VOYAH FREE 3 maintenance (EN)

3. Maintenance Manual 3-1 Contents Contents Contents 3.1 Maintenance .............................................................................................................................................. 3-4 3.1.1 Maintenance interval chart ..................................................................................................................... 3-4 3.1.2 Precautions for maintenance ................................................................................................................. 3-7 3.1.3 Oil specification and filling volume .........................................................................................................

3-8 3.1.4 Vehicle maintenance inspection ............................................................................................................ 3-9 3.1.4.1 Replacement of engine oil and oil filter ............................................................................................... 3-9 3.1.4.2 Replacement of air filter .................................................................................................................... 3-12 3.1.4.3 Replacement of A/C filter ..................................................................................................................

3-13 3.1.4.4 Replacement of brake fluid ............................................................................................................... 3-14 3.1.4.5 Replacement of spark plug ............................................................................................................... 3-17 3.1.4.6 Replacement of wiper blade ............................................................................................................. 3-18 3.1.4.7 Replacement of drive motor and high voltage battery coolant (REV) ..............................................

3-19 3.1.4.8 Replacement of drive motor and high voltage battery coolant (EV) ................................................. 3-21 3.1.4.9 Replacement of engine coolant ........................................................................................................ 3-23 3.1.4.10 Replacement of A/C refrigerant ...................................................................................................... 3-26 3.1.4.11 Replacement of front drive motor assembly lubricating oil ............................................................. 3-28 3.1.4.12 Replacement of rear drive motor assembly lubricating oil ..............................................................

3-30 3.1.4.13 Replacement of generator lubricating oil ........................................................................................ 3-32 3.1.4.14 Replacement of engine oil and oil filter (Facelift) ............................................................................ 3-34 3.1.4.15 Replacement of brake fluid (Facelift) .............................................................................................. 3-37 3.1.4.16 Replacement of drive motor and high voltage battery coolant (REV Facelift) ............................... 3-40 3.1.4.17 Replacement of drive motor and high voltage battery coolant (EV Facelift) ..................................

3-42 3.1.4.18 Replacement of front drive motor assembly lubricating oil (Facelift) .............................................. 3-44 3.1.4.19 Replacement of rear drive motor assembly lubricating oil (Facelift) .............................................. 3-46 3.1.5 Vehicle oil inspection ............................................................................................................................ 3-48 3.1.5.1 Inspection of engine oil .....................................................................................................................

3-48 3.1.5.2 Inspection of drive motor and high voltage battery coolant (REV) ................................................... 3-49 3.1.5.3 Inspection of drive motor and high voltage battery coolant (EV) ...................................................... 3-51 3.1.5.4 Inspection of engine coolant ............................................................................................................. 3-52 3.1.5.5 Inspection of brake fluid ....................................................................................................................

3-54 3.1.5.6 Inspection of windshield washer liquid .............................................................................................. 3-54 3.1.6 Maintenance inspection of body parts and electrical appliances ........................................................ 3-57 3.1.6.1 Maintenance inspection of battery .................................................................................................... 3-57 3.1.6.2 High voltage removal ........................................................................................................................

3-60 3.1.6.3 Maintenance inspection of seat belt ................................................................................................. 3-62 3.1.6.4 Maintenance inspection of airbag ..................................................................................................... 3-65 3.1.6.5 Inspection of door window and sunroof ............................................................................................ 3-66 VOYAH FREE

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3-2 Contents 3. Maintenance Manual 3.1.6.6 Inspection and adjustment of windshield cleaning direction ............................................................. 3-68 3.1.6.7 Maintenance inspection of door locks, safety buttons, child locks ................................................... 3-69 3.1.6.8 Inspection of door stoppers, door locks, hinges ............................................................................... 3-69 3.1.6.9 Maintenance and inspection of water pump belt ..............................................................................

3-71 3.1.6.10 Inspection of battery high-voltage harness ..................................................................................... 3-71 3.1.6.11 Inspection of bolted connections between the integrated MCU and the engine compartment high- voltage box .................................................................................................................................................... 3-72 3.1.6.12 Self diagnosis: inspection of DTC ................................................................................................... 3-73 3.1.7.13 Reading and uploading of data being monitored by OBD ..............................................................

3-73 3.1.6.14 High voltage removal (Facelift) ....................................................................................................... 3-74 3.1.7 Maintenance inspection of chassis ...................................................................................................... 3-75 3.1.7.1 Maintenance inspection of wheel fixing bolt ..................................................................................... 3-75 3.1.7.2 Maintenance inspection of tires ........................................................................................................

3-76 3.1.7.3 Tire rotation ....................................................................................................................................... 3-77 3.1.7.4 Inspection of brake pad ..................................................................................................................... 3-78 3.1.7.5 Inspection of brake disc .................................................................................................................... 3-78 3.1.7.6 Inspection of electronic parking brake ..............................................................................................

3-79 3.1.7.7 Inspection of shock absorber bearing ............................................................................................... 3-80 3.1.7.8 Inspection of steering tie rod ball joint and dust cover ..................................................................... 3-80 3.1.7.9 Inspection of lower swing arm ball joint and stabilizer bar tie rod ball joint ...................................... 3-82 3.1.7.10 Inspection of drive shaft and dust cover ......................................................................................... 3-83 3.1.7.11 Inspection of high voltage battery and integrated MCU fixing bolts ...............................................

3-83 3.1.7.12 Tightening of chassis bolts .............................................................................................................. 3-83 3.1.7.13 Test run ........................................................................................................................................... 3-91 3.1.7.14 Inspection of lower swing arm ball joint and stabilizer bar tie rod ball joint (Facelift) ..................... 3-92 3.1.7.15 Tightening of chassis bolts (Facelift) ..............................................................................................

3-93 3.1.8 Oil specification and filling volume (Facelift) ...................................................................................... 3-100 3.2 Health and safety .................................................................................................................................. 3-101 3.2.1 Safety instructions .............................................................................................................................. 3-101 3.2.2 Acid and alkali ....................................................................................................................................

3-101 3.2.3 Airbag ................................................................................................................................................. 3-101 3.2.4 A/C refrigerant .................................................................................................................................... 3-102 3.2.5 Adhesives and sealants ..................................................................................................................... 3-102 3.2.6 Engine coolant ...................................................................................................................................

3-103 3.2.7 Asbestos ............................................................................................................................................. 3-103 3.2.8 Battery acid ........................................................................................................................................ 3-103 3.2.9 Brake fluid .......................................................................................................................................... 3-104 3.2.10 Chemicals ......................................................................................................................................... 3-104 VOYAH FREE

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3. Maintenance Manual 3-3 Contents 3.2.11 Dust .................................................................................................................................................. 3-104 3.2.12 Electric shock ................................................................................................................................... 3-104 3.2.13 Exhaust gas ..................................................................................................................................... 3-105 3.2.14 Fiber isolation ...................................................................................................................................

3-105 3.2.15 Fire .................................................................................................................................................. 3-105 3.2.16 First aid ............................................................................................................................................. 3-105 3.2.17 Foam - polyurethane ........................................................................................................................ 3-106 3.2.18 Fuel ..................................................................................................................................................

3-106 3.2.19 Gas cylinder ..................................................................................................................................... 3-106 3.2.20 General workshop tools and equipment .......................................................................................... 3-107 3.2.21 Lubricants and greases .................................................................................................................... 3-107 3.2.22 Noise ................................................................................................................................................

3-107 3.3 Special tools and equipment ................................................................................................................. 3-108 3.3.1 List of special tools ............................................................................................................................. 3-108 VOYAH FREE

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3-4 Maintenance 3.

Maintenance Manual Maintenance 3.1 Maintenance 3.1.1 Maintenance interval chart VOYAH FREE Operations Maintenance item First maintenance (6 months or 5,000km) Routine maintenance Maintenance interval REV EV REV EV Must be replaced Oil (range extender lubricating oil) ● ● Replace every 1 year or 10,000 km (mileage of range extender) Oil filter ● ● Replace every 1 year or 10,000 km (mileage of range extender) Air filter element ● Replace every 1 year or 20,000 km (mileage of range extender) Canister air filter ● Replace every 2 years or 40,000 km (mileage of range extender) Coolant ● ● Replace every 4 years or 80,000 km Brake Fluid ● ● Replace every 3 years or 40,000 km Spark plug ● Replace every 30,000 km (mileage of range extender) Drive motor gear lubricant (including reducer) ● ● Replace every 4 years or 80,000 km Generator lubricating oil ● ● Replace every 4 years or 80,000 km A/C filter element ● ● Replace every 1 years or 20,000 km Check fluid level or add coolant (fluid level needs to be between MAX and MIN) Coolant (fluid level needs to be between MAX and MIN) ● ● ● ● Regular maintenance inspection Brake fluid (fluid level needs to be between MAX and MIN) ● ● ● ● Regular maintenance inspection Inspect, adjust or replace Wear of front brake pad (eccentric wear, thickness of single pad should be greater than 2mm) ● ● ● ● Regular maintenance inspection Wear of rear brake pad (eccentric wear, thickness of single pad should be greater than 2mm) ● ● ● ● Regular maintenance inspection Tension and wear condition of accessory belt (normal tension, wear) ● Replace every 6 years or 100,000 km (mileage of range extender) Check Whether the engine and transmission are subjected to leakage ● ● Regular maintenance inspection Ignition coil (aging, damage) ● ● Regular maintenance inspection Fuel pipe and joint (aging of fuel pipe, crack or damage of joint) ● ● Regular maintenance inspection Whether the wiper and wiper blade are normal, and whether the windshield washer fluid level is normal ● ● ● ● Regular maintenance inspection Cooling system hoses and joints (leakage, etc.) ● ● ● ● Regular maintenance inspection Whether the cooling effect of A/C is normal ● ● ● ● Regular maintenance inspection

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