PERODUA MYVI WORKSHOP MANUAL PERODUA MYVI K3/EJEV 2010 By www.e-bookmanual.com [SINCE 2003] Copyright В©2014 e-bookmanual.com Your e-manual solution source SAMPLE WORKSHOP MANUAL ONLY USD 19.90 111O PAGE @ 18.1 MB 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 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 .............................. A1вЂ“ GENERAL DESCRIPTION ................................. A1вЂ“ WARNINGS, CAUTIONS AND NOTES .............. A1вЂ“ GENERAL WARNINGS ...................................... A1вЂ“ HOW TO USE THIS MANUAL ................................ A1вЂ“ ARTICLE TO BE PREPARED ............................. A1вЂ“ REMOVAL AND INSTALLATION PROCEDURES ................................................ A1вЂ“ DESCRIPTION OF SERVICE STANDARD VALUE ......................................... A1вЂ“ CONTENTS NOT DESCRIBED IN THIS MANUAL ................................................. A1вЂ“ DEFINITIONS OF TERMS .................................. A1вЂ“ ABBREVIATION CODES ........................................ A1вЂ“ HOW TO GRASP SPECIFIED TIGHTENING TORQUE FOR GENERAL STANDARD BOLT AND NUT ...................................................... A1вЂ“ DETERMINING PROCEDURE FOR TIGHTENING TORQUE FOR GENERAL STANDARD BOLTS AND NUTS ....................................................... A1вЂ“ UNIT ......................................................................... A1вЂ“ NEW UNIT BECAUSE OF THE INTRODUCTION OF THE SI UNIT ................... A1вЂ“ PREFIX USED IN SI UNIT .................................. A1вЂ“ GENERAL SERVICE INSTRUCTION ..................... A1вЂ“ JACK UP OR LIFT UP ....................................... A1вЂ“ INSTALLATION AND REMOVAL OF BATTERY TERMINAL ...................................... A1вЂ“ CONNECTING/DISCONNECTING THE EARTH ..................................................... A1вЂ“ REPAIRING OF FUEL SYSTEM ......................... A1вЂ“ USE OF THE SST .............................................. A1вЂ“ REMOVAL, DISASSEMBLY ............................... A1вЂ“ CHECK AND MEASUREMENT OF PARTS ........................................................ A1вЂ“ INSTALLATION, ASSEMBLING ......................... A1вЂ“ ADJUSTMENT, OPERATION CONFIRMATION ............................................. A1вЂ“ HANDLING OF HOSE OR THE LIKE................. A1вЂ“ TOUCH UP ........................................................ A1вЂ“ SUPPORTING POINTS FOR JACKS AND SAFETY STANDS .......................................... A1вЂ“ 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 .......................... A1вЂ“ 14 TOWING INSTRUCTIONS ...................................... A1вЂ“ 15 TOWING WITH ROPE (ONLY FOR EMERGENCY) ............................. A1вЂ“ 15 USING FLAT BED TRUCK ................................. A1вЂ“ 15 WHEEL LIFT TYPE............................................. A1вЂ“ 15 DIAGNOSTICS INSTRUCTIONS ............................ A1вЂ“ 16 HOW TO PROCEED DIAGNOSIS ..................... A1вЂ“ 16 DATA LINK CONNECTOR ...................................... A1вЂ“ 19 ARRANGEMENT OF DLC TERMINAL ....................................................... A1вЂ“ 19 HOW TO SHORT-CIRCUIT THE DLC................ A1вЂ“ 19 HOW TO SHORT-CIRCUIT USING THE TEST ........................................................ A1вЂ“ 20 HOW TO CONNECT WITH THE DIAGNOSIS TESTER(DS-21/DS-II) ...................................... A1вЂ“ 20 INSTRUCTIONS FOR SYSTEM INSPECTION ........................................................... A1вЂ“ -21 HANDLING INSTRUCTION OF CONNECTOR ............................................ A1вЂ“ 21 CONNECTOR REMOVAL/ INSTALLATION PROCEDURE ......................... A1вЂ“ 21 CHECK PROCEDURE OF WIRE HARNESS AND CONNECTOR ........................ A1вЂ“ 23 CIRCUIT INSPECTION OF COMPUTER UNIT ............................................ A1вЂ“ 24 HANDLING INSTRUCTION OF SYSTEM ..................................................... A1вЂ“ 25 INSTRUCTIONS FOR RADIO INSTALLATION ....................................................... A1вЂ“ 25 HANDLING INSTRUCTIONS ON CATALYTIC CONVERTER-EQUIPPED VEHICLES ............................................................... A1вЂ“ 25 PRECAUTION FOR VEHCLES EQUIPEED WITH SRS AIRBAG ................................................ A1вЂ“ 26 VEHICLE IDENTIFICATION .................................... A1вЂ“ 31 MODEL CODE................................................... A1вЂ“ 31 BODY COLOR CODE........................................ A1вЂ“ 31 VEHICLE IDENTIFICATION NUMBER ......................................................... A1вЂ“ 32 ENGINE TYPE AND ENGINE NUMBER ......................................................... A1вЂ“ 32 MVA000001-00000 B2вЂ“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 E1вЂ“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 I1вЂ“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 ....................................................... B1вЂ“ 1 ITEMS TO BE PREPARED ........................ B1вЂ“ 1 BASIC CHECK AND ADJUSTMENT ......... B1вЂ“ 2 B1 B1вЂ“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 вЂў 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 вЂў 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. вЂў In cases where the tension is measured after the belt has been assembled, the measurement should be performed after cranking two turns. вЂў When the belt is replaced with a new one, the belt tension should be adjusted to the mid-value of the specified value for вЂњWhen a new part is installed.вЂќ вЂў As regards the belt that has been used for more than five minutes, ensure that the belt tension conforms to the specified value for вЂњDuring inspection.вЂќ вЂў 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 вЂњDuring inspection.вЂќ 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. B1вЂ“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 вЂў For the removal and installation procedures of each part, refer to the section under вЂњRemoval and Installation of Camshaft.вЂќ 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 We at e-bookmanual are committed to providing high quality information, services and solutions to complement the expertise of professional automotive service providers. We support the efforts of automotive service professionals to maximize efficiency and build lasting relationships with their customers. 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