PERODUA MYVI WORKSHOP MANUAL

PERODUA MYVI K3/EJEV 2010

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HOW TO BUY

COPYRIGHT 2012

www.e-bookmanual.com

SERVICE MANUALPERODUA

M300

FOREWORD

This service manual has been prepared to proved information covering general service repairsfor 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 improvementsin design without advance notice and without incurring any obligation to us.

Published in May, 2005

PERODUA SALES SDN. BHD.

© 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.

COGENERAL INFORMATION

PERODUA

MYVI

IMPORTANT SAFETY NOTICE .............................. A1– 1

GENERAL DESCRIPTION ................................. A1– 1

WARNINGS, CAUTIONS AND NOTES.............. A1– 1

GENERAL WARNINGS...................................... A1– 2

HOW TO USE THIS MANUAL ................................ A1– 3

ARTICLE TO BE PREPARED ............................. A1– 3

REMOVAL AND INSTALLATIONPROCEDURES ................................................ A1– 3

DESCRIPTION OF SERVICESTANDARD VALUE ......................................... A1– 4

CONTENTS NOT DESCRIBED INTHIS MANUAL ................................................. A1– 5

DEFINITIONS OF TERMS .................................. A1– 5

ABBREVIATION CODES ........................................ A1– 6

HOW TO GRASP SPECIFIED TIGHTENING

TORQUE FOR GENERAL STANDARD

BOLT AND NUT ...................................................... A1– 7

DETERMINING PROCEDURE FORTIGHTENING TORQUE FORGENERAL STANDARD BOLTSAND NUTS....................................................... A1– 7

UNIT ......................................................................... A1– 9

NEW UNIT BECAUSE OF THEINTRODUCTION OF THE SI UNIT................... A1– 9

PREFIX USED IN SI UNIT .................................. A1– 9

GENERAL SERVICE INSTRUCTION ..................... A1– 10

JACK UP OR LIFT UP ....................................... A1– 10

INSTALLATION AND REMOVAL OFBATTERY TERMINAL ...................................... A1– 10

CONNECTING/DISCONNECTINGTHE EARTH ..................................................... A1– 10

REPAIRING OF FUEL SYSTEM ......................... A1– 10

USE OF THE SST .............................................. A1– 11

REMOVAL, DISASSEMBLY ............................... A1– 11

CHECK AND MEASUREMENTOF PARTS........................................................ A1– 11

INSTALLATION, ASSEMBLING......................... A1– 11

ADJUSTMENT, OPERATIONCONFIRMATION ............................................. A1– 11

HANDLING OF HOSE OR THE LIKE................. A1– 11

TOUCH UP ........................................................ A1– 11

SUPPORTING POINTS FOR JACKS

AND SAFETY STANDS .......................................... A1– 12

A1

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 DLCTERMINAL ....................................................... A1– 19

HOW TO SHORT-CIRCUIT THE DLC................ A1– 19

HOW TO SHORT-CIRCUIT USINGTHE TEST ........................................................ A1– 20

HOW TO CONNECT WITH THE DIAGNOSISTESTER(DS-21/DS-II) ...................................... A1– 20

INSTRUCTIONS FOR SYSTEM

INSPECTION ........................................................... A1– -21

HANDLING INSTRUCTIONOF CONNECTOR ............................................ A1– 21

CONNECTOR REMOVAL/INSTALLATION PROCEDURE......................... A1– 21

CHECK PROCEDURE OF WIREHARNESS AND CONNECTOR ........................ A1– 23

CIRCUIT INSPECTION OFCOMPUTER UNIT............................................ A1– 24

HANDLING INSTRUCTIONOF 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 IDENTIFICATIONNUMBER ......................................................... A1– 32

ENGINE TYPE AND ENGINENUMBER ......................................................... A1– 32

MVA000001-00000

B2–37

(2) Loosen the oil pipe union bolt at the oil filter bracketside.

(3) Remove the oil pipe cramp bolt from the cylinderhead.

(4) Remove the oil pipe union bolt with oil filter from the

camshaft bearing cap No. 1.

(5) Remove the camshaft bearing cap No. 1 by removing

the bolts in a sequence, as indicated in the rightfigure.

(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).

(7) Remove the camshaft bearing cap No. 2 by removingthe bolts in a sequence, as indicated in the right

figure.

wr

t

e

q

w!0yr

!2i

u qot

!1 e

Sub-gear

hold bolt

10. Removal of camshaft bearing cap No. 1 and camshaftbearing cap No. 2.

(1) Using the hexagonal section of the camshaft No. 2,set the mating marks of the camshaft gear sectionsto the relationship as indicated in the right figure.

Camshaft center line10˚ - 20˚

MEM00033-00032

LEM00034-00033

MEM00035-00034

MEM00036-00035

MEM00037-00036

E1–60

M21C7063T10

M21C7064T10

M21C7068T10

(2) Drum, brake1. If the drum cannot be removed because it has seized to

the rear axle hub & bearing Assy, screw two appropriatebolts (M6)1.00) into the screw holes of the drum and

remove it.

(3) Hub & bearing Assy, rear axle1. Remove the bolt retaining the hub & bearing assembly, using a long Torx wrench T55.

TOOL: Long TORX® 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 drum1. 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 grindthe lining.

SPECIFIED VALUE: No significant poor contact ispresent.

2. Be sure to wipe off the chalk.

(2) Cylinder Assy, disc brake, rear1. 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.

13-1-6 POINTS OF INSTALLATION(1) Hub & bearing Assy, rear axle1. 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 longTorx wrench T55.

TOOL: Long TORX® wrench T55

(2) Drum, brake1 .Insert a flat screwdriver through the shoe adjusting hole

of the RH/LH rear brake backing plate S/A and turn theRH/LH automatic adjusting ratchets by . In this wAssy,release the engagement with the RH/LH automatic ad-

justing lever S/A. Then, fully contract the brake shoeAssy No. 3 at the leading side and the trailing side. Un-der this condition, install the drum into position.

I1–32

11-1-2 REMOVAL AND INSTALLATION PROCEDURES(1) Components

(2) Removal and installation procedures

T11B5024S33

T:9.0&5.7 {92&57}

a

b

B

N

TKOS143_00007993E

1 a Lever S/A, back door lock open

i 2 b Cable S/A, fuel lid lock control

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:

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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

pay@e-bookmanual.com

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.

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HOW TO BUY

COPYRIGHT 2012

www.e-bookmanual.com

B1 ENGINEK3/EJ

PERODUA

MYVI

K3/EJENGINE....................................................... B1– 1

ITEMS TO BE PREPARED ........................ B1– 1BASIC CHECK AND ADJUSTMENT......... B1– 2

B1

B1–5

1-2-7 CHECK AND ADJUSTMENT OF TENSION (DEFLECTION AMOUNT) OF V-BELT FORALTERNATOR

(1) Check1. 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

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 thiscondition, neasure the deflection amount.

• In cases where the tension is measured after the belt has been assembled, the measurementshould 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 ofthe 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 tensionconforms to the specified value for “During inspection.”

• When the belt that has been used for more than five minutes is assembled, the belt tension shouldbe adjusted to the mid-value of the specified value for “During inspection.”

590&100{60&10.2}

490 - 690

9 - 11

4 - 5

EJ

K3

EJ

K3

During inspection

390&50{40&5.1}

340 - 440

13 - 15

6 - 7

When a new part is installed

Tension value (N{kgf})

Deflection amount (mm) (Pushing force 100N{10.2kgf})

TKOS143-00006353E

T11E8503ES16

i- EJ-VE ii- K3-VE

Water pump pully

Water pump pully

Idler pully

Alternator pully

Crankshaft pully

Alternator pully

Crankshaft pully A/C pully

A/C pully

Idler pully

Measuringsection(A)

Measuringsection

(2) Adjustment1. Loosen the bolts (B) for retaining the alternator.2. Loosen the bolts (A) for retaining the adjusting bar.

B1–6

AEJ

B

3. After loosening, lightly tighten the bolts (A) by hand.4. Adjust the tension by turning the adjusting bolt of the ad-

justing bar.5. Tighten the bolts (A) for retaining the adjusting bar.6. Tighten the bolts (B) for retaining the alternator

TIGHTENING TORQUE (K3): Bolt A19.0&3.8N;m{190&38kgf;cm}Bolt B44.0&8.8N;m{450&90kgf;cm}

TIGHTENING TORQUE (EJ): Bolt A29.0&5.8N;m{295.6&59.1kgf;cm}Bolt B52.0&10.4N;m{530&106kgf;cm}

7. Confirm the belt tension.

1-2-8 CHECK AND ADJUSTMENT OF VALVE CLEARANCEEJPlease refer to section B2.K3(1) Specified value

(2) CheckNOTE• For the removal and installation procedures of each

part, refer to the section under “Removal and Installa-tion of Camshaft.”

Refer to Page B2-12.

1. Remove the cylinder head cover.2. Turn the crankshaft in the normal direction, until the tim-

ing mark of the crankshaft pulley is aligned with the indi-cator of the timing chain cover.

3. Ensure that the mating marks at the top of the drive gearand driven gear of the camshaft are aligned with eachother. If they are not aligned, make one more turn so thatthe mating marks are aligned.

4. Using a thickness gauge, check the valve clearancesshown in the right figure.

J04E6058ET10

Mate mark

J04E6007T10

TKOS143-00006343E

TKOS143-00006344E

Cylinder No.1 Cylinder No.2 Cylinder No.3 Cylinder No.4

IN EX IN EX IN EX IN EX

< < < ( ( < ( (

Valve clearance (mm)

IN 0.18'0.055

(0.035Vehicle mounted with Type

K3-VE engine EX

During cold pe-

riod 0.31'0.055

(0.035

T11E6011T10

A

B

K3

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PERODUA MYVI WORKSHOP MANUAL

By www.e-bookmanual.com

[SINCE 2003] Copyright ©2014 e-bookmanual.com Your e-manual solution source