Руководство по эксплуатации Voyah Free 4 Powertrain (EN)

H97a-4-动力集成系统4.1-4.5（2022年6月8日）-1-336

4. Powertrain system 4-1 Contents Contents Contents 4.1 Intake system .......................................................................................................................................... 4-11 4.1.1 Precautions .......................................................................................................................................... 4-11 4.1.2 Introduction to structure and principle .................................................................................................. 4-11 4.1.3 Location diagram of range extender assembly ....................................................................................

4-12 4.1.4 Exploded view of structure ................................................................................................................... 4-13 4.1.4.1 Air filter assembly ............................................................................................................................... 4-13 4.1.4.2 Intake manifold assembly ................................................................................................................. 4-15 4.1.4.3 Intercooler assembly .........................................................................................................................

4-17 4.1.5 Technical parameters ........................................................................................................................... 4-19 4.1.6 Special tools ......................................................................................................................................... 4-19 4.1.7 Common faults ..................................................................................................................................... 4-20 4.1.7.1 Weak power of ranger extender .......................................................................................................

4-20 4.1.7.2 Turbocharger failure .......................................................................................................................... 4-20 4.1.8 Air filtering apparatus ............................................................................................................................ 4-21 4.1.8.1 Removal and refitting of air filter assembly ....................................................................................... 4-21 4.1.8.2 Removal and refitting of air filter body ..............................................................................................

4-23 4.1.8.3 Removal and refitting of air filter element ......................................................................................... 4-25 4.1.8.4 Removal and refitting of air filter rubber block .................................................................................. 4-27 4.1.8.5 Removal and refitting of air filter inlet pipe assembly ....................................................................... 4-28 4.1.8.6 Removal and refitting of air filter outlet pipe assembly .....................................................................

4-30 4.1.8.7 Removal and refitting of intake manifold assembly .......................................................................... 4-33 4.1.9 Intercooler assembly ............................................................................................................................ 4-37 4.1.9.1 Removal and refitting of intercooler assembly .................................................................................. 4-37 4.1.9.2 Removal and refitting of intercooler air inlet hose 1# .......................................................................

4-40 4.1.9.3 Removal and refitting of intercooler air inlet hose 1# ....................................................................... 4-42 4.1.9.4 Removal and refitting of intercooler air outlet hose .......................................................................... 4-44 4.1.9.5 Removal and refitting of intercooler air outlet pipe assembly ........................................................... 4-47 4.2 Exhaust system .......................................................................................................................................

4-49 4.2.1 Precautions .......................................................................................................................................... 4-49 4.2.2 Introduction to structure and principle .................................................................................................. 4-50 4.2.3 Position diagram of parts ..................................................................................................................... 4-51 4.2.4 Structural exploded view of exhaust system and turbocharger ...........................................................

4-52 4.2.5 Structural exploded view of exhaust system and muffler .................................................................... 4-54 4.2.6 Technical parameters ........................................................................................................................... 4-56 4.2.7 Special tools ......................................................................................................................................... 4-56 VOYAH FREE

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H97a-4-动力集成系统4.1-4.5（2022年6月8日）-1-336

4-2 Contents 4. Powertrain system 4.2.8 Common faults ..................................................................................................................................... 4-57 4.2.8.1 Exhaust system failure ...................................................................................................................... 4-57 4.2.8.2 Exhaust system emissions unacceptable ......................................................................................... 4-57 4.2.8.3 Exhaust system noisy .......................................................................................................................

4-57 4.2.9 Exhaust hot end ................................................................................................................................... 4-58 4.2.9.1 Removal and refitting of three-way catalytic converter assembly .................................................... 4-58 4.2.9.2 Removal and refitting of bellows assembly ...................................................................................... 4-60 4.2.9.3 Removal and refitting of oxygen sensor I ..........................................................................................

4-63 4.2.9.4 Removal and refitting of oxygen sensor II ......................................................................................... 4-65 4.2.9.5 Removal and refitting of exhaust manifold lower heat shield ........................................................... 4-66 4.2.9.6 Removal and refitting of exhaust manifold upper heat shield ........................................................... 4-68 4.2.9.7 Removal and refitting of intake manifold assembly .......................................................................... 4-69 4.2.9.8 Removal and refitting of exhaust manifold gasket ............................................................................

4-71 4.2.10 Muffler assembly ................................................................................................................................ 4-72 4.2.10.1 Removal and refitting of front muffler assembly ............................................................................. 4-72 4.2.10.2 Removal and refitting of rear muffler assembly .............................................................................. 4-74 4.2.10.3 Removal and refitting of front muffler gasket ..................................................................................

4-76 4.2.10.4 Removal and refitting of rear muffler gasket ................................................................................... 4-77 4.2.10.5 Removal and refitting of front muffler heat shield ........................................................................... 4-78 4.2.10.6 Removal and refitting of fuel tank heat shield ................................................................................. 4-79 4.3 Fuel system .............................................................................................................................................

4-80 4.3.1 Precautions .......................................................................................................................................... 4-80 4.3.2 Introduction to structure and principle .................................................................................................. 4-81 4.3.3 Position diagram of parts ..................................................................................................................... 4-82 4.3.4 Exploded view of structure ...................................................................................................................

4-83 4.3.5 Technical parameters ........................................................................................................................... 4-91 4.3.5.1 Tightening Torque ............................................................................................................................. 4-91 4.3.6 Special tools ......................................................................................................................................... 4-91 4.3.7 Common faults .....................................................................................................................................

4-92 4.3.8 Fuel sender .......................................................................................................................................... 4-93 4.3.8.1 Removal and refitting of electronic fuel pump assembly .................................................................. 4-93 4.3.8.2 Removal and refitting of fuel inlet pipe 2# assembly ........................................................................ 4-96 4.3.8.3 Removal and refitting of fuel inlet pipe 2# assembly ........................................................................

4-98 4.3.8.4 Removal and refitting of canister desorption tube 1# ..................................................................... 4-100 4.3.8.5 Removal and refitting of canister desorption tube 1# ..................................................................... 4-102 4.3.8.6 Removal and refitting of high-pressure desorption tube assembly ................................................ 4-104 VOYAH FREE

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H97a-4-动力集成系统4.1-4.5（2022年6月8日）-1-336

4. Powertrain system 4-3 Contents 4.3.8.7 Removal and refitting of fuel rail assembly ..................................................................................... 4-106 4.3.8.8 Removal and refitting of injector nozzle .......................................................................................... 4-109 4.3.9 Fuel tank assembly ............................................................................................................................ 4-111 4.3.9.1 Removal and refitting of fuel tank assembly ...................................................................................

4-111 4.3.9.2 Removal and refitting of fuel pump seal ring .................................................................................. 4-114 4.3.9.3 Removal and refitting of fuel filler pipe ............................................................................................ 4-115 4.3.9.4 Removal and refitting of fuel filler hose ........................................................................................... 4-117 4.3.9.5 Removal and refitting of fuel tank mounting strap I .........................................................................

4-118 4.3.9.6 Removal and refitting of fuel tank mounting strap II ........................................................................ 4-119 4.3.10 Fuel evaporator ................................................................................................................................ 4-120 4.3.10.1 Removal and refitting of air filter ................................................................................................... 4-120 4.3.10.2 Removal and refitting of air filter conduit 1# ..................................................................................

4-122 4.3.10.3 Removal and refitting of DMTL ..................................................................................................... 4-124 4.3.10.4 Removal and refitting of clean air conduit .................................................................................... 4-126 4.3.10.5 Removal and refitting of canister & accessories assembly .......................................................... 4-128 4.3.10.6 Removal and refitting of fuel tank isolation valve guide ................................................................ 4-129 4.3.10.7 Removal and refitting of fuel tank isolation valve assembly .........................................................

4-130 4.3.10.8 Removal and refitting of fuel vapor pipe assembly ....................................................................... 4-132 4.3.10.9 Removal and refitting of canister control valve assembly ............................................................ 4-133 4.3.10.10 Removal and refitting of canister desorption tube 1# ................................................................. 4-134 4.4 Cooling system ......................................................................................................................................

4-137 4.4.1 Precautions ........................................................................................................................................ 4-137 4.4.2 Introduction to structure and principle ................................................................................................ 4-138 4.4.3 Position diagram of parts ................................................................................................................... 4-140 4.4.4 Exploded view of structure .................................................................................................................

4-143 4.4.5 Technical parameters ......................................................................................................................... 4-159 4.4.6 Special tools ....................................................................................................................................... 4-159 4.4.7 Common faults ................................................................................................................................... 4-160 4.4.8 Front-end module assembly ..............................................................................................................

4-161 4.4.8.1 Removal and refitting of water outlet chamber end cover .............................................................. 4-161 4.4.8.2 Removal and refitting of thermostat ................................................................................................ 4-162 4.4.8.3 Removal and refitting of water outlet chamber assembly ............................................................... 4-163 4.4.8.4 Removal and refitting of radiator fan motor assembly (REV) .......................................................... 4-165 4.4.8.5 Removal and refitting of low temperature radiator assembly (REV) ...............................................

4-168 4.4.8.6 Removal and refitting of radiator assembly .................................................................................... 4-172 4.4.8.7 Removal and refitting of radiator upper bracket ............................................................................. 4-175 VOYAH FREE

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H97a-4-动力集成系统4.1-4.5（2022年6月8日）-1-336

4-4 Contents 4. Powertrain system 4.4.8.8 Removal and refitting of radiator upper bracket bushing ................................................................ 4-176 4.4.8.9 Removal and refitting of radiator lower bracket .............................................................................. 4-177 4.4.8.10 Removal and refitting of radiator lower bracket bushing .............................................................. 4-178 4.4.8.11 Removal and refitting of water bottle vent hose ...........................................................................

4-179 4.4.8.12 Removal and refitting of generator water inlet pipe ...................................................................... 4-181 4.4.8.13 Removal and refitting of generator water outlet pipe .................................................................... 4-183 4.4.8.14 Removal and refitting of low temperature radiator inlet pipe ........................................................ 4-185 4.4.8.15 Removal and refitting of low temperature radiator outlet pipe ...................................................... 4-187 4.4.8.16 Removal and refitting of water bottle inlet hose ............................................................................

4-189 4.4.8.17 Removal and refitting of water pump assembly ............................................................................ 4-191 4.4.8.18 Removal and refitting of generator water outlet pipe rear section ................................................ 4-193 4.4.8.19 Removal and refitting of low temperature radiator outlet pipe rear section .................................. 4-195 4.4.8.20 Removal and refitting of four-way control valve water pipe I ......................................................... 4-197 4.4.8.21 Removal and refitting of middle channel water outlet hose ..........................................................

4-199 4.4.8.22 Removal and refitting of PTC heater inflow pipe assembly ............................................................ 4-201 4.4.8.23 Removal and refitting of battery cooler water outlet pipe assembly ............................................. 4-202 4.4.8.24 Removal and refitting of four-way control valve water pipe III ....................................................... 4-204 4.4.8.25 Removal and refitting of water pump inlet hose ........................................................................... 4-205 4.4.8.26 Removal and refitting of water pump outlet hose .........................................................................

4-207 4.4.8.27 Removal and refitting of battery pack outflow pipe assembly ...................................................... 4-209 4.4.8.28 Removal and refitting of battery pack inflow pipe assembly ........................................................ 4-211 4.4.8.29 Removal and refitting of four-way control valve assembly ........................................................... 4-213 4.4.8.30 Removal and refitting of battery cooler assembly ........................................................................ 4-215 4.4.8.31 Removal and refitting of coolant temperature sensor on radiator assembly ................................

4-217 4.4.8.32 Removal and refitting of three-way proportional valve assembly ................................................. 4-218 4.4.8.33 Removal and refitting of water bottle inlet hose ............................................................................ 4-220 4.4.8.34 Removal and refitting of three-way proportional valve mounting bracket .................................... 4-222 4.4.8.35 Removal and refitting of water pump assembly ............................................................................ 4-224 4.4.8.36 Removal and refitting of electronic water pump right mounting bracket ......................................

4-227 4.4.8.37 Removal and refitting of water pipe assembly .............................................................................. 4-229 4.4.8.38 Removal and refitting of water pump assembly ............................................................................ 4-232 4.4.8.39 Removal and refitting of middle channel water outlet pipe ........................................................... 4-234 4.4.8.40 Removal and refitting of middle channel water inlet pipe ............................................................. 4-237 4.4.8.41 Removal and refitting of rear motor water outlet hose .................................................................

4-240 4.4.8.42 Removal and refitting of rear motor water inlet hose .................................................................... 4-242 4.4.8.43 Removal and refitting of charger water pipe assembly ................................................................ 4-244 VOYAH FREE

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