ...en the headlights are illuminating press down the lighting control lever the high beam will illuminate and high beams will signal light on the combination meters to also turn on If you only need the high beam to give a signal for a moment pull up the lever gently release the hand it could return to the original position after giving signal 3 Turn signal light switch Turn signal light switch and li...

Page 28: ...l begin The INT intermittent position is used for mist or slightly rainy weather When the wiper s control lever is on LO position the wiper will sway slowly and continuously When the wiper s control lever is on HI position the wiper will sway quickly and continuously Turn the lever to OFF position to stop the wiper The washer for windshield will spray when you push the switch lever up ...

Page 29: ...WHEN EMPTY THIS MAY RESULT DAMAGE TO THE WASHER MOTOR NEVER WIPE THE DRY WINDSHIELD THIS MAY RESULT IN BLADE AND WINDSHIELD DAMAGE ALWAYS WET THE WINDSHIELD BEFORE OPERATING THE WIPER CLEAN UP THE WIPER BLADE BEFORE YOU OPERATE THE WIPER CHECK THE LEVEL OF THE FLUID REGULARLY THE FREQUENCY OF CHECKING SHOULD INCREASE IN BAD WEATHER IN COLD WEATHER ADD ONLY FILL TANK TO 75 CAPACITY FLUID WITH EXPAN...

Page 30: ...s and the two turning indicator lights shall flash Press this switch again the warning light signal stops 6 Front fog light switch Press this switch the fog lights turn on WARNING IN CASE OF EMERGENCY PRESS THE SWITCH THE VEHICLE LIGHT WILL BE ACTIVATED TO ALERT OTHER DRIVERS ON THE ROAD ...

Page 31: ... rear fog light switch the rear fog lights turn on 8 Rear wiper switch When the ignition switch is set to the position of ON press this switch the rear wiper begins to work 9 Rear washer switch When the ignition switch is set to the position of ON press this switch the rear washer begins to work ...

Page 32: ... switch is set to the position of ON press this switch the defogger begins to work 11 Electric window wiper switch Refer to item 4 for detailed contents 12 Horn Pressing the mark horn button on the steering wheel will result in the horn sounding ...

Page 33: ...the position START b Pulling the parking brake lever up c The braking fluid level falling below the definite level d While driving if the brake warning light is on this may indicates that the brake system failed and the following should be done IMMEDIATELY PULL OVER SAFELY TO THE SIDE OF THE ROAD TEST BRAKE PERFORMANCE AFTER CONFIRMING IT IS SAFE PROCEED TO THE NEAREST SERVICE STATION AT A LOW SPE...

Page 34: ...l be off after starting the engine and while the engine is running the light illuminated indicates that the oil pressure is dangerously low Check and refill immediately WARNING IF THE WARNING LIGHT STAYS ON OR DOES NOT ILLUMINATE WHEN THE IGNITION SWITCH IS TURNED ON OR IF THE EBD WARNING LIGHT ILLUMINATES DURING DRIVING THIS IS AN INDICATION THAT THE EBD IS MALFUNCTIONING WARNING DRIVING WITH THE...

Page 35: ...light shall be off after starting the engine If the battery system is not fully operational the light shall continue to be illuminated 5 Seat belt warning light This light illuminates when the ignition switch is set to ON position and it goes off when fastening the seat belt on the driver s side ...

Page 36: ...ystem failure 7 Turn signal indication light When the side turn signal light is turned on this indication light shall flash on 8 High beam indication light When the high beam switch is turned on the indicator light shall be illuminated WARNING WHEN THE CHECK ENGINE INDICATION LIGHT IS ILLUMINATED WHILE DRIVING IT INDICATES SYSTEM FAILURE AVOIDING DRIVING AT HIGH SPEEDS AND HAVE THE SYSTEM CHECKED ...

Page 37: ...d the tailgate are closed the dome light goes out 4 ON position The light illuminates 5 Personal lights at the front dome light Push the button to turn on the light Push it again to turn it off WARNING IF YOU LEAVE THE LIGHTS ON WITHOUT RUNNING THE ENGINE THE BATTERY WILL LOSE CHARGE BEFORE YOU LEAVE THE VEHICLE MAKE SURE THAT THE LIGHTS ARE TURNED OFF Front Dome Light Rear Dome Light ...

Page 38: ...38 3 7 Instruments 1 Combination meter Tachometer Speedometer km Fuel gauge Water temperature gauge Odometer Trip meter Warning and indication lights Trip meter reset button ...

Page 39: ...er does not rise to the red zone otherwise it is indicated that the engine RPMs are too high Speedometer The speedometer indicates the vehicle s speed in km h The odometer indicates total distance the vehicle has traveled The trip meter indicates the distance traveled of one trip or between two times filling ...

Page 40: ...en the indication is on E or in the red area it means that the fuel is not sufficient in the tank and the fuel must be filled as soon as possible WARNING DO NOT DRIVE WITH LOW FUEL LEVEL THIS WILL RESULT IN ELECTRICAL FUEL PUMP FAILURE IT IS RECOMMENDED THAT AT LEAST 8 LITERS OF FUEL BE CONTAINED IN THE FUEL TANK THIS INCLUDES THE INITIAL FILLING ...

Page 41: ... between C and H marks When the indication is in the red area it indicates that the engine is over heated immediately stop the vehicle and not to start engine until the engine cool WARNING DO NOT DRIVE VEHICLE IF ENGINE IS OVERHEATING Odometer Trip meter Odometer will keep accurate mileage for the life of the vehicle The trip meter will measure individual segments and may be reset Warning and indi...

Page 42: ...d Ashtray 1 Cigarette lighter Set the ignition switch to ACC or ON Press in on lighter When heated the lighter will pop out and will be hot 2 Ashtray Ashtray can be used by pulling out from dash WARNING ALWAYS PUT OUT MATCHES AND CIGARETTES BEFORE THEY ARE PLACED IN THE ASHTRAY ALWAYS CLOSE THE ASHTRAY IF LEFT OPEN OTHER CIGARETTE BUTTS IN THE ASHTRAY MAY BE REKINDLED NEVER PUT PAPERS AND OTHER FL...

Page 43: ...r conditioner equipped in the vehicle has many functions such as cooling heating ventilation and defrosting a From center defogger b From side defogger c From side ventilator d From center ventilator e From under the instrument panel ...

Page 44: ...ater air blows from foot vent outlet colder air blows from center and side vent outlet When the position of the temperature control dial is on full hot or full cold the temperature of air is same on all vent outlets Foot position Air blows from foot vent Foot defogger position Air blows from foot vent and defogger Defogger position Air blows from defogger ...

Page 45: ...ce position 3 Front face position 4 Foot position 5 Foot defogger position 6 Defogger position 7 Air inlet mode selector 8 Temperature control dial 9 Blower speed selection dial b Temperature control dial c Controls the temperature of air blowing d Air inlet mode selector e Alternates between outside air introduction Fresh air and inside air recirculation Recycle air ...

Page 46: ...urn the mode selection dial to heating and dial the air inlet mode selector lever to the Fresh then turn the temperature control dial and switch for blower speed to the position you need If you want to increase the efficiency of air conditioning rotate the blower speed to the higher speed i Rapid ventilation of heating air using the recycle air Dial the air inlet mode selector lever to recycle oth...

Page 47: ...mode Turn the mode selection dial to foot defogger position and dial air inlet mode selector to the Fresh position then turn the temperature control dial to what you need and dial the blower speed selection dial to the high After the windscreen is clear turn the blower speed selection dial to what you need iv Defogger Turn mode selection dial to defogger position and dial the air inlet mode select...

Page 48: ... the A C button and turn the blower speed selector dial to the position except OFF Turn on the air conditioning system causes the indicator light to illuminate Press the A C button once more to turn the system off vi When using the air conditioning the rotate speed of engine may slightly change the change is normal the air conditioning compressor is switched on off automatically To maintain the se...

Page 49: ... adjusts the air blower from the upper air vent 3 To start the air conditioning Set the temperature control dial around the maximum cool position turn on the air conditioning switch then operate the blower speed selection dial on the heater air blower control panel at the moment the engine speed may slightly change the change is normal After starting the air conditioner select the front evaporator...

Page 50: ... 2 When the cooling system is opening rotate temperature control dial to the blue area and dial air inlet mode selector to Recycle If the cooling system has been opened for a long time you should often put the air inlet mode selector on Fresh 3 If the blower speed selection dial has been turned to the low for a long time the compressor often cut off for temperature on the outlet is low This is bec...

Page 51: ...been operated for a long time in the winter you should operate it for 5 minutes every two weeks It can prevent the refrigerant from leaking and protect the air conditioning 7 Always use preferred refrigerant HFC 134A Do not mix with other refrigerant 3 11 Glove Box To open pull the lever To close push the lid down until it s locked WARNING ALWAYS KEEP THE GLOVE BOX LID CLOSED WHILE DRIVING TO AVOI...

Page 52: ...ake lever To release depress the brake pedal and then pull up the parking brake lever a little and use your thumb to press the knob on the end of the parking brake lever to the original position If you want to inspect whether the parking brake whether adjusted correctly or not you should pull up the lever to parking position slowly WARNING RELEASE PARKING BRAKE LEVER DURING VEHICLE DRIVING OTHERWI...

Page 53: ...hicle is not moving before engaging the Hi or Low application The Hi Low Lever is located below the gear shift 2 High Gear Ensure that the vehicle is at a complete stand still Shift the lever to the left or toward the driver s side until you feel a click Hi gear is now engaged and ready to use ...

Page 54: ...omplete stand still Shift the lever to the right or toward the passenger s side until you feel a click Hi gear is now engaged and ready to use 4 4WD or 2WD Switch This switch is located on the right side of the dash next to the recirculation control ...

Page 55: ...n be in motion but at a speed of no more than 10 miles per hour Switching at higher speeds will cause damage 4WD mode is best used for Off Road terrains and engaging 4WD on asphalt is NOT recommended To switch to 2WD the vehicle can be in motion but at a speed of no more than 10 miles per hour Switching at higher speeds will cause damage 2WD mode is best used on asphalt roads ...

Page 56: ...mission regulations A catalytic converter is installed between the exhaust pipe and silencer assembly An oxygen sensor is fitted on the exhaust manifold WARNING AVOIDED WATER CONTACT ON OXYGEN SENSOR AND HARNESS AVOID HIGH TEMPERATURE AND FRICTION In order to avoid possible damage to the catalytic converter notice the following during driving a The vehicle must use 89octane and above Using quality...

Page 57: ...ined in maintenance center If engine exhaust purifying system is involved it is recommended to have the vehicle checked 4 2 Inspecting Items Before Daily Use a The windows rearview mirror and lights should be clean and unobstructed b Inspect tire conditions c Inspect oil and water d Adjust the positions of seat and headrest e Inspect the braking and clutch pedals f Inspect the working conditions o...

Page 58: ...while ignition key is in START position If engine cannot be started then spark plug short circuit failure was caused by gasoline overflow of the engine At this time fully depress accelerator and start the engine system cut off the gasoline supply for 5 6 seconds high speed airflow will blow down the gasoline overflow then release the accelerator and start the engine again WARNING ONLY ATTEMPT INGN...

Page 59: ...e same time releasing clutch b Completely depress clutch pedal when changing gears c Avoid allowing engine to be in high speed when changing gears and starting engine as this will shorten life of the engine d All forward gears have the synchronizer speed and gear can be easily changed e Always keep engine speed within a certain range to save fuel and extend vehicle life WARNING CONTINUOUS DEPRESSI...

Page 60: ... LOW Brake distance is different according to road situation especially vehicle runs in high speed in rain day will form water layer phenomenon high speed running on the water accumulated road If vehicle speed exceed a speed tires will not remove water on the road thus form skidding state and lose to control on water road And generate the phenomenon of no braking efficiency as driving on water roa...

Page 61: ...ress clutch pedal as the No 1 in the figure can depart the output engine power from the tires depress the clutch pedal when start up engine and change into other gear WARNING EXTENDED USE OF CLUTCH CAN RESULT IN A PREMATURE WEARING OF CLUTCH ASSEMBLY ...

Page 62: ...aybe it is normal because of environment like coldness dampness or snow weather Start the engine step on braking pedal at 30kgf the distance B from pedal to floor not be less than 145mm the distance measure does not include the thickness of floor cushion 3 Accelerator The accelerator pedal marker 3 is used to control the rotation speed of the engine When depressing the accelerator pedal the engine...

Page 63: ... H Fifth gear 25KM H 1 Each speed should not exceed the max speed that is recommended in the table above 2 Allow the engine to gradually warm up after starting 3 The vehicle should be driven on flat and good road surface and driving on bad road such as the mud sand and steep slope should be avoided as practically possible 4 Gear should always be changed when breaking do not go at same gear positio...

Page 64: ...of time 2 When raining moisture film will formed between tire and ground surface which will cause hydroplaning of vehicle Use caution while driving on wet surface 3 Use caution while driving at high speed in tunnels during high wind conditions or wet road surfaces 4 10 Driving on Special Roads 1 Driving on a sloping road a You must shift to lower speed while climbing steep grade b Reduce the shift...

Page 65: ...ensions of the chains and the wheels and then tighten the chain firmly on the front wheels After assembly check the gaps between the wheels and the anti splash guard drive 1 kilometer at a low speed then check whether the chains are firm so as to ensure safety b Vehicle stuck in snow When shifting release the accelerator If you continue depressing the accelerator the tires may turn which will incr...

Page 66: ...MAGING THE VEHICLE ANY CARGO SHOULD BE LAID SYMMETRICALLY AND TIED SAFELY PREVENT CARGO FROM MOVING DURING VEHICLE OPERATION CARGO HEIGHT MUST NOT EXCEED SEAT LEVEL 1 Towing Towing can only be done by an authorized towing company While towing other vehicle the towing rope should be tied to the hook WARNING DO NOT TRY TO TOW A VEHICLE WHICH IS HEAVIER THAN ITSELF ...

Page 67: ...and C e If the water temperature gauge does not drop stop the engine and check whether the belt and belt wheel is destroyed or is slipping f Check the coolant tank to verify coolant level is not below LOW and whether there is leakage in each water hoses g If coolant level is below LOW fill to appropriate level WARNING IF STEAM IS COMING FROM THE ENGINE DRIVE THE VEHICLE TO A SAFE LOCATION AND STOP...

Page 68: ...WING AS THIS WILL RESULT IN DAMAGE TO VEHICLE To properly tow a manual transmission vehicle hang the rear wheels and the front wheels and turn the ignition key to ACC position DO NOT lock the steering wheel 5 3 Assistance Emergency If the engine does not start please operate as follows a Turn on the light switch and turn the ignition switch to START position If the headlights do not illuminate the...

Page 69: ...m and wheel spanner 6 2 Use of the Jack a Park the vehicle on horizontal and hard ground b Pull the parking brake lever up and push the gear shift lever to reverse position and withstand the lifting wheels on the cross c Turn on the hazard switch d Place the jack underneath vehicle and vertically raise the vehicle e Smoothly and slowly operate the jack to appropriate height 6 3 Changing the Tire T...

Page 70: ...R THE VEHICLE WHILE IT IS RAISED BY THE JACK DO NOT START THE ENGINE WHEN THE VEHICLE IS RAISED BY THE JACK 1 Replacing the Wheels In order to make the tire evenly wear and prolong their life wheel positions should be changed every 10 000km The alternate method is shown in figure depicted in regular maintenance schedule After that adjust the front and rear tires pressure according to tire pressure...

Page 71: ...ut not removed c Jack the vehicle d Remove the wheel nuts and tire e Install the new tire and wheel nuts which are faced with conical side to the wheel tighten wheel nuts by hand and then fasten the wheel to hub f Lower the jack and tighten all nuts crossly with wheel nut spanner according to the figure g The torque of nut 80 90Nm ...

Page 72: ... 10kPa 6 4 Spark Plug Spark plugs should be changed every 10000km Replacement type is DK7RTC DA465Q 16MC engine F6TC other engines and screw is M14 1 25 The surface between central pole insulator and external pole should be clean without carbon deposit which can be eliminated by fine sand paper The clearance of spark plug is 1 0 1 2mm and the clearance should be symmetrical and same on whole centr...

Page 73: ...r vehicle The first is identified as the class fuse housing There are two fuses in it one is to protect the positive terminal of the battery from short circuit and the other is to prevent the output terminal of the generator from short circuit The fuse housing is located in the engine compartment near the battery ...

Page 74: ...s to protect the electrical equipments of large power consumption in it The fuse housing is located in the left upper area of the front compartment 1 Main power 2 Lighting 3 ABS 4 Headlight RH 5 Headlight LH 6 Condenser fan 7 Main relay 8 Radiator fan 9 ABS The third class fuse housing The fuse housing is located at the right side of the steering column in the instrument panel ...

Page 75: ...ump 7 Compressor evaporator 8 Rear window defogger 9 Heater 10 Electric regulator 11 ECM diagnosis connector 12 Horn 13 Gauge radio speed sensor 14 Position lights and tail lights LH background light 15 Position lights and tail lights RH 16 Front fog lights rear fog lights 17 Hazard lights stop lights dome lights 18 Wiper washer 19 Radio cigarette lighter ...

Page 76: ...76 WARNING THE FUSE MUST HAVE THE SAME CAPABILITY AS THE REPLACED ONE NEVER USE METAL WIRE TO REPLACE THE FUSE ...

Page 77: ...LY HALOGEN BULBS COMPRESSED HALOGEN GAS IS IN THE HEAD LIGHT S BULBS IF THE BULBS FALL DOWN OR BREAK BY KNOCKING THEY MAY BURST CAUSING SERIOUS INJURY DO NOT TOUCH BULBS SURFACE WHEN REPLACING 1 Installing dome light bulb Using a flat head screwdriver wrapped with a soft cloth safely remove bulb ...

Page 78: ... the arrow shown in figure b The bulbs in these lights are circular shape or egg shape To remove or install the egg shape bulbs just pull out or push in c To take out the circular bulbs from the base you should handhold and rotate bulbs in counter clockwise direction then pull out the bulbs The bulbs can be installed by pressing and rotating in clockwise direction d To take down the base from the ...

Page 79: ...t 5 Stop light running light in the tail light 21 5 Reversing light in the tail light 21 Front turn signal light in the head light 21 Side turn signal light 5 Rear turn signal light in the tail light 21 License light 5 Front fog light 55 Outside Rear fog light 21 Front dome light 7 5 Inside Rear dome light 8 ...

Page 80: ...s necessary to support the vehicle with under props before entering into underside of vehicle body g The battery and high voltage cable work with high voltage never short circuit battery from positive to negative Keep the terminals and connections tight to avoid sparks and fire h The engine adopts a multi point electronically controlled gasoline injection system The pressure of the feed line is a ...

Page 81: ...hts position lights and other lights turn on Depress the brake pedal the stop light should illuminate Put the gear shift in R Reverse position the reverse light should illuminate Each light cover should be clean and without damage 3 Horn turn signal lights wiper washer washer fluid Check if horn turn signal lights wiper washer work properly 4 Door locking device Check door locking device it should...

Page 82: ... of coolant d Inspect engine oil oil filter transmission oil differential oil e Inspect the exhaust system of engine f Inspect air cleaner g Inspect fuel tank cap and fuel line fuel filter charcoal canisters h Inspect spark plugs i Inspect engine harness and terminal high tension ignition wire battery fuse j Inspect PCV valve k Inspect work state of the transmission shift mechanism and cable parki...

Page 83: ...d water pump belt 8 Washer fluid quantity of windscreen 9 Door locking device 10 Work condition of illuminated device 11 Work condition of indication lights and instrument 12 Rear view mirror and license plate 13 Work condition of horn and turn signal lights 14 Fuel capacity in the fuel tank 15 Battery electrolyte quantity 16 The gap about clutch pedal brake pedal 17 The work state of transmission...

Page 84: ...nth numbers 2 6 12 18 24 30 36 42 48 Engine 1 Water pump belt tension and wearing A I R I R 2 Synchronous indented belt damage and aging I I I I I 3 Clearance of inlet valve and exhaust valve A A A A A 4 Tightening torque for manifold mounting bolts and nuts cylinder head bolt T T T T T 5 Engine oil filter R R R R R R R R R 6 Engine oil Change it every 5000km if driving on bad sand road surface ch...

Page 85: ...ss aging and damage I I I 10 Spark plug R R R R R R R R 11 Air filter Clean it every 10000km for bituminous road surface and clean it every 2500km for dust road surface 12 Acceleration cable assembly and throttle body shaft I L I L I L I L I L I L I L I L 13 Fuel filter R R 14 PCV valve I I I I 15 Clutch gap I I I I I I I I I 16 Transmission gear oil check the leakage under level condition R I I I...

Page 86: ...orque for knock sensor A A A A A A A A A 23 Distributor cap and distributor track wearing and aging I I I 24 Canister Change it every 50000km for adverse environment check should be often conducted if lockage or liquid fuel immersed is found then change it in time Chassis and body 25 Clutch pedal stroke I I I I I I I I I 26 Braking disc and braking lining abrasion and damage Braking shoes and brak...

Page 87: ...stroke and damage I I I I I I I I I 31 Tire abnormal wearing pressure I I I I I I I I 32 Wheel nut damage torque I I I I I I I I I 33 Damper leakage damage I I I I I I I I I 34 Parallel shaft damage relax I I I I 35 Differential leakage and oil height R I I I R I I I R 36 Suspension loose damage click damage I I I I I I I I I 37 Test run Test run after examine and repair 38 Connectors of wiring ha...

Page 88: ...h the electric fuel injection engine DA465Q 1A supplied by UAES Note Symbols in table above A Check or adjustment R Replace I Inspection adjustment or change should be conducted if necessary T Tighten the torque with special wrench to check L Lubrication ...

Page 89: ...0 000km or 24 months Fuel filter B C Replace every 20 000km or 12 months Transmission gear oil A B C Replace every 30 000km or 24 months Note Rigorous road code A Short distance time after time repeat driving B Unpredictable dangerous conditions on road C High Wind Conditions D Cold weather bitumen road driving E In cold weather short distance time after time repeat driving F Often using cold air ...

Page 90: ...n again pull out it again oil mark should be located between top and bottom markings two holes of the oil gauge if oil mark is close to bottom line then oil should be filled to top line a Filling oil Using the engine oil reference Southward all year and northward summer 10W 30SE northward winter November to March next year 5W 30SE Take down the oil cap filling the specified oil to the limit 3 5L a...

Page 91: ...anticlockwise using a special wrench and then take down it Clean the mounting surface of oil filter using a cleaning cloth Apply a little oil on the rubber washer of the new oil filter Screw oil filter with hand until the washer comes into contact with mounting surface Screw three quarter circle more with wrench after contact point Add transmission gear oil The specified transmission gear oil is N...

Page 92: ...new oil after installing the drain plug The adding capacity of transmission gear oil is as follows Item Capacity 4th gear 1 0 Liters 5th gear 1 3 Liters WARNING WHEN TIGHTENING OIL FILTER IT IS IMPORTANT TO IDENTIFY THE CONTACT POSITION EXACTLY BETWEEN THE WASHER AND MOUNTING SURFACE ...

Page 93: ...tainer so as not to pollute the ground Tighten oil drain plug tighten torque is 50 70N m Add 1 3L GL 5 80W 90 oil from oil filler hold Tighten oil filler plug tighten torque is 40 6 N m WARNING AFTER DRIVING VEHICLE OIL WILL BE HOT AND MAY CAUSE INJURY UPON CONTACT ENSURE VEHICLE IS COOL BEFORE CHECKING OR REPLACING OIL ...

Page 94: ...in the reservoir should be between the MIN mark and MAX mark Fill the same type of braking fluid into the braking system to the MAX mark when the fluid level is less than the MIN mark WARNING WHEN THE BRAKE FLUID LEVEL FALLS TO THE MIN MARK THE BRAKING LIGHT ON THE DASHBOARD WILL TURN ON SERVICE IMMEDIATELY ...

Page 95: ... to high acid concentration Distilled water is recommended When used in winter the garage should be heated otherwise coolant should be drained immediately after shutdown to avoid damaging the radiator and engine WARNING GENERALLY FREEZING POINT OF THE COOLANT USED SHOULD BE 5 C LOWER THAN MINIMUM TEMPERATURE IN OPERATION ZONE ...

Page 96: ... thermostat relief screw cannot fall off drain air e Tighten thermostat relief screw after draining air tighten torque 3 0N m 31kgf cm and add coolant from coolant filler hole f Repeat item 2 3 three times until coolant leak from bleeder screw g Add coolant continually into radiator and coolant pot to FULL mark h Insert air relief hose of heater screw radiator cap and pot cap i Allow engine to run...

Page 97: ...n jacket of cylinder after removing coolant drain plug of jacket at the bottom of the fourth cylinder d After draining out the coolant in system install the coolant pot tighten drain valve plug and pipe as per original condition Tighten coolant drain plug at the bottom of radiator and coolant drain plug of jacket at the bottom of the fourth cylinder e Fill in new coolant to the radiator as per fil...

Page 98: ...IT IS SUGGESTED THAT FD40 TYPE VEHICLE ENGINE COOLANT OR GLYCOL AQUEOUS SOLUTION WHICH PH VALUE IS BETWEEN 7 0 AND 8 5 IS ADOPTED DIFFERENT BRANDS OF COOLANT SHOULD NOT BE MIXED THE COOLANT SHOULD NOT CONTAIN ALCOHOL OR METHANOL OR COMMON WATER UNDER ANY CIRCUMSTANCES THIS WILL RESULT IN COOLING SYSTEM DAMAGE c Washer fluid ...

Page 99: ... fluid and 2 portions water 10 Degrees Cold areas winter 1 portion fluid and 1 portion water 20 Degrees Extremely cold areas winter Without water 50 Degrees WARNING IF THE WASHER FLUID IS EXTREMELY THIN IT MAY FREEZE ON THE GLASS NEVER START THE WASHER MOTOR WITHOUT WASHER FLUID 4 Air filter WARNING IF AIR FILTER IS JAMMED BY DUST THE INTAKE RESISTANCE WILL INCREASE THIS WILL RESULT IN DECREASED O...

Page 100: ...ure gauge make adjustments if necessary WARNING IT IS RECOMMENDED TO CHECK TIRES IN COLD VS WARM CONDITIONS FOR ACTUAL RESULTS WHILE ADDING PRESSURE TO TIRES STOP WHEN SPECIFIED PRESSURE HAS BEEN REACHED AS THIS MAY RESULT IN OVER INFLATION WHICH MAY CAUSE TIRE TO EXPLODE DEPTH OF TIRE GROOVE SHOULD BE OVER 1 6MM BUMPING THE CURB OR DRIVING OVER STONE CAN DAMAGE TIRE AND CHANGE WHEEL ALIGNMENT ...

Page 101: ...will affect voltage of dynamo and may cause belt to overheat When checking the tension of belt apply 100N force to belt in the middle of dynamo and to the water pump The depressive displacement should be between 7 to 10mm and should be 10 to 15mm for an old belt a Adjusting or changing of water pump belt i Unscrew two bottom screws and two top adjusting screw of AC dynamo when the engine stops run...

Page 102: ...sistance which is between 0 30MM turn the steering wheel left and right slowly Inspect for smoothness of the operation 8 Checking clutch pedal Move clutch pedal with hand and measure the moving gap before you feel light resistance The gap which is the clutch pedal free stroke should be within 20 30MM ...

Page 103: ...removing rinse with the clear fresh water When the vehicle is to be left unused for at least 15 days disconnect the negative terminal of the battery to avoid corrosion WARNING THE FLAMMABLE GASES GENERATED FROM THE BATTERY MIGHT CATCH FIRE AND EXPLODE KEEP SPARKS AND FLAMES AWAY DO NOT SMOKE WHEN CHARGING THE BATTERY WHEN CHECKING THE BATTERY DISCONNECT NEGATIVE TERMINAL CONNECTED TO THE BATTERY D...

Page 104: ...e carpet with a soft cloth such as gauze dipped in 3 neutral detergent Remove the detergent with the soft cloth soaked in clear fresh water 3 Leather Surfaces Remove dirt with soft cloth such as gauze dipped in 3 neutral detergent recommended specifically for leather cleaning WARNING THE SURFACE MAYBE DAMAGED IF YOU WIPE IT WITH NYLON OR SYNTHETIC BRUSH SOLVENT SUCH AS GASOLINE ACID ALKALI AND ALC...

Page 105: ...irt you can use the neutral detergent Use water to remove the dirt c Wipe the water with the deerskin or soft cloth d Do not splash water into engine while cleaning under body as this may result in engine damage WARNING COIN CAR WASHES HAVE HIGH TEMPERATURE AND PRESSURE THIS MAY DISTORT AND DEFORM RESIN PARTS IF USING A CAR WASH GLASS MUST BE KEPT MORE THAN 50CM AWAY FROM WASH NOZZLE AND AUTO BODY...

Page 106: ...screen detergent glass detergent etc to clean windows WARNING AVOID DAMAGE TO THE ELECTRIC FUSE WHILE WASHING INSIDE 4 Maintenance of the wiper a Clean the rubber with a soft moist wet cloth b If the rubber has been worn replace the brush of the wiper as soon as possible 5 Maintenance of the resin parts Use sponge to clean surface such as bumper The bumper color will turn to white when wax has bee...

Page 107: ... of Erosion a Accumulating salt clay and humidity etc at uncommon parts in body and chassis b Scraping the outer protective paint layer because of accident or stone collision c Environmental conditions accelerate erosion salty air industrial pollution dust full of chemical substance salt and alkali on roads d Relative higher humidity especially in areas where temperature is above zero degree e Dam...