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PERODUA MYVI WORKSHOP MANUAL - e-bookmanual

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PERODUA MYVI WORKSHOP MANUAL
PERODUA MYVI K3/EJEV 2010
By www.e-bookmanual.com
[SINCE 2003] Copyright В©2014 e-bookmanual.com
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SAMPLE WORKSHOP MANUAL
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111O PAGE @ 18.1 MB
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Acc. Holder Name : DZULKIFLEE
Acc. Number
: 152068638890
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Acc. Holder Name : DZULKIFLEE
Acc. Number
: 02039020168377
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COPYRIGHT 2012
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SERVICE MANUAL
PERODUA
M300
FOREWORD
This service manual has been prepared to proved information covering general service repairs
for the model M300 series manufactured in May, 2005 afterward.
For the service specifications and repair procedures of the model M300 series other than those
listed in this manual, refer to the following manuals.
All information used in this service manual was in effect at time when the manual was printed.
However, the specifications and procedures may be revised owing to continuing improvements
in design without advance notice and without incurring any obligation to us.
Published in May, 2005
PERODUA SALES SDN. BHD.
В© 2005 PERODUA SALES SDN. BHD.
All rights reserved. This material may not be reproduced or copied, in whole or in part,
without the written permission of PERODUA SALES SDN. BHD.
PERODUA
MYVI
GENERAL INFORMATION
CO
A1
IMPORTANT SAFETY NOTICE .............................. A1–
GENERAL DESCRIPTION ................................. A1–
WARNINGS, CAUTIONS AND NOTES .............. A1–
GENERAL WARNINGS ...................................... A1–
HOW TO USE THIS MANUAL ................................ A1–
ARTICLE TO BE PREPARED ............................. A1–
REMOVAL AND INSTALLATION
PROCEDURES ................................................ A1–
DESCRIPTION OF SERVICE
STANDARD VALUE ......................................... A1–
CONTENTS NOT DESCRIBED IN
THIS MANUAL ................................................. A1–
DEFINITIONS OF TERMS .................................. A1–
ABBREVIATION CODES ........................................ A1–
HOW TO GRASP SPECIFIED TIGHTENING
TORQUE FOR GENERAL STANDARD
BOLT AND NUT ...................................................... A1–
DETERMINING PROCEDURE FOR
TIGHTENING TORQUE FOR
GENERAL STANDARD BOLTS
AND NUTS ....................................................... A1–
UNIT ......................................................................... A1–
NEW UNIT BECAUSE OF THE
INTRODUCTION OF THE SI UNIT ................... A1–
PREFIX USED IN SI UNIT .................................. A1–
GENERAL SERVICE INSTRUCTION ..................... A1–
JACK UP OR LIFT UP ....................................... A1–
INSTALLATION AND REMOVAL OF
BATTERY TERMINAL ...................................... A1–
CONNECTING/DISCONNECTING
THE EARTH ..................................................... A1–
REPAIRING OF FUEL SYSTEM ......................... A1–
USE OF THE SST .............................................. A1–
REMOVAL, DISASSEMBLY ............................... A1–
CHECK AND MEASUREMENT
OF PARTS ........................................................ A1–
INSTALLATION, ASSEMBLING ......................... A1–
ADJUSTMENT, OPERATION
CONFIRMATION ............................................. A1–
HANDLING OF HOSE OR THE LIKE................. A1–
TOUCH UP ........................................................ A1–
SUPPORTING POINTS FOR JACKS
AND SAFETY STANDS .......................................... A1–
1
1
1
2
3
3
3
4
5
5
6
7
7
9
9
9
10
10
10
10
10
11
11
11
11
11
11
11
12
SUPPORTING POINTS OF LIFTS .......................... A1– 14
TOWING INSTRUCTIONS ...................................... A1– 15
TOWING WITH ROPE
(ONLY FOR EMERGENCY) ............................. A1– 15
USING FLAT BED TRUCK ................................. A1– 15
WHEEL LIFT TYPE............................................. A1– 15
DIAGNOSTICS INSTRUCTIONS ............................ A1– 16
HOW TO PROCEED DIAGNOSIS ..................... A1– 16
DATA LINK CONNECTOR ...................................... A1– 19
ARRANGEMENT OF DLC
TERMINAL ....................................................... A1– 19
HOW TO SHORT-CIRCUIT THE DLC................ A1– 19
HOW TO SHORT-CIRCUIT USING
THE TEST ........................................................ A1– 20
HOW TO CONNECT WITH THE DIAGNOSIS
TESTER(DS-21/DS-II) ...................................... A1– 20
INSTRUCTIONS FOR SYSTEM
INSPECTION ........................................................... A1– -21
HANDLING INSTRUCTION
OF CONNECTOR ............................................ A1– 21
CONNECTOR REMOVAL/
INSTALLATION PROCEDURE ......................... A1– 21
CHECK PROCEDURE OF WIRE
HARNESS AND CONNECTOR ........................ A1– 23
CIRCUIT INSPECTION OF
COMPUTER UNIT ............................................ A1– 24
HANDLING INSTRUCTION
OF SYSTEM ..................................................... A1– 25
INSTRUCTIONS FOR RADIO
INSTALLATION ....................................................... A1– 25
HANDLING INSTRUCTIONS ON
CATALYTIC CONVERTER-EQUIPPED
VEHICLES ............................................................... A1– 25
PRECAUTION FOR VEHCLES EQUIPEED
WITH SRS AIRBAG ................................................ A1– 26
VEHICLE IDENTIFICATION .................................... A1– 31
MODEL CODE................................................... A1– 31
BODY COLOR CODE........................................ A1– 31
VEHICLE IDENTIFICATION
NUMBER ......................................................... A1– 32
ENGINE TYPE AND ENGINE
NUMBER ......................................................... A1– 32
MVA000001-00000
B2–37
10. Removal of camshaft bearing cap No. 1 and camshaft
bearing cap No. 2.
(1) Using the hexagonal section of the camshaft No. 2,
set the mating marks of the camshaft gear sections
to the relationship as indicated in the right figure.
Camshaft center line
10Лљ - 20Лљ
MEM00033-00032
(2) Loosen the oil pipe union bolt at the oil filter bracket
side.
(3) Remove the oil pipe cramp bolt from the cylinder
head.
(4) Remove the oil pipe union bolt with oil filter from the
camshaft bearing cap No. 1.
LEM00034-00033
(5) Remove the camshaft bearing cap No. 1 by removing
the bolts in a sequence, as indicated in the right
figure.
w
r
t
e
q
MEM00035-00034
(6) Secure the camshaft sub-gear to the gear section of
the camshaft No. 1, using a bolt (M5 size with a.
0.8 mm pitch).
Sub-gear
hold bolt
MEM00036-00035
(7) Remove the camshaft bearing cap No. 2 by removing
the bolts in a sequence, as indicated in the right
figure.
y i
t
u
!2
!0
o !1
w
q
r
e
MEM00037-00036
E1–60
(2) Drum, brake
1. If the drum cannot be removed because it has seized to
the rear axle hub & bearing Assy, screw two appropriate
bolts (M6)1.00) into the screw holes of the drum and
remove it.
M21C7063T10
(3) Hub & bearing Assy, rear axle
1. Remove the bolt retaining the hub & bearing assembly, using a long Torx wrench T55.
TOOL: Long TORXВ® wrench T55
2. Slowly pull out the hub & bearing assembly from the rear suspension arm assembly. Disconnect the
connector from the speed sensor wire.
13-1-5
INSPECTION
(1) Contact between brake shoe lining and brake drum
1. Apply chalk to the inner surface of the drum. Slide the
lining, while it is being pressed against the inner surface
of the drum. If poor contact is present, be sure to grind
the lining.
SPECIFIED VALUE: No significant poor contact is
present.
2. Be sure to wipe off the chalk.
(2) Cylinder Assy, disc brake, rear
1. Check the cylinder assembly for corrosion and damage.
(3) Plate S/A, brake backing, rear RH/LH
1. Check the plate subassembly for wear and damage.
M21C7064T10
13-1-6
POINTS OF INSTALLATION
(1) Hub & bearing Assy, rear axle
1. Connect the connector of the speed sensor wire to the hub & bearing assembly. Then, install the hub
& bearing assembly to the rear suspension arm assembly.
2. Secure the hub & bearing assembly and brake backing rear plate subassembly RH/LH, using a long
Torx wrench T55.
TOOL: Long TORXВ® wrench T55
(2) Drum, brake
1 .Insert a flat screwdriver through the shoe adjusting hole
of the RH/LH rear brake backing plate S/A and turn the
RH/LH automatic adjusting ratchets by . In this wAssy,
release the engagement with the RH/LH automatic adjusting lever S/A. Then, fully contract the brake shoe
Assy No. 3 at the leading side and the trailing side. Under this condition, install the drum into position.
M21C7068T10
I1–32
11-1-2
REMOVAL AND INSTALLATION PROCEDURES
(1) Components
N
a
b
B
T:9.0&5.7 {92&57}
T11B5024S33
(2) Removal and installation procedures
1
i 2
a Lever S/A, back door lock open
b Cable S/A, fuel lid lock control
TKOS143_00007993E
HOW TO BUY
Payment methods:
1. For buy with credit card just choose and click
button at the end of price list in
Product Item Number or click the the PayPal link down here first and signup now before make
payment:
2. For online banking transfers, to verified your payment please give the Product Item Number,
your e-mail (must valid to receive the download link), Name of Bank, Total of transaction,
Date&hour of transaction and fill the form at contact form or send to
[email protected]
Maybank Account Number:
Acc. Holder Name : DZULKIFLEE
Acc. Number
: 152068638890
Bank Islam Account Number:
Acc. Holder Name : DZULKIFLEE
Acc. Number
: 02039020168377
CIMB Bank Account Number:
Acc. Holder Name : DZULKIFLEE
Acc. Number
: 02110042053522
You will receive the download link in 24hour after the payment verified
from system admin. If any other problem about your payment system
admin will contact you.
Or you will reach us at: [email protected]
COPYRIGHT 2012
www.e-bookmanual.com
PERODUA
MYVI
B1 ENGINE
K3/EJ
K3/EJ
ENGINE ....................................................... B1– 1
ITEMS TO BE PREPARED ........................ B1– 1
BASIC CHECK AND ADJUSTMENT ......... B1– 2
B1
B1–5
1-2-7
CHECK AND ADJUSTMENT OF TENSION (DEFLECTION AMOUNT) OF V-BELT FOR
ALTERNATOR
(1) Check
1. Check the V-ribbed belt for cracks, deterioration and significant wear.
2. Check the tension of the V-ribbed belt, using a belt tension gauge.
NOTE
• The check can be performed by measuring the deflection amount of the V-belt.
Specified value
Tension value (N{kgf})
Deflection amount (mm) (Pushing force 100N{10.2kgf})
EJ
K3
EJ
K3
When a new part is installed
590&100{60&10.2}
490 - 690
4-5
9 - 11
During inspection
390&50{40&5.1}
340 - 440
6-7
13 - 15
TKOS143-00006353E
NOTE
• When checking the deflection amount of the belt, push a point between the water pump pulley and
alternator pulley or crankshaft pulley and A/C pulley with a force of 100 N (10.2 kgf). Under this
condition, neasure the deflection amount.
• In cases where the tension is measured after the belt has been assembled, the measurement
should be performed after cranking two turns.
• When the belt is replaced with a new one, the belt tension should be adjusted to the mid-value of
the specified value for “When a new part is installed.”
• As regards the belt that has been used for more than five minutes, ensure that the belt tension
conforms to the specified value for “During inspection.”
• When the belt that has been used for more than five minutes is assembled, the belt tension should
be adjusted to the mid-value of the specified value for “During inspection.”
i- EJ-VE
ii- K3-VE
Idler pully
Water pump pully
Measuring
section(A)
Idler pully
Measuring
section
Water pump pully
A/C pully
Alternator pully
Alternator pully
Crankshaft pully
Crankshaft pully
A/C pully
T11E8503ES16
(2) Adjustment
1. Loosen the bolts (B) for retaining the alternator.
2. Loosen the bolts (A) for retaining the adjusting bar.
B1–6
3. After loosening, lightly tighten the bolts (A) by hand.
4. Adjust the tension by turning the adjusting bolt of the adjusting bar.
5. Tighten the bolts (A) for retaining the adjusting bar.
6. Tighten the bolts (B) for retaining the alternator
TIGHTENING TORQUE (K3): Bolt A
19.0&3.8N;m
{190&38kgf;cm}
Bolt B
44.0&8.8N;m
{450&90kgf;cm}
TIGHTENING TORQUE (EJ): Bolt A
29.0&5.8N;m
{295.6&59.1kgf;cm}
Bolt B
52.0&10.4N;m
{530&106kgf;cm}
7. Confirm the belt tension.
CHECK AND ADJUSTMENT OF VALVE CLEARANCE
1-2-8
EJ
Please refer to section B2.
K3
(1) Specified value
Vehicle mounted with Type
K3-VE engine
IN
EX
EJ
A
B
K3
A
B
T11E6011T10
Valve clearance (mm)
During cold pe0.18'0.055
(0.035
riod
0.31'0.055
(0.035
TKOS143-00006343E
(2) Check
NOTE
• For the removal and installation procedures of each
part, refer to the section under “Removal and Installation of Camshaft.”
Refer to Page B2-12.
1. Remove the cylinder head cover.
2. Turn the crankshaft in the normal direction, until the timing mark of the crankshaft pulley is aligned with the indicator of the timing chain cover.
3. Ensure that the mating marks at the top of the drive gear
and driven gear of the camshaft are aligned with each
other. If they are not aligned, make one more turn so that
the mating marks are aligned.
Mate mark
J04E6058ET10
4. Using a thickness gauge, check the valve clearances
shown in the right figure.
Cylinder No.1
IN
EX
<
<
Cylinder No.2
IN
EX
<
(
Cylinder No.3
IN
EX
(
<
Cylinder No.4
IN
EX
(
(
TKOS143-00006344E
J04E6007T10
PERODUA MYVI WORKSHOP MANUAL
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