MANUAL REPARACIÓN LIFAN

LF 1025 1,3

- 11 -

CAPITULO: MOTOR
 Engine 11-1

Engine
Parameters of Engine .......................11-2

Check and Adjustment of Performance

Influencing Factor ...........................11-11

Cooling System ...............................11-70

Lubrication System.........................11-77

Exhaust Emission Control .............11-86 - 11 -

Electrical System ............................11-92

11-2 Engine
Parameters of Engine

I. Technical specifications of engine

Technical specifications of engine

Item Unit Spec.
Engine model LF470Q-h
Four-stroke, water-cooling, in-line 4-cylinder, diagonal
rear-drive
Engine type
Double overhead camshafts, 4 valve for each cylinder,
multi-point electronic injection
Combustion chamber type Ridge type combustion chamber
Cylinder bore X stroke Mm 69.7X79
Total displacement L 1.206
Compression ratio 10:1 - 11 -
Ignition order 1-3-4-2
Start type Electric start
Lubrication method Pressure and splashing combined type
Cooling method Compulsory water cooling circulation
Idle speed/high idle speed Rpm 750±30/2500±30
Rated speed/maximum speed Rpm 60006300
Rated power kW/rpm 62 / 6000
Power per liter kW/L 51.4
Maximum torque N.m/rpm 108 / 4000
Minimum fuel consumption g/kW·h ≤260
Oil-fuel consumption percentage % ≤0.3
Ignition Advance Angle 5 ±3 º /750 r/min
•Compression pressure ≥1100kPa/400r/min
Differential pressure of each cylinder ≤100kPa/400r/min
Exhaust temperature: 760～820℃/6000r/min
Idle speed 800r/min 100～200
280～360
Oil
Speed 4000 r/min kPa
pressure:
Rated speed 6000r/min 300～400
Oil temperature 90-110℃/6000r/min
Antifreeze coolant outlet temperature 88±5℃/6000r/min
Thermostat opening/full open
temperature
℃ 82±2 /95

Thermostat lift ≥8
Spark Plug Model DK7RTC
Clutch model Dry single disc diagram spring
Transmission model 5-speed manual mechanical transmission
1st
Transmission reduction ratio 3.857
speed
 Engine 11-3
nd
2
2.176
speed
nd
3
1.419
speed
4th
1.000
speed
5th 0.808
speed
Reverse 4.128
Final drive ratio See rear axle parameters of the complete vehicle
Odometer gear reduction ratio 11
Rotating direction of engine (view from
Counterclockwise
output end)
Transmission rotation direction (view
Counterclockwise
from output end)
Net mass of engine kg 102

Net mass of the transmission kg 25

- 11 -
Power assembly net weight kg ≤127
Engine overall size (length X width X 568×667×470
mm
height)
Transmission length mm 428
Power assembly overall size (length *
mm 996×667×470
width * height)
Home 15W/40, not less than SJ grade GB 11121
Below -40 ℃ If no mark, refer to local standard
Winter in the

Engine oil model

area of northern
latitude of
0W/40 、
API SN/SM ACEA A3/B3 & A3/B4
40°and above
-20℃～40℃ 10W/40 not less than SL grade GB 11121
-20℃～50℃ 10W/50 not less than SL grade GB 11121
-30℃～30℃ 5W/30 not less than SL grade GB 11121
Oil volume L New engine fill 2.7

Transmission gear -26℃～40℃ SAE80W/90 GL-4

oil brand -40℃～30℃ SAE75W/90 GL-4
Volume of transmission gear oil L 1.3
Fuel model Unleaded gasoline no less than No. 93 GB17930
Ethylene glycol antifreeze coolant of which the freezing
Antifreezing coolant point is below 5-10 ℃ of the lowest local temperature and
meets the SH0521 standard.

II. Common check and adjustment parameters

Common check and adjusting parameters

Item Unit Parameters
Intake/exhaust valve clearance in cold mm 0.075 ～0.115/0.23～0.28
11-4 Engine
state
Spark plug clearance mm 0.70.8
Under the action of normal force, the point of strength of
Adjust the tension of the water pump
the long-side belt moves 7-9mm, or the long-side belt turns
belt
over 100°.
A/C compressor belt tension The long-side belt can turn over 100°.

III. Quality, dimension and clearance of main parts

1. Piston mechanism of crank connecting rod Option of mass, size and clearance of the parts

1. Option of mass of piston and connecting rod

The pistons are divided into A and B mass groups. The pistons of the same mass group shall be used on the same
engine.
The connecting rods are divided into mass groups of A, B, C, D, E, F, G, H, I and J; the connecting rods of the
same mass group shall be used on the same engine. - 11 -

2. Size of cylinder hole and piston Unit : mm

Cylinder bore diameter 69.72069.710 Diameter of the piston: 69.68769.673
Cylinder hole – tolerance clearance of piston Unit : mm
Piston
Cylinder bore 0.0230.047

Standard clearance: 0.023 ～0.047 Limiting clearance: 0.05max

3 Size of connecting rod large hole, connecting rod neck of

Unit : mm
crankshaft and connecting rod bearing bush
1# connecting 1# bearing
1# connecting
41.00041.006 rod journal 3837.994 bush 1.4841.490
rod hole diameter
diameter thickness
2# connecting 2# bearing
2# connecting
41.006141.012 rod journal 37.98837.939 bush 1.4901.496
rod hole diameter
diameter thickness
3# connecting 3# bearing
3# connecting
41.012141.018 rod journal 37.987937.982 bush 1.4961.502
rod hole diameter
diameter thickness
Tolerance clearance of connecting rod large hole – crankshaft
Unit : mm
connecting rod journal – connecting rod bearing.
Connecting rod journal No.
Connecting rod journal No. 2 Connecting rod journal No. 3
1
Connecting rod Bearing Bearing Bearing
large hole No. 1 bush No. 1 1.5-0.010
-0.016 bush No. 1 1.5-0.010
-0.016 bush No. 2 1.5-0.004
-0.010

Connecting rod Bearing Bearing Bearing

large hole No. 2 bush No. 1 1.5-0.010
-0.016 bush No. 2 1.5-0.004
-0.010 bush No. 2 1.5-0.004
-0.010

Connecting rod Bearing Bearing Bearing

large hole No. 3 bush No. 2 1.5-0.004
-0.010 bush No. 2 1.5-0.004
-0.010 bush No. 3 1.5+0.002
-0.004
 Engine 11-5

Thickness of connecting rod bushing: The wall thickness of the axial center of the connecting rod bushing.
Option method: take the whole [(connecting rod macropore number+ connecting rod journal number/2)] =
connecting rod bearing bush number.
Standard clearance: 0.020 ～0.050 Limiting clearance: 0.07max

4 Dimensions of main shaft hole, crankshaft main journal and

Unit : mm
main bearing bush
1#
Aspindle 1# main
hole 53.000 ～53.006 journal 48.994 ～49.000 bearing
bush
1.987 ～1.991
diameter diameter
thickness
2#
Bspindle 2# main
hole ＞53.0061～53.012 journal ～＜48.9939
48.988
bearing
bush
＞1.990～1.994
diameter diameter
thickness
3#
Cspindle 3# main
hole ＞53.012～53.018 journal ～＜48.9879
48.982
bearing
bush
＞1.993～1.997 - 11 -
diameter diameter
thickness
4# bearing
bush ＞1.996～2.000
thickness
5#
bearing
bush
＞1.999～2.003
thickness
Tolerance clearance of main shaft hole – main journal of
Unit : mm
crankshaft – main bearing bush
Main journal No.1 Main journal No.2 Main journal No.3
Main shaft Bearing Bearing Bearing
0.0180.038 0.0180.038 0.0180.038
hole No.1 bush No. 1 bush No. 2 bush No. 3
Main shaft Bearing Bearing Bearing
0.0180.038 0.0180.038 0.0180.038
hole No.2 bush No. 2 bush No. 3 bush No. 4
Main shaft Bearing Bearing Bearing
0.0180.038 0.0180.038 0.0180.038
hole No.3 bush No. 3 bush No. 4 bush No. 5
Thickness of main bearing bush: refers to thickness of the axial center of the main bearing bush
Matching method: spindle hole number + main journal number -1=main bearing bush number.
Standard clearance: 0.018 ～0.038 Limiting clearance: 0.05max

2. Piston mechanism of crank connecting rod Size and clearance

Crank connecting rod piston mechanism Size and clearance

S/N Clearance and size name Standard value mm Limit value mm
Piston pin diameter 17+0-0.006
1 Piston pin hole diameter 17+0.014+0.006
Radial clearance of piston pin and piston pin hole 0.0060.020 0.030max
2 Connecting rod small hole diameter 17+0.014+0.006
11-6 Engine
Radial interference of piston pin and connecting rod small 0.0060.020
Thickness of top
1.2-0.01-0.03
compression ring
Width of 1st ring groove 1.2+0.03+0.01
Backlash of top
0.010.03 0.05max
compression ring
Thickness of the 2nd ring 1.2-0.01-0.03
Backlash between the piston
3 nd
ring and piston ring groove Width of the 2 ring
1.2+0.03+0.01
groove
nd
Backlash of the 2 ring 0.010.03 0.05max
Oil ring thickness 2-0.02-0.12
Oil ring groove width 2+0.05+0.03
Oil ring backlash 0.030.05
st
1 ring 0.200.35 0.6max
Piston ring opening nd
4 2 ring 0.250.45 0.6max
clearance
Film loop 0.200.70 0.9max
- 11 -
Axial clearance of connecting rod big end 0.100.25 0.3max
Inclination between large and small holes of connecting
0.03mm/100mm 0.05mm/100mm
5 rod
Torsion resistance between large and small holes of
0.06mm/100mm 0.08mm/100mm
connecting rod
Radial run-out of No. 3 main journal of crankshaft 0.02 0.04max
6 Cylindricity of crankshaft main journal 0.005 0.01max
Cylindricity of crankshaft connecting rod journal 0.005 0.01max
Crankshaft thrust slot
23+0.2+0.15
width
Crankshaft thrust plate
2.5+0.03+0.02
thickness
7 Crankshaft axial clearance
Crankcase thrust spindle
18 0-0.05
hole thickness
Crankshaft axial
0.110.31 0.40max
clearance

3. Camshaft tappet valve mechanism Size and clearance

Camshaft tappet valve mechanism Size and clearance

S/N Size and clearance name Standard value mm Limit value mm
Intake 99.17 99.07min
1 Valve stem length
Exhaust 100.01 99.91min
Intake φ4.972±0.007
Valve stem diameter
Exhaust φ4.963±0.007
2 Valve guide inner diameter 5.000～5.012
Radial clearance between valve Intake 0.047～0.021 0.05max
stem and valve guide pipe Exhaust 0.056～0.03 0.06max
3 Outside diameter of valve guide 10+0.068+0.053
 Engine 11-7

Diameter of valve guide hole 10+0.015+0.000

Valve guide – radial interference of valve guide hole 0.038 ～0.068
Valve spring free length 44.77
4
Pressure of valve spring 230±8.4N/25.7mm 120Nmin/32.23mm
Tappet diameter φ26-0.025-0.041
5 Tappet hole diameter φ26+0.021+0
Tappet--- radial clearance of tappet hole 0.0250.062 0.07max
Camshaft journal diameter Journal 23-0.04-0.061
Camshaft bearing cap bore
6 Bearing cover 23+0.021-0
diameter
Axial clearance between camshaft and camshaft hole 0.04～0.082 0.15max
Width of thrust groove of intake camshaft 21.12+0.04-0.02
Thickness of intake thrust bearing cover of cylinder head 21 0-0.1
6
Axial clearance of intake camshaft (installed on the half
hole of cylinder head camshaft)
0.10 ～0.26 0.30max

Width of thrust groove of exhaust camshaft 21.12+0.04+0.02 - 11 -

Thickness of exhaust thrust bearing cover of cylinder
19.5-0.000-0.021
7 head
Axial clearance of exhaust camshaft (installed on the half
hole of cylinder head camshaft)
0.10 ～0.26 0.30max

Intake 7.989±0.04 7.939min

Camshaft protruding height
8 Exhaust 7.450.04 7.40min
Radial runout of each journal of camshaft 0.03 0.04max

4. Other parts Size and clearance

Other parts Size and clearance

S/N Size and clearance name Standard value mm Limit value mm
1 Flatness of the upper surface of crankcase 0.03 0.05max
Flatness of the lower surface of cylinder head 0.05 0.07max
Flatness of intake surface of cylinder head 0.10 0.20max
2 Flatness of the exhaust surface of cylinder head 0.10 0.20max
Width of the sealing tape of the cylinder head intake and
1.20.2
exhaust valve
Axial clearance between the oil pump internal and
0.0450.1 0.15max
external rotors and the pump body
Radial clearance for mutually aligning with humps of inner
3 0.050.10 0.20max
and outer rotors in the engine oil pump
Radial clearance between oil pump external rotor and the
0.100.14 0.18max
pump body
4 Flatness of exhaust manifold intake flange 0.08 0.3max

IV. Parts applied with oil, grease and glue

11-8 Engine
1. Part applied with lubricating oil/grease

Part applied with lubricating oil/grease

Specification of lubricating
S/N Applied parts (as per assembly sequence)
oil/grease
1 At the seal ring of intake air temperature and pressure sensor 15W-40 SF lubricating oil GB11121
2 PCV valve mounting end 15W-40 SF lubricating oil GB11121
3 Tongue of carbon tank support 15W-40 SF lubricating oil GB11121
4 Valve stem end 15W-40 SF lubricating oil GB11121
5 Tappet lower end 15W-40 SF lubricating oil GB11121
6 Camshaft journal placed on cylinder head camshaft half hole 15W-40 SF lubricating oil GB11121
Install it to the upper shell working surface of main shaft of the
7 15W-40 SF lubricating oil GB11121
crankcase
Each main journal of crankshaft placed on the main shaft bearing
8 15W-40 SF lubricating oil GB11121
bush of crankcase
9 Crankcase cylinder bore wall 15W-40 SF lubricating oil GB11121 - 11 -
Piston-piston ring-connecting rod-connecting rod upper bearing
bush assembly oil ring (1 point), piston pin (internal 2 side points),
10 15W-40 SF lubricating oil GB11121
working surface of connecting rod upper bearing bush (clean
before applying)
Each connecting rod journal of the crankshaft before installation of
11 15W-40 SF lubricating oil GB11121
connecting rod cover
12 Thread of cylinder head mounting bolt 15W-40 SF lubricating oil GB11121
13 Front oil seal lip of crankshaft (applied by supplier) ZL-2 lithium base grease GB 7324
14 Rear oil seal lip of crankshaft (applied by supplier) ZL-2 lithium base grease GB 7324
Note: Wipe the working surfaces of upper and lower bearing bushes of the main shaft and the bearing bush of the
camshaft after installation.

2. Parts applied with sealant /tightening glue

Parts applied with sealant /tightening glue

S/N Application position Specification of sealant/tightening glue.
1 Joint surface of timing cover Darbond 2599 (or Tonsan 1596) plane sealant
The lower ridge of the rear end cover sealing gasket
2 Darbond 2599 (or Tonsan 1596) plane sealant
joint surface of the crankcase small amount
3 Oil pan joint surface Darbond 2599 (or Tonsan 1596) plane sealant
4 Thread parts of timing tensioner Darbond 2567 (or Tonsan 1567) thread sealant
5 Threaded part of the oil pressure alarm sensor Darbond 2567 (or Tonsan 1567) thread sealant
6 Thread part of water temperature sensor Darbond 2567 (or Tonsan 1567) thread sealant
Darbond 2242 (or GY-242) thread fastening
7 Screw-in thread of strainer stud bolt
glue
Darbond 2242 (or GY-242) thread fastening
8 Thread of the camshaft timing chain mounting bolt
glue
Darbond 2242 (or GY-242) thread fastening
9 Threads of crankshaft pulley mounting bolt
glue
Darbond 2242 (or GY-242) thread fastening
10 Thread of flywheel mounting bolt
glue
 Engine 11-9

V. Threaded fastener torque

1. Torque value of main thread tightening parts

Torque value
S/N Tightened object Thread fastener specification
N.m
Intake air pressure sensor Hexagon socket countersunk head screw
01 911
mounting screw M5×22
02 Moving rail mounting bolt Bolt M6×35-10.9 10 ～13
03 Cylinder head mounting bolt Bolt M10×99×1.25-10.9 6065
04 Oil pan mounting bolt Bolt M6×16-8.8 1013
05 Lower barrier of transmission Bolt M6×10-8.8 911
Fastening clamp mounting bolt on
06 Bolt M6×10-8.8 911
water inlet pipe of water pump
07 EGR heat Shield Bolt M6×12-8.8 911
08 Oil level indicator Bolt M6×12-8.8 911 - 11 -
09 Orbit determination mounting bolt Bolt M6×12-8.8 911
Water pump inlet pipe mounting
10 Bolt M6×15-8.8 911
bolt
11 Oil rail mounting bolt Bolt M6×16-8.8 9～11
9～11
Crankshaft position sensor
12 Bolt M6×16-8.8
mounting bolt
13 End cover mounting bolt Bolt M6×20-8.8 9～11
14 Thermostat cover mounting bolt Bolt M6×20-8.8 9～11
15 Timing cover mounting bolt Bolt M6×25-8.8 9～11
16 Cylinder head cover mounting bolt Bolt M6×25-8.8 9～11
17 Intake manifold mounting bolt Bolt M6×30-8.8 9～11
18 Tensioner mounting bolt Bolt M6×30-10.9 9～11
19 Ignition coil mounting bolt Bolt M6×35-8.8 9～11
20 Throttle body mounting bolt Bolt M6×40-8.8 1011
21 Timing cover mounting bolt Bolt M6×40-8.8 (Full thread) 9～11
22 Cylinder head cover mounting bolt Bolt M6×60-8.8 9～11
23 Vehicle speed sensor mounting bolt Bolts with spring gasket M6×16-8.8 9～11
24 Oil strainer mounting bolt Bolts with spring gasket M6×16-8.8 9～11

9～11
Top and bottom heat insulator
25 Bolt with flat washer M6 X 10-8.8
mounting bolts of exhaust manifold

10～12
Cylinder head trim cover mounting
26 Hexagon socket screw M6×16-8.8-
bolt

22～25
Intake/exhaust timing chain
27 Bolt M8×1×12-10.9
mounting bolt

9～11
Drain bolt of the water inlet of water
28 Bolt M8×13-8.8
pump

18～20
Intake manifold bracket mounting
29 Bolt M8×15-8.8
bolt
30 Out-water seat mounting bolt Bolt M8×20-10.9 18～20
31 Knock sensor mounting bolt Bolt M8×25-8.8 18～20
11-10 Engine
32 Water pump body mounting bolt Bolt M8×30-8.8 18～20
33 Support mounting bolt Bolt M8×30-8.8 25～30
34 Starter motor mounting bolt Bolt M8×35-8.8 30～35
35 Timing cover mounting bolt Bolt M8×1×38-8.8 20～25
36 Alternator mounting bolts Bolt M8×40-8.8 30～35
37 Alternator support mounting bolt Bolt M8×40-8.8 32～35
38 Timing cover mounting bolt Bolt M8×42-8.8 20～25
39 Thermostat body mounting bolt Bolt M8×62-8.8 18～20
40 Alternator mounting bolts Bolt M8×70-8.8 30～35
41 Clutch pressure plate mounting bolt Bolt M8×16-10.9 30～35

15～18
Camshaft position sensor mounting
42 Bolt M8×16-8.8
bolt
43 Mounting bolts for rear lifting hook Bolt with flat washer M6 X 16-8.8 15～18
44 Flywheel mounting bolt Bolt M10×17×1-10.9 55～60

20～25
Intake manifold bracket mounting - 11 -
45 Bolt M10×20×1.25-8.8
bolt

46
Transmission mounting bolts
(transmission)
Bolt M10×50×1.25-10.9 40 ～45
47
Transmission mounting bolt
(cylinder block)
Bolt M10×50×1.25-10.9 50～55
33～38
Crankshaft belt tensioner mounting
48 Hexagon socket screw M10×43×1.5-10.9
bolt
49 Right suspension mounting bolt Double-washer bolt M10×30×1.25-9.8 45～50
50 Left suspension mounting bolt Double-washer bolt M10×25×1.25-9.8 45～50
51 Crankshaft pulley mounting bolt Bolt M12×30×1.25-10.9 90～95
52 Oil pan drain bolt Bolt M14×12×1.5-8.8 30～35

9～11
Crankshaft rear end cover Cross recessed countersunk head screw
53
mounting bolts M6×10-8.8
54 Main shaft journal mounting bolt Bolt M10×1.25×60-8.8 55～60
55 Camshaft bearing cap bolt Bolt M6×35-8.8 9～11
56 Cylinder head Spark plug 25～30

15～20
Mounting stud of alternator support
57 Stud M8×65
frame
58 Cylinder head intake stud Stud M6×68
59 Cylinder head exhaust stud Stud M8×45
Stud bolt of the cylinder head outlet
60 Stud M8×55
pipe
61 Intake manifold mounting nut Nut M6 911
62 Front lifting hook mounting nut Nut M6- 9 ～11
63 EGR breather pipe mounting nuts Nut M6 9～11
64 Exhaust manifold mounting nut Nut M8 25～30
EGR seat, water outlet pipe,
65 alternator, alternator support Nut M8 25～30
mounting nuts

66
Mounting nuts for top and bottom
covers of connecting rod
Nut M8×0.75 30 ～35
 Engine 11-11

Check and Adjustment of Performance Influencing

Factor

I. Check and adjustment of tail gas concentration

Note: This check is only used for ensuring whether the idling exhaust emission meets the
regulations of law.

1. Check the starting condition

Check connector
(1) The engine is at the normal working
temperature
(2) The engine is equipped with air filter
(3) All pipes and hoses of air intake system are - 11 -
well connected.
(4) All vacuum pipelines are connected
correctly
(5) The connectors of EFI wires are well
connected Fig. 2-1-1

(6) Ignition time sets correctly

(7) All auxiliary appliances (e.g. air conditioner)
are turned off
(8) Transmission is in the neutral position.
(9) Tachometer and tail gas tester are
calibrated.

2. Check the concentration of idling tail gas

CO tester
Caution: It is recommended to use tail gas
tester when adjusting idling mixed gas.
If there is no tail gas tester, please do not try to
adjust idling mixed gas.
(a) Connect terminals TE1 and E1 of connector
for check with the special tool (Figure 2-1-1).
(b) Make the engine speed reach 2500rpm for
about 3 minutes.
(c) Insert the tester probe into the exhaust pipe Fig. 2-1-2
for 40cm (Figure 2-1-2).
(d) Wait for at least 1 minute before measuring
to make the concentration stable, and finish
measuring within 3 minutes.
2500 rpm high idling speed CO maximum
concentration: 0.3%
2500 rpm high idling speed HC maximum
concentration: 100ppm
11-12 Engine

3. Diagnosis and adjustment

CO concentration exceeds the maximum value

Symptom Cause
1. Air filter (clogging)
2. EFI failure
3. Fuel pressure regulator
failure
4. Coolant temperature sensor
1. Unstable idling
fault.
2. Exhaust with
5. Failure in intake
black smoke
temperature/pressure sensor
6. Engine ECU failure
7. The injector nozzle fails.
8. Throttle position sensor - 11 -
failure
 Engine 11-13
II. Check and adjustment of cylinder compression pressure

Note: If the engine is powerless or has bad fuel economy, measure the compression pressure of
the cylinder.

1 Warm up engine to normal temperature and Compression

then shut down pressure gauge

2 Disconnect ignition coil connector

3. Remove high-voltage damper from spark
plug
Remove the high-voltage damper line at the
rubber protection cover, do not pull the damper
line.
Note: Stretching or bending the damper line will
damage the inner conductor (Figure 2-2-1).
Fig. 2-2-1
4. Remove 4 spark plugs - 11 -
5. Remove the connectors of the 4 injector
nozzles to make them not work
6. Check the cylinder compression pressure.
(1) Insert compression pressure gauge to the
spark plug hole
(2) Open throttle valve fully and depress down
clutch petal

(3) Measure compression pressure while

starting the engine (Figure 2-2-2)
Note: It is suggested to used fully charged
battery to make the engine speed over 400 Error
rpm.
(4) Repeat steps (1) to (3) to every cylinder Correct

Caution: this test shall be completed as soon as

possible.
Compression pressure: ≥1100kPa
Pressure difference of cylinders: ≤100kPa Fig. 2-2-2

(5) If there is one or more cylinder with low

compression pressure, fill a little engine oil to
the cylinder via spark plug hole, and then
repeat steps (1) to (3) to cylinders with low
compression pressure.
If the engine oil contributes to perfecting
compression pressure, it indicates the abrasion
or damage of piston ring and/or cylinder wall.
If compression pressure is still very low, it may
be caused by valve jamming, incomplete
closing, or leakage in cylinder pad.
7 Reinstall spark plug
11-14 Engine
8 Reconnect the high-voltage damper to the
spark plug
9 Reconnect the connector of the ignition coil
10. Reconnect injection nozzle connector

III. Check and adjustment of valve clearance

Note: check and adjust valve clearance while

engine is in cold state.

1. Pull out high-voltage damper from the 4

spark plugs
2. Remove cylinder head trim cover and
cylinder head cover - 11 -
(1) Remove 4 bolts, and remove cylinder head
trim cover from cylinder head cover
(2) Remove engine conductor wire harness Fig. 2-3-1
from cylinder head cover
(a) Disconnect engine oil pressure alarm switch
connector
(b) Remove wire harness

(3) Remove crankcase breather pipe and PCV valve hose

(4) Remove 12 bolts, cylinder head cover and seal ring thereof
3 Set the 1st cylinder as the TDC of compression stroke
(1) Rotate crankshaft clockwise by 2 turns; align mark 2 on crankshaft belt 1 to scribed line 3 of
engine hood timing check mark 0. Fig. 2-3-1
(2) Check whether camshaft timing pulley “K” mark aligns to crankshaft timing mark. If not aligned,
rotate the crankshaft by 1 turn.
4. Check and record clearances of intake and exhaust valves
(1) Firstly, check valve clearance of valve in Figure 2-3-2 and Figure 2-3-3
● Measure valve clearance between tappet and camshaft base circle
● Record measuring data of unqualified valve clearance. The data is used for determining the
tappet model required for replacement
Cold state valve clearance: Intake 0.075-0.115mm, exhaust 0.23-0.28mm
(2) Rotate crankshaft pulley by 1 turn to make groove on pulley align to “0” mark on timing belt
cover.
(3) Check valves in Figure 3-2-7. Measure and record the valve clearance; the steps are same as
(1).
 Engine 11-15

Fig. 2-3-2 Fig. 2-3-3

5. Adjustment of intake valve clearance

(1) Remove the intake camshaft.
Caution: since axial clearance of camshaft is small, keep camshaft level while removing. If the - 11 -
camshaft can not keep level, the part of the cylinder head that born the axial thrust may crack or
damage, and cause camshaft stuck or broken.

Fig. 2-3-4
Fig. 2-3-5

(a) Loosen evenly with several times and remove 8 intake bearing cap bolts in sequence shown in
(Figure 2-3-4).
(b) Remove No. 2-5 intake bearing caps, and then lift intake camshaft.
Note: If the camshaft can not be lifted vertically, reinstall the bearing cover No.3 with two bolts and
then lift the camshaft gear, alternately loosen the bearing cover bolts and remove the bearing
cover (Figure 2-3-5).
Caution: do not use tools or other objects to move or violently apply force to the camshaft.
(2) Take out the tappet.
Suck tappet out with a magnetic bar.
11-16 Engine
(3) Confirm size of replaced tappet.
(a) Measure thickness of tappet with screw
micrometer.
Fig. 2-3-6
(b) Measure thickness of new tappet and make
valve clearance within specific range.
Cold clearance value: intake valve
0.075-0.115mm
Exhaust Valve: 0.23 ~ 0.28mm
Fig. 2-3-6
(c) Choose new tappet closed to calculated
value.
Note: there are tappets of 40 types of
thickness, with sizes from 3.12mm to 3.90mm,
stage difference 0.02mm.

(4) Install new tappet

- 11 -
Install the new tappet to the tappet hole.
(5) Install the intake camshaft.
Caution: since axial clearance of camshaft is small, keep camshaft level while installing. If
camshaft cannot keep level, cylinder head part bearing axial thrust will crack or damage, causing
camshaft getting stuck or broken.
To avoid such condition, follow the steps below to install:
(a) Rotate crankshaft pulley, and screw intake camshaft to cylinder head bearing semi-hole with
intake camshaft timing sprocket mark on the left towards the center.
(b) Align the mark of intake and exhaust camshaft timing sprocket to that of the timing chain (as
shown in Figure 2-3-7). Note: the above mounting angle allows tips of intake camshaft No. 1 and
No. 3 cylinder cams to push the valve tappets evenly.

Fig. 2-3-7
(c) Apply engine oil to all camshaft journals.
(d) Install No. 2-5 bearing caps to respective location.
 Engine 11-17
Caution: arrow mark on the bearing cap shall be forward

(e) Tighten the bearing cap bolts evenly in

several times in sequence shown in (Figure
2-3-8). Torque: 9 - 11N·m
(f) Remove the bolts for maintenance.
(g) Install No. 1 bearing cap.
Caution: arrow mark on the bearing cap shall
be forward
(h) Fasten 2 bearing cap bolts in several times
alternately.
Torque: 9 -11N·m
(6) Check valve clearance again. Fig. 2-3-8

6. Adjustment of valve clearance - 11 -

Note: Before reading “adjust the exhaust valve clearance”, please read “adjust intake valve
clearance” first, in which notes, cautions and torques are also applicable to “adjust the clearance
of exhaust valve”.
(1) Remove exhaust camshaft
(a) Remove exhaust No. 1 bearing cap.
(b) Loose evenly with several times and remove 8 exhaust bearing cap bolts in sequence shown
in (Figure 2-3-5)
(c) Remove No. 2-5 exhaust bearing caps and lift the exhaust camshaft
(2) Take out the tappet.
(3) Confirm size of replaced tappet.
(a) Measure thickness of tappet with screw micrometer. (Figure 2-3-6)
(b) Measure thickness of new tappet and make valve clearance within specific range.
(c) Choose new tappet closed to calculated value.
(4) Install new tappet
(5) Install the exhaust camshaft
(a) Rotate crankshaft pulley, and screw intake camshaft to cylinder head bearing semi-hole with
exhaust camshaft timing sprocket mark on the right towards the center (Figure 2-3-7).
b) Align the intake/exhaust camshaft timing chain mark with the timing chain mark (Figure2-3-7).
(c) Screw exhaust camshaft to cylinder head bearing semi-hole and make drive gear and driven
gear engaged with each other.
(d) Apply engine oil to each camshaft journal.
(e) Install No. 2-5 bearing caps to respective location.
(F) Tighten evenly in several times in sequence shown in (Figure 2-3-8)
(g) Install No. 1 bearing cap.
(h) Fasten 2 bearing cap bolts in several times alternately.
(6) Check valve clearance again.
11-18 Engine
7. Installation of cylinder head cover
(1) Install cylinder head cover seal ring to seal groove of cylinder head cover.
(2) Install cylinder head cover with 12 bolts.
Torque: 9 - 11N·m
(3) Connect crankcase breather pipe and PCV valve hose to cylinder head cover.
(4) Connect engine harness.
(5) Switch on engine oil pressure alarm switch connector
8. Connect the high-voltage resistance line to the spark plug
9 Install the cylinder head trim cover.
IV. Check and adjustment of idling
1 Initial condition
(1) The engine is at the normal working temperature
(2) The engine is equipped with air filter
- 11 -
(3) All pipes and hoses of air intake system are well connected.
(4) All vacuum pipelines are connected correctly
(5) The connectors of EFI wires are well connected
(6) Ignition time sets correctly
(7) All auxiliary appliances (e.g. air conditioner) are turned off
(8) Transmission is in the neutral position.
2 Connect tachometer
3 Check idling speed
Idling rotate speed: 750±30r/min, if the idling speed does not meet the specification, check the
idling control valve system (ISC).
4 Remove the tachometer
 Engine 11-19
V. Check and adjustment of timing chain

Exploded view of timing chain

- 11 -

1. Timing cover cap 2. Bolt 3. Crankshaft front 4. Crankshaft pulley

oil seal
5. Bolt 6. Belt 7 Timing chain 8. Moving rail
9. Stable rail 10. Tensioner 11.Crankshaft timing 12. Camshaft timing
sprocket sprocket
13. Cylinder head 14. Cylinder head 15. High-voltage
cover gasket cover damper

I Remove timing chain and pulley

11-20 Engine
1 Take down water pump generator belt
(1) Unscrew belt tensioner bolt (Figure 2-5-1)
(2) Unscrew generator mounting bolt
(3) Unscrew generator and lock bolt
(4) Take down water pump generator belt
2. Remove cylinder cover trim cap
3 Pull out high-voltage damper from the 4
spark plugs
4 Remove the cylinder head cover
(1) Remove engine conductor wire harness
from cylinder head cover
Fig. 2-5-1
(a) Disconnect engine oil pressure alarm switch
connector
(b) Remove wire harness - 11 -
(2) Remove crankcase breather pipe and PCV
valve hose
(3) Remove 12 bolts, cylinder head cover and
seal ring thereof

5 Set the cylinder No.1 as the TDC of the compression stroke

(1) Rotate crankshaft pulley and align the groove mark to that of timing chain. (Figure 2-5-2)
(2) Check alignment between mark of crankshaft pulley and the reference mark by scales on
timing cover.(Figure 2-5-3) If not, rotate crankshaft by 1 turn.

Fig. 2-5-2 Fig. 2-5-3

6 Remove the crankshaft pulley

(1) Use the special tool to avoid rotation of crankshaft pulley, and unscrew the pulley mounting bolt
(Figure 2-5-4).
(2) Pull out crankshaft with special tool (Figure 2-5-5).
 Engine 11-21

Fig. 2-5-4 Fig. 2-5-5

7. Remove timing cover cap

(1) Remove 14 timing cover cap mounting bolts.
- 11 -
(2) Remove timing cover cap (Figure 2-5-6).

Fig. 2-5-6

8 Take down the timing chain.

Make matching mark on the sprocket and chain as shown in the figure (Figure 2-5-7).
(1) Unscrew tensioner mounting bolt. Try to push tensioner to the left as much as possible, and
then unscrew tensioner mounting bolt. (Figure 2-5-8)
(2) Take off the chain.
11-22 Engine
Fig. 2-5-7 Fig. 2-5-8

9 Remove timing chain tensioner.

10. Pull out the crankshaft timing sprocket
If the sprocket cannot be removed with hands, please pry out the pulley with 2 screwdrivers
(Figure 2-5-9)
Caution: put cloth as shown in the figure to protect parts.
11. Remove the camshaft timing sprocket.
Fix camshaft hexagon column with a wrench, and remove bolts and timing sprocket (Figure
2-5-10)
Note: Do not damage cylinder head with wrench.

- 11 -

Fig. 2-5-9 Fig. 2-5-10

II Check the timing chain and chain wheel.

1. Inspect timing chain
Check the following items:
(1) Detach too early
(a) Check for correct installation
(b) Check timing cover cap for damage and correct installation.
(2) If there is crack or damage in timing chain, check whether camshaft is stuck.
(3) If there is evident wear or crack on timing chain, check whether tensioner is smooth and
flexible.
(4) If there is evident wear on chain teeth, replace the timing chain.
2. Inspect tensioner
Check whether the tensioner is rotated smoothly and flexibly (Figure 2-5-11). If necessary, replace
the tensioner.
 Engine 11-23

Fig. 2-5-11

III Install timing chain wheel and timing chain

1 Install the camshaft timing sprocket.
3. Install the camshaft timing chain - 11 -
(1) Align sprocket mark to the camshaft and then install it to the camshaft.
(2) Install the timing sprocket bolt temporarily.
(3) Fix camshaft hexagonal column with a wrench and tighten the timing sprocket bolt (Figure
2-5-12)
Torque: 22-25N•m
4 Install crankshaft timing sprocket
(1) Install timing sprocket, and align locating slot to the keyway, with taper outward.
(2) Align the timing sprocket locating key to keyway of timing sprocket (Figure 2-5-13)

Fig. 2-5-12 Fig. 2-5-13

(3) Install timing pulley in a sliding way, with flange side inward.
5. Set No. 1 cylinder as compression stroke dead center.
(1) Rotate camshaft hexagon head part, and align mark of camshaft timing sprocket to that of
bearing cap (Figure 2-5-14).
11-24 Engine

Fig. 2-5-14

(2) Use camshaft pulley bolt to rotate the crankshaft, and align the timing mark of crankshaft
sprocket to mark of oil pump body.
4 Install the timing chain
- 11 -
Caution: The engine shall be in cold state.
Rotate the crankshaft clockwise, align the timing mark g on the crankshaft sprocket with the
triangle mark f on the cylinder block, align the timing mark e on the intake camshaft with color
code d on the timing chain, align the timing mark b on the exhaust camshaft with another color
code on the timing chain. (Figure 2-6-16).

Fig. 2-6-16

5 Install timing chain fixing rail and moving rail

(1) Tighten timing chain guide rail bolt with torque of: 10±2N.m
(2) Tighten timing chain rail fixing bolt with torque of: 12±2N.m
6. Install tensioner
(1) Install tensioner with bolts, but do not tighten.
(2) Push tensioner support pillar to the left as possible, and then tighten the bolt.
6 Check valve timing
(1) Pull out the stop pin of tensioner support pillar
(2) Rotate crankshaft slowly by 2 turns from TDC to TDC.
Note: rotate the crankshaft clockwise.
(3) Check whether each sprocket aligns to timing mark as shown in the figure. If the timing mark is
not aligned, take off the timing belt and install again (Figure 2-5-16).
 Engine 11-25
(4) Tighten the tensioner bolts.
Torque: 9-11N•m
(5) Remove the crankshaft pulley bolts installed temporarily.

7 Install the timing cover cap

(1) Install the timing cover cap with 11 bolts
Torque: 9-11N•m and 20-25 N•m
8 Install the crankshaft pulley
(1) Align the pulley locating key to the pulley
keyway, and push it smoothly into the pulley
(2) Use a special anti-rotating tool to install
pulley bolts (Figure 2-5-17)
Torque: 90-95N•m
Fig. 2-5-17
- 11 -
11. Installation of cylinder head cover
(1) Install cylinder head cover seal ring to seal groove of cylinder head cover.
(2) Install cylinder head cover with 12 bolts.
Torque: 9 - 11N·m
(3) Connect crankcase breather pipe and PCV valve hose to cylinder head cover.
(4) Connect engine harness.
(5) Switch on engine oil pressure alarm switch connector

12. Connect the high-voltage resistance line to the spark plug

13 Install cylinder cover trim cap

14 Install the water pump alternator belt

(1) Install water pump generator belt
(2) Screw tightly tensioner probably and adjust
bolt (Figure 2-5-18)
(3) Screw tensioner bolt

Fig. 2-5-18

14 Check deflection of water pump generator belt

Under the action of normal force, the point of strength of the long-side belt moves 7-9mm, or the
long-side belt turns over 100°.
11-26 Engine

VI. Removal, repair and installation of cylinder head

I Remove the cylinder head

1. Drain off engine antifreeze coolant

2. Remove cylinder cover trim cap
3 Pull out high-voltage damper from the 4 spark plugs
4. Remove engine wiring harness
(1) Disconnect the connector of oil pressure alarm switch
(2) Remove engine conductor wire harness from cylinder head cover

- 11 -
 Engine 11-27
Exploded view of cylinder head assembly

- 11 -

1. Cylinder cover 2. High-voltage 3. Cylinder head 4. Cylinder head

trim cap damper assembly cover assembly cover seal ring
5. Bolt 6. Camshaft bearing 7. Filler cap 8. Camshaft bearing
cap cap I
9. Bolt 10. Intake& exhaust 11.Tappet 12. Valve spring seat
timing sprocket
13. Valve oil seal 14. Intake and 15. Valve lock clip 16. Valve spring
exhaust valves
17. Valve guide pipe 18.Exhaust Manifold 19.Exhaust manifold 20. Nut
gasket
21. Intake manifold 22. Bolt 23. Bolt 24. Bolt
bracket
25. Thermostat 26. Thermostat 27. Water outlet pipe 28. EGR sealing
cover gasket
11-28 Engine
29. EGR valve 30. Camshaft 31. Sealing gasket of 32. Cylinder head
position sensor water outlet pipe assembly
33. Spark plug 34. Intake/exhaust 34. Water outlet 36. Bolt
camshaft hose
37. Throttle valve 38. Throttle body 39. Thermostat seat 40. Fuel rail
heater outlet pipe assembly assembly assembly
41. Bolt 42. Intake manifold 43. Small-cycle hose 44. Thermostat
assembly heater inlet pipe

5 Remove the engine discharging tube and

front lifting hook
(1) Water outlet pipe (Figure 2-6-1)
(2) Remove front lifting hook
6. Remove the engine thermostat and the
thermostat seat - 11 -
(1) Remove water outlet hose (Figure 2-6-1)
(2) Remove the thermostat cover.
(3) Remove the thermostat seat.
Fig. 2-6-1

7. Remove the exhaust manifold (Figure

2-6-2).
(1) Remove the lower heat insulator
(2) Remove the upper heat insulator
(3) Remove exhaust manifold and the sealing
ring
8 Remove oil rail, throttle body, water inlet
pipe and water pipe.
9. Remove the intake manifold and its
support
Fig. 2-6-2
10 Remove the ignition coil
11 Remove the rear lifting hook of the
engine

12 Remove oil dipstick and the guide pipe (Figure 2-6-3)

(1) Remove the tightening bolt
(2) Pull out the oil dipstick and the guide pipe
(3) Remove the O-ring of oil dipstick guide pipe
13 Remove water outlet pipe and EGR (Figure 2-6-4)
(1) Remove 2 EGR mounting nuts
(2) Disconnect the water outlet pipe and hose
(3) Remove the water outlet pipe and the seal ring
 Engine 11-29

Fig. 2-6-3 Fig. 2-6-4

14. Take down water pump generator belt

(1) Loosen the tensioner mounting bolt.
(2) Take down water pump generator belt
- 11 -
15. Take down water pump
16 Remove generator bracket
17 Remove the cylinder head cover
(1) Remove crankcase breather pipe and PCV valve hose
(2) Remove cylinder cover cap and the seal ring
18. Set No. 1 cylinder to compression stroke TDC
(1) Rotate crankshaft timing pulley and align the pulley groove to timing mark of No. 1 timing cover
cap
(2) Check for alignment between the mark of camshaft timing pulley and the timing mark. If not,
rotate crankshaft by 1 turn (360°)
19 Remove timing chain from camshaft timing sprocket
(1) Mark on timing chain and camshaft timing sprocket, with the mark aligning to the top of timing
sprocket (Figure 2-6-5)
(2) Unscrew tensioner mounting bolt (Figure 2-6-6)
(3) Remove belt from camshaft timing sprocket

Fig. 2-6-5 Fig. 2-6-6

20 Remove the camshaft timing pulley

11-30 Engine
Fix the camshaft hexagonal column, and then remove the bolts and timing pulley (Figure 2-6-7)
Caution: be careful to the wrench to avoid cylinder head damage.

Fig. 2-6-7
Fig. 2-6-8
- 11 -
21 Remove intake/exhaust camshaft
(1) See 5 “Adjust intake valve clearance” in 2.3 “Check and adjustment of valve clearance”
(1) See 6 “Adjust exhaust valve clearance” in 2.3 “Check and adjustment of valve clearance”
22 Remove the cylinder head
(1) Unscrew evenly in several times with a special tool in the sequence shown in the figure, and
remove 10 cylinder cover bolts (Figure 2-6-8)
Note: Incorrect sequence of removing bolts may cause cylinder head warping or fracture.
(2) Remove 10 washers
(3) Lift cylinder head from the locating pin of cylinder block, and then put it on a wooden block of
the workbench.
Note: If the cylinder head is difficult to lift, use a straight screwdriver to lift between the cylinder
head and the crankcase boss. (It is better to rotate crankshaft slightly after removing cylinder head
bolt so that the cylinder head will be separated from the crankcase when compressing air)
Caution: Be careful not to damage the contact surface of the cylinder head and the crankcase.

II Disassemble cylinder head

1 Take out the tappet
Suck tappet out with a magnetic bar.
Note: Place the valve tappets in correct
sequence.
2 Remove the valve
(1) Use a special tool to compress valve spring
and remove 2 valve lock plates (Figure 2-6-9)
(2) Remove the following parts:
Fig. 2-6-9
(a) Valve spring
(b) Valve
(c) Spring retainer
 Engine 11-31
(3) Take out valve oil seal with needle nose pliers (Figure 2-6-10)
(4) Blow air to remove spring seat with compressed air and magnetic bar (Figure 2-6-11)
Note: Place the air valve, valve spring, spring seat and valve lockpin in correct sequence.

Fig. 2-6-10 Fig. 2-6-11

- 11 -
III. Check and clean

1 Clean the piston top and crankcase top

(1) Rotate the crankshaft to raise every piston to the TDC. Remove all carbon deposit on the top of
piston with a liner scraper (Figure 2-6-12)
(2) Use gasket scraper to remove all sealing gasket material from top of the crankcase (Figure
2-6-13).
(3) Use compressed air to blow away the carbon deposit and engine oil in the bolt holes.
Caution: When using high-pressure compressed air, mind to keep your eyes.

Fig. 2-6-12
Fig. 2-6-13

2 Clean the cylinder head

(1) Remove the sealing gasket materials from the bottom of the cylinder head.
Use gasket scraper to clean all sealing gasket material on the bottom of the crankcase (Figure
2-6-14).
Caution: be careful not to scratch the bottom of crankcase
11-32 Engine
(2) Clean combustor
Clean all carbon deposit in the combustion chamber with a wire brush (Figure 2-6-15)
Caution: Be careful not to scratch the bottom of cylinder head.

Fig. 2-6-14 Fig. 2-6-15

(3) Clean valve guide pipe - 11 -

Clean all guide pipes with valve guide pipe brush and solvent (Figure 2-6-16).
(4) Completely clean the cylinder head with brush and solvent (Figure 2-6-17).

Fig. 2-6-16 Fig. 2-6-17

3. Inspection of cylinder head

(1) Check flatness
Detect the flatness of the cylinder head with a precise straight rule (or knife straight edge) and
feeler gauge (Figure 2-6-18).
Flatness of the bottom surface of cylinder head Maximum 0.07mm
Flatness of the intake surface of cylinder head: maximum 0.20mm
Flatness of the exhaust surface of cylinder head: maximum 0.20mm
If the flatness exceeds the maximum value, replace the cylinder head.
 Engine 11-33

Cylinder
block side

Fig. 2-6-19

Intake
manifold side

Exhaust
manifold side
- 11 -

Fig. 2-6-18 Fig. 2-6-20

(2) Check whether there is crack

Use dye penetrant to check the surface of
combustor, intake, exhaust and the crankcase
for cracks (Figure 2-6-19).
Replace the cylinder head if there are cracks.
4 Clean the air valve
(1) Clean the carbon deposit on the end of the
valve with gasket scraper.
Fig. 2-6-21
(2) Completely clean the valve with wire brush
(Figure 2-6-20)

5. Check the vale stem and guide pipe

(1) Use a caliper gauge to measure the internal diameter of the guide pipe (Figure 2-6-21).
Conduit internal diameter: φ5.000-φ5.012mm
(2) Measure the valve stem diameter with a screw micrometer.
Valve stem diameter
Intake: φ4.963±0.007mm
Exhaust: φ4.963±0.007mm
(3) Calculate the valve stem clearance
Valve stem clearance=internal diameter of guide - valve stem diameter
Standard Clearance:
Intake: 0.021±0.047mm
11-34 Engine
Exhaust: 0.030±0.056 mm
Maximum clearance: intake 0.05mm exhaust
0.06mm
If the clearance of the valve stem exceeds the
maximum value, replace the valve or guide
pipe, or replace both.
6 Check and polish valve
(1) Polish the valve until the pits and carbon Fig. 2-6-22
deposit disappear.
(2) Check whether the valve is polished to
correct cone angle (Figure 2-6-22).

Valve cone angle: 45.5°

(3) Check the edge thickness of the valve cone
(Figure 2-6-23)
Edge thickness of intake valve: (0.93-1.13)mm
- 11 -
Edge thickness of exhaust valve: (1.0-1.2)mm
Edge
thickness
If the edge thickness is smaller than the
minimum value, replace the air valve.
(4) Check the full length of the valve (Figure
2-6-24). Fig. 2-6-23
Standard full length: intake 99.17mm, exhaust
100.01mm
Minimum full length: intake 99.07 mm, exhaust
99.91 mm
If the full length of the valve is shorter than the
minimum value, replace the valve.

(5) Check the abrasion of valve stem end surface.

If the valve stem is worn, polish the end with grinding wheel or replace the valve (Figure 2-6-25).
Note: Do not over-polish to the minimum value.

Full length

Fig. 2-6-24 Fig. 2-6-25

7 Check and clean the valve seat

(1) Use a 45°carbide ceramic knife to mill or polish the valve seat. Remove proper amount of
metal to clean the valve seat (Figure 2-6-26)
 Engine 11-35
(2) Check the valve seating position
Apply a thin layer of Prussian blue or white lead, press the air valve lightly to the valve seat, and
do not rotate the air valve (Figure 2-6-27).

45° Carbide ceramic knife

Width

Fig. 2-6-26 Fig. 2-6-27

(3) Check the following items of the valve surface and valve seat:
- 11 -
● If the blue pigment on the valve cone surrounds the valve center for 360°, it indicates that the
valve cone and the valve stem are coaxial. Otherwise replace the air valve.
● If the blue pigment on the valve seat cone surrounds the valve center for 360°, it indicates the
valve seat cone and the guide pipe are coaxial. Otherwise replace the air valve.
● Check whether the valve seat cone is in the center of the valve surface; its width is: 2.1-2.35mm.
Or correct the valve seat ring as per the method below:
(a) If the valve seat ring cone is too high above the valve cone, rectify the valve seat ring with knife
of 60°and75° (Figure 2-6-28).
(b) If the valve seat ring cone is too low above the valve cone, rectify the valve seat ring with knife
of 15°and15° (Figure 2-6-28).

Intake valve seat

Exhaust valve seat

Fig. 2-6-28 Fig. 2-6-29

(4) Use polish material to manually polish the valve and the valve seat
(Figure 2-6-29).
(5) After manual polishing, clean the valve and the valve seat.

8 Check the valve spring.

(1) Measure the perpendicularity of the valve spring with angle square (Figure 2-6-30).
If the perpendicularity is greater than the maximum value, please replace the valve spring.
11-36 Engine
(2) Measure the free height of the valve spring by a dial caliper.
Unsupported height: 44.77mm (Figure 2-6-31)
If the unsupported height fails to meet the requirement, replace the valve spring.

Deviations

Fig. 2-6-30 Fig. 2-6-31

(3) Use a spring tester to measure the pressure of valve spring at the specified installation height
(Figure 2-6-32). - 11 -
Pressure at the height of 25.7mm : 230N
If this pressure is less than 210N, replace the valve spring.

9 Check the camshaft and camshaft bearing

(1) Inspection of camshaft radial run-out
(a) Put the camshaft on the V-block (Figure 2-6-33)
(b) Measure the radial runout at the countershaft journal with dial indicator.
Radial skip standard value: 0.03mm
If the round runout exceeds 0.04mm, replace the camshaft.

Fig. 2-6-32 Fig. 2-6-33

 Engine 11-37

(2) Check the cam lip

(a) Use spiral micrometer to measure the cam
height (Figure 2-6-34).
(b) Rotate the camshaft 90°from (a) position,
and use spiral micrometer to measure the base
diameter
(c) Cam lip height= cam height - base diameter
Standard height of the cam angle:
Intake 7.989±0.04mm, exhaust 7.45±0.04mm
Fig. 2-6-34
Minimum height of camshaft tip:
Intake: 7.939mm Exhaust: 7.40mm
If the tip height is less than the minimum,
replace the camshaft.

(3) Check the camshaft journal diameter - 11 -

Use spiral micrometer dial to measure the diameter of journal (Figure 2-6-35).
Standard diameter of journal:
～
22.939 22.996mm
If the journal diameter does not meet the standard value, check the oil clearance.
(4) Check the camshaft bearing
Check the bearing for falling and burning. If the bearing is damaged, replace the whole set of
cylinder head and bearing cover (Figure 2-6-36).

Fig. 2-6-35 Fig. 2-6-36

(5) Check the oil clearance of the camshaft journal.

(a) Clean the bearing cover and the camshaft journal.
(b) Put the camshaft on the cylinder head.
11-38 Engine

Fig. 2-6-38
Fig. 2-6-37

(c) Put one plastic clearance gauge on each camshaft journal (Figure 2-6-37).
(d) Install bearing cover (Figure 2-6-38).
Torque: 9 - 11N·m
Caution: do not rotate the camshaft.
- 11 -
(e) Remove bearing cover.
(F) Measure the maximum thickness of the plastic clearance gauge as the oil clearance of the
journal (Figure 2-6-39).
～
Standard oil-film clearance 0.04 0.082mm
Maximum oil-film clearance 0.15mm
If the oil clearance exceeds the maximum value, replace the camshaft. Replace the whole set of
bearing cover and cylinder head if necessary.
(g) Completely remove all plastic clearance gauges.

Fig. 2-6-39 Fig. 2-6-40

(6) Inspection of camshaft axial clearance

(a) Install the camshaft
(b) Use dial indicator to measure the axial clearance while moving the camshaft back and forth
(Figure 2-6-40).
Standard axial clearance: intake 0.10-0.26mm, exhaust 0.10-0.26mm
Maximum clearance: intake 0.30mm exhaust 0.30mm
If the axial clearance exceeds the maximum, replace the camshaft. Replace the bearing cover and
cylinder cover if necessary.
 Engine 11-39
10 Check the tappet and tappet hole
(1) Use caliper gauge to measure the diameter of the cylinder head tappet hole (Figure 2-6-41).
Standard diameter of tappet hole: φ26. 000 ～φ26. .021mm
(2) Use spiral micrometer to measure the tappet diameter (Figure 2-6-42).
～
Standard tappet diameter: φ25.959 φ25.975mm
(3) Calculate the tappet oil clearance
Tappet oil clearance=tappet hole diameter - tappet diameter
Standard oil film clearance: 0.025 ~ 0.062mm
Maximum oil-film clearance ：0.07mm
If the oil clearance exceeds the maximum value. Replace the tappet. Replace the cylinder head if
necessary.

- 11 -

Fig. 2-6-41 Fig. 2-6-42

11. Inspection of exhaust manifold

Use a precise straight ruler and feeler gauge to measure the flatness of intake flange (Figure
2-6-43).
Maximum flatness: 0.10mm
If the flatness exceeds the maximum, replace the manifold.

12 Check the bolt of cylinder head (Figure 2-6-44).

Standard external diameter: 10mm
Minimum external diameter: 9.8mm
If the external diameter is smaller than the minimum value, replace the bolt.
11-40 Engine
Intake

Exhaust

Fig. 2-6-44
Fig. 2-6-43

- 11 -

Fig. 2-6-45

IV Replace parts of cylinder head

Replace valve guide

(1) Gradually heat the cylinder head to 80-100 ℃ (Figure 2-6-45)
(2) Knock out the guide pipe with special tool and hammer (Figure 2-6-46).
(3) Use calipers to measure the external diameter of the valve guide pipe of the cylinder head
(Figure 2-6-47).
～
Standard valve guide external diameter (cold state): 10.053 10.068mm
(4) Select new guide pipe
● If the external diameter of the guide pipe exceeds 10.068mm, machine it to:10.053-10.068mm
● If the diameter of the cylinder head guide pipe hole exceeds 10.015mm, replace the cylinder
head.
 Engine 11-41

Fig. 2-6-46 Fig. 2-6-47

(5) Gradually heat the cylinder head to 80-100 ℃.

(6) Use special tool and hammer to knock in the new guide pipe, until the length out of the cylinder
head is 12.8-13.2mm (Figure 2-6-48).
(7) Use a sharp 5mm reamer to ream the guide pipe to make the clearance between the guide
- 11 -
pipe and the valve stem meets the standard value (Figure 2-6-49).

13.2mm

Sharp reamer of 5mm

Fig. 2-6-48 Fig. 2-6-49

V Assemble cylinder head

Tips :
Completely clean all the parts to be installed.
Before part assembly, apply new engine oil to all sliding and rotating surfaces.
Replace all gaskets and oil seal with new ones.

Fig. 2-6-52 Fig. 2-6-53

11-42 Engine

2 Install valve oil seal

Use special tool to press the new valve oil seal (Figure 2-6-5-2).
Note: The intake valve oil seal is the same as the exhaust valve oil seal (Figure 2-6-53)
3. Install air valve (Figure 2-6-54).
(1) Install air valve and relevant parts:
(a) Valve spring
(b) Valve
(c)Spring retainer
(2) Press the valve spring with special tool, and put 2 locking plates around the valve stem (Figure
2-6-55).
(3) Knock the valve stem top slightly with a plastic hammer to ensure the assembly is in good
condition.
- 11 -

Fig. 2-6-55
Fig. 2-6-54

4 Install the tappet

(1) Install the tappet
(2) Check the tappet with hands, and the tappet shall rotate smoothly.

VI Install the cylinder head

1. Installation of cylinder head

(1) Install the new cylinder head sealing gasket to the crankcase (Figure 2-6-56).
Caution: the side with marks and characters shall be upward.
(2) Put the cylinder head to the sealing gasket
(3) Screw in the cylinder head bolt
Note: Do not use bolts with cracks or deformed bolts.
(a) Apply a thin layer of engine oil under the cylinder head bolt and to the thread.
(b) Use special tool to tighten 10 cylinder head bolts evenly by several times according to the
sequence shown in the figure (Figure 2-6-57).
 Engine 11-43
Torque: 60 - 65N•m

If the bolt does not meet the torque

specification, replace it.
Note: The length of the cylinder head bolt is
99mm.

Length

Fig. 2-6-56 - 11 -

Fig. 2-6-57

2 Install the intake camshaft

Caution: since axial clearance of camshaft is small, keep camshaft level while installing. If
camshaft does not keep level, cylinder head part bearing thrust will crack or damage, causing
camshaft get stuck or broken. In case of this happens, follow the steps below to operate.

(1) Install exhaust camshaft and make the locating pin higher than the top of the cylinder head
(Figure 2-6-58).

Fig. 2-6-58

(2) Install the intake camshaft to the bearing seat.

Note: the above angle allows tips of intake camshaft No. 1 and No. 3 cylinder cams to push the
valve tappets evenly.
(3) Apply a thin layer of engine oil to the thread end of the bearing cover mounting bolts.
11-44 Engine
(4) Install No.2-5 bearing coves to their corresponding positions (Figure 2-6-59).
(5) Apply a thin layer of engine oil to the thread end of the bearing cover mounting bolts.
(6) Tighten 20 bearing cover bolts evenly by several times according to the sequence shown in the
figure (Figure 2-6-60).
Torque: 9-11N•m

Fig. 2-6-59 Fig. 2-6-60

- 11 -

(8) Remove bolts used for repair.

(9) With the arrow mark facing forward, install bearing cover No.1.
(10) Apply a thin layer of engine oil to the thread end of the bearing cover mounting bolts.
(11) Install and tighten 2 mounting bolts by several steps.
Torque: 9-11N•m
(12) Rotate the exhaust camshaft clockwise to make the locating pin upward (Figure 2-6-61).
(13) Check whether the timing mark of the camshaft chain wheel is aligned with each other.
Note: At this moment, the installation mark shall be on the top

Fig. 2-6-61

3 Check and adjust the valve clearance

Rotate the camshaft, with the camshaft tip upward. Check and adjust the valve clearance.
Valve clearance (cold):
Intake: 0.075±0.115mm
 Engine 11-45
Exhaust: 0.23±0.28mm
4 Install the camshaft timing pulley
(1) Align the camshaft locating pin with locating pin groove on the side with belt mark (with two
locating pin grooves), and slip to the timing pulley.
(2) Install the timing pulley mounting bolts.
(3) Fix the hexagonal column of camshaft with a wrench, and tighten the timing pulley mounting
bolts.
Tightening torque: 20~25N.m
6 Install the timing chain
Tip:
● Check whether the matching mark of timing belt aligns with the end of the timing belt lower
cover. If the matching mark is not aligned, please move the meshing part of the timing pulley until
it is aligned.
● Align the timing chain with the matching mark of the camshaft timing pulley (Figure 2-6-62).
(1) Swipe the oil or water on camshaft timing wheel to keep it clean.
- 11 -
(2) Install the timing chain, and check the tension between crank timing chain and the camshaft
timing pulley.
7 Check valve timing
(1) Loosen the tensioner mounting bolt.
(2) Slowly rotate the crankshaft clockwise by 2 turns, from TDC to TDC.
(3) Check whether each pulley is aligned with timing mark as shown in the figure. If the timing
mark is not aligned, remove the timing belt and reinstall (Figure 2-6-62).

Timing mark Timing mark

Timing mark
Front cover shell upper
surface

Mark groove

Fig. 2-6-62 Fig. 2-6-63

(3) Tighten tensioner mounting bolts.

Torque: 9 - 11N·m
8. Installation of cylinder head cover
(1) Install the cylinder head cover with 12 bolts.
Torque: 9 - 11N·m
9. Installation of spark plug
10. Install outlet pipe
11-46 Engine
(1) Install a new water outlet sealing gasket to the rear end of the cylinder head.
(2) Connect the water outlet hose to the thermostat seat assembly.
(3) Install the water outlet pipe with 2 bolts and 2 nuts (Figure 2-6-63).
Torque: 25 -30 N.m
11 Install EGR
(1) Install a new EGR sealing gasket to the water outlet
(2) Install the water outlet pipe with 2 nuts, torque: 22-25N.m
11. Re-installation of water pump
Use 4 bolts (Figure 2-6-64) Torque: 25 -30 N.m
12. Installation of intake manifold

Install the new gasket and intake manifold with

3 bolts and 7 nuts.
Tighten the bolts and nuts evenly by several
times (Figure 2-6-64).
- 11 -
11-37
Torque: 9-11N•m
13. Install intake manifold bracket
14. Install oil rail
15. Install throttle body and water pipe
16. Install front lifting hook
Fig. 2-6-64
17. Install rear lifting hook

18. Installation of thermostat

(1) Install thermostat seat
(2) Put the thermostat valve
(3) Install the thermostat cover.
19. Install the ignition coil
20. Install exhaust manifold (Figure 2-6-65)
(1) Install a new sealing gasket and exhaust
manifold with 9 nuts.
Screw up the nut evenly by several times
Fig. 2-6-65
Torque: 25-30N•m

(2) Install the upper heat shield to its position.

(3) Install the lower heat shield to its position.
(4) Install the heat shield to the exhaust
manifold with 9 bolts.
Torque: 9-11N•m
21. Install alternator support (Figure 2-6-66)
22 Install the alternator
(21) Install water pump generator belt
 Engine 11-47
22. Adjust the drive belt tension Fig. 2-6-66

23. Tighten the tensioner mounting bolts

24 Connect the oil inlet hose to the oil rail
25 Connect the engine harness
26 Fill antifreeze coolant

VII. Disassembly, repair and installation of crankcase

I Remove the crankcase

1. Remove the flywheel

Remove 6 mounting bolts and the flywheel
(Figure 2-7-1). - 11 -
2. Remove transmission partition
3. Install engine on special bracket for
removal
4. Remove water pump generator belt and
pulley
5. Remove generator and generator bracket Fig. 2-7-1
(Figure 2-7-2)
6. Remove the cylinder cover trim cap and
cylinder head cover
7. Remove oil pan
8 Remove the oil dipstick and timing cover

9. Remove the timing chain

Fig. 2-7-2

10. Remove the cylinder head

11. Remove the water pump
(1) Remove 4 bolts and the water pump.
）
(2 Take off the O-ring
11-48 Engine
12. Remove the oil filter
Exploded view of crankcase

- 11 -

1. Oil strainer 2 .Water pump room 3. Bolt 4. Bolt

5. Knock sensor 6. Oil pan assembly 7. Cylinder block 8. Bolt
main bearing cap
9. Flywheel 10. Driven disc 11. Pressure plate 12. Bolt
assembly of clutch assembly, clutch
13 Water inlet pipe 14. Crankshaft rear 15. Crankshaft rear 16.Dowel pin
end cover oil seal end cover
17. Oil filter (18) Oil filter 19. Lower crankshaft 20. Crankshaft
mounting solenoid main bearing bush
 Engine 11-49
21. Upper crankshaft 22. Oil pressure 23. Cylinder block 24. Cylinder block
main bearing bush switch sealing gasket
25.Dowel pin 26. Connecting rod 27. Lower 28. Upper
cap connecting rod connecting rod
bearing bush bearing bush
29. Connecting rod 30. Piston 31. Piston ring 32. Piston pin
components
33. Bolt

13. Remove the oil pressure alarm switch

14. Remove the knock sensors
15. Remove the crankshaft rear cover and oil seal
16. Check the axial clearance of the connecting rod
Move the connecting rod back and forth and measure its axial clearance with a micrometer. (See
Figure 2-7-3) - 11 -
Standard axial clearance: 0.100.25mm
Maximum axial clearance: 0.30mm
If the axial clearance exceeds the maximum value, replace the connecting rod piston components
or crankshaft.

Fig. 2-7-3 Fig. 2-7-4

17. Remove the connecting rod cover and check oil clearance
(1) Check the matching mark on the connecting rod and the cover to ensure correct reassembly
(Figure 2-7-4).
(2) Remove the connecting rod cover nuts.
(3) Knock the connecting rod bolts slightly with a plastic hammer and lift the connecting rod cover
(Figure 2-7-5).
Note: Keep the lower bearing bush inserted in the connecting rod cover.
(4) Sheath a hose to the connecting rod bolts to protect the crankshaft from damage (Figure
2-7-6).
11-50 Engine

Fig. 2-7-5 Fig. 2-7-6

(5) Clean crank pin and bearing bush.

(6) Check whether the crank pin and the bearing bush have pit and scratch (Figure 2-7-7).
If the crank pin or bearing bush is damaged, replace the bearing bush. If it is necessary, polish or
replace the crankshaft.
- 11 -
(7) Pass a plastic oil clearance gauge through the crank pin (Figure 2-7-8).

Plastic oil clearance

gauge

Fig. 2-7-7 Fig. 2-7-8

(8) Install connecting rod cover.

Tighten the connecting rod cover nuts (Figure
2-7-9).
Torque: 30-35N•m
Caution: do not rotate the crankshaft.
(9) Remove the connecting rod cover.
(10) Measure the oil clearance at the thickest
part of the plastic oil clearance gauge
Fig. 2-7-9
(Figure 2-7-10).

Standard oil-film clearance

Standard type: 0.020-0.05mm
Enlarged 0.25 type: 0.019-0.060mm
Maximum oil film clearance: 0.07mm
If the oil clearance exceeds the maximum value, replace the bearing bush, polish or replace
crankshaft if necessary.
 Engine 11-51
Note: if standard bearing bush is used, it needs to be replaced by the bearing bush with the
number same as that on connecting rod cap. There are 3 dimensions of standard bearing bushes,
marked with “1”, “2” and “3” correspondingly (Figure 2-7-11).

Mark 1, 2
or 3

Mark 1, 2
or 3
Front end mark
(bumped)

Fig. 2-7-10 Fig. 2-7-11

(11) Take out all plastic oil clearance gauges.

19. Remove the connecting rod piston components - 11 -
(1) Remove all carbon deposit on cylinder top with a cylinder reamer.
(2) Sheath a hose to the connecting rod bolts to protect the crankshaft from damage.
(3) Push the connecting rod piston components and take them out from the crankcase top.
Tip:
◎ Place the bearing bushing, the connecting rod and the connecting rod cap together.
◎ Place the piston and the connecting rod assembly in a correct order.
20. Check the crankshaft axial clearance
Pry crankshaft with a screwdriver, and measure
the axial clearance with dial gage (Figure
2-7-12).

Fig. 2-7-12

Standard axial clearance: 0.110.31mm

Maximum axial clearance: 0.40mm
If the axial clearance exceeds the limit, replace
the whole set of thrust washer.
Thickness of thrust gasket: 2.520-2.53mm
21. Remove main bearing cap, and check oil
clearance
(1) Loosen and remove main shaft cover bolts
evenly by several times according to the Fig. 2-7-13
sequence shown in the figure (Figure 2-7-13).
11-52 Engine
(2) Use the removed main shaft cover bolt to
pry the main shaft cover back and forth, and
remove the main shaft cover, lower main
bearing bush and lower thrust plate.
(Figure 2-7-14).

(3) Take out the crankshaft from the top

Note: Put the upper main bearing bush, upper thrust gasket and crankcase together (Figure
2-7-15).

- 11 -

Fig. 2-7-14 Fig. 2-7-15

(4) Clean all main journals and main bearing bush (Figure 2-7-16).
(5) Check all main journals and main bearing bush for pit or scratch. If the main journal or main
bearing bush is damaged, replace the bearing bush. If it is necessary, polish or replace the
crankshaft.
(6) Install the crankshaft to the crankcase.
(7) Pass each journal with a plastic oil clearance (Figure 2-7-17).

Plastic oil
clearance gauge

Fig. 2-7-16 Fig. 2-7-17

(8) Install the main shaft cover (Figure

2—7-18).
Torque: 55-60N.m
Caution: do not rotate the crankshaft.
(9) Remove the main shaft cover.

Fig. 2-7-18
 Engine 11-53
(10) Measure the plastic oil clearance gauge at the widest part (Figure 2-7-19).
Standard oil-film clearance
Standard type: 0.018-0.038mm
Enlarged 0.25 type: 0.019 ～0.050mm
Maximum oil film clearance: 0.06mm
Note: if it needs to replace the crankcase components, the standard clearance of bearing bush
～
shall be : 0.018 0.038mm
If the oil film clearance exceeds the maximum, replace the bearing bushing. If necessary, polish
(with enlarged main shaft bearing shall) or replace the crankshaft.
The numbers of crankcase and the crankshaft are shown in the figure (2-7-20).
◎ If a standard bearing bushing is used, replace it with the bearing bushing with the same
number.
(11) Take out all plastic oil clearance gauges.
- 11 -
No. 1 No. 2 No. 3 No. 4 No. 5

Mark 1, 2
or 3

No. 1

Fig. 2-7-19
No. 2 No. 3 No. 4 No. 5

Fig. 2-7-20

Sizes of connecting rod large hole, crankshaft connecting rod

Unit : mm
journal and connecting rod bearing bush
1# connecting 1# connecting 1# bearing
rod hole 41.00041.006 rod journal 3837.994 bush 1.4841.490
diameter diameter thickness
2# connecting 2# connecting 2# bearing
rod hole 41.006141.012 rod journal 37.98837.939 bush 1.4901.496
diameter diameter thickness
3# connecting 3# connecting 3# bearing
rod hole 41.012141.018 rod journal 37.987937.982 bush 1.4961.502
diameter diameter thickness
Tolerance clearance of connecting rod large hole – crankshaft
Unit : mm
connecting rod journal – connecting rod bearing.
Connecting rod journal No. Connecting rod journal No.
Connecting rod journal No. 2
1 3
Connecting Bearing Bearing
Bearing
rod large hole bush 1.5-0.010
-0.016 bush No. 1 1.5-0.010
-0.016 bush No. 1.5-0.004
-0.010
No. 1 No. 1 2
11-54 Engine
Connecting Bearing Bearing
Bearing
rod large hole bush 1.5-0.010
-0.016 bush No. 2 1.5-0.004
-0.010 bush No. 1.5-0.004
-0.010
No. 2 No. 1 2
Connecting Bearing Bearing
Bearing
rod large hole bush 1.5-0.004
-0.010 bush No. 2 1.5-0.004
-0.010 bush No. 1.5+0.002
-0.004
No. 3 No. 2 3
Thickness of connecting rod bushing: The wall thickness of the axial center of the connecting rod bushing.
Option method: take the whole [(connecting rod macropore number+ connecting rod journal number/2)] =
connecting rod bearing bush number.
～
Standard clearance: 0.020 0.050 Limiting clearance: 0.07max

Size of the main shaft hole, crankshaft main shaft journal and main
Unit : mm
bearing bush
1#
Aspindle 1# main
hole 53.000 ～53.006 journal 48.994～49.000 bearing
bush
1.987 ～1.991
diameter diameter
thickness
- 11 -
2#
Bspindle 2# main
hole ＞53.0061～53.012 journal 48.988 ～＜48.9939 bearing
bush
＞1.990～1.994
diameter diameter
thickness
3#
Cspindle 3# main
hole ＞53.012～53.018 journal 48.982 ～＜48.9879 bearing
bush
＞1.993～1.997
diameter diameter
thickness
4# bearing
bush ＞1.996～2.000
thickness
5#
bearing
bush
＞1.999～2.003
thickness
Tolerance clearance of main shaft hole – main journal of crankshaft
Unit : mm
– main bearing bush
Main journal No.1 Main journal No.2 Main journal No.3
Bearing Bearing Bearing
Main shaft
hole No.1
bush 0.018～0.038 bush 0.018 ～0.038 bush 0.018～0.038
No. 1 No. 2 No. 3
Bearing Bearing Bearing
Main shaft
hole No.2
bush 0.018～0.038 bush 0.018 ～0.038 bush 0.018～0.038
No. 2 No. 3 No. 4
Bearing Bearing Bearing
Main shaft
hole No.3
bush 0.018～0.038 bush 0.018 ～0.038 bush 0.018～0.038
No. 3 No. 4 No. 5
Thickness of main bearing bush: refers to thickness of the axial center of the main bearing bush
Matching method: spindle hole number + main journal number -1=main bearing bush number.
Standard clearance: 0.018 ～0.038 Limiting clearance: 0.05max
 Engine 11-55

22. Remove the crankshaft

(1) Take out the crankshaft upwards (Figure
2-7-21).
(2) Remove the upper main bearing bush and
the upper thrust gasket from the crankcase.
Note: Place the main bearing cap, main bearing
bush and thrust washer in a correct sequence.

Fig. 2-7-21

II Check the crankcase

1 Clean the crankcase - 11 -

(1) Clear the gasket material
Use gasket scraper to remove all gasket materials from the top of crankcase (Figure 2-7-22).

Fig. 2-7-22 Fig. 2-7-23

(2) Clean the crankcase

Completely clean the crankcase with brush and solvent.
2 Check the flatness of crankcase top
Use the precision straight edge and clearance gauge to measure the flatness of to crankcase top.
(Figure 2-7-23).
Flatness standard value: 0.03mm
Maximum flatness:0.05mm
If the flatness exceeds the maximum value, replace crankcase.
3 Check whether the cylinder hole has abrasion in vertical direction.
Visually check whether there are scrape marks in the vertical direction. If there are deep
scratches, the four cylinders shall be resized again. Replace the crankcase if necessary.
(Figure 2-7-24).
4 Check the internal diameter of the cylinder
Note: there are 3 size types of standard cylinder internal diameters. This mark is printed on the top
11-56 Engine
of crankcase.

Use a cylinder diameter gauge to measure the

crosswise and lengthwise diameters of the
cylinder at three positions (Figure 2-7-24).
Cylinder diameter:
Standard type
Mark :69.710- 69.720 mm
Maximum diameter:
Standard type: 69.715mm
Enlarged 0.5 type: 70.215mm ①Thrust direction
Front ② Axis direction
If the diameter exceeds the maximum, all four
cylinders need to fix bore again.
Replace the crankcase if necessary. 10mm
(0.39 inches)
- 11 -
10mm
(0.39 inches)

Fig. 2-7-24

5 Remove the bumped part of the cylinder mouth.

If the wear is less than 0.2mm, polish the top of cylinder with cylinder reamer (Figure 2-7-25).

Fig. 2-7-25 Fig. 2-7-26

6. Check the fit condition between the connecting rod and piston pin
Try to see whether the connecting rod is able to move in the vertical direction of the piston pin. If it
can move, replace the connecting rod piston components (Figure 2-7-26).
 Engine 11-57

7 Remove the piston ring

Piston ring expander
(1) Use piston ring expander to remove 2 gas
rings (Figure 2-7-27).
(2) Remove 2 plate rings and lining rings
Note: put compression rings in correct order.

Fig. 2-7-27

8 Remove the connecting rod from the piston.

Press out piston pin from connecting rod with special tool and take off the connecting rod (Figure
2-7-28).
- 11 -
Tip:
● Connecting rod, piston pin and piston are joint parts.
● Install piston, piston pin, piston ring, connecting rod and connecting rod bearing bush in the
correct sequence.

Fig. 2-7-28 Fig. 2-7-29

9 Clean the pistons

(1) Clear the carbon deposit on the piston top with gasket scraper (Figure 2-7-29).
(2) Use groove cleaning tool or broken ring to clean piston groove (Figure 2-7-30).
(3) Clean the piston with solvent and brush (Figure 2-7-31).
Caution: do not use wire brush.
11-58 Engine

Fig. 2-7-30 Fig. 2-7-31

10 Check piston and piston ring

1. Check piston oil clearance
Note: The piston diameter is marked on top of the piston. Fig. 2-7-32 - 11 -
(a) Use micrometer (screw micrometer) to measure the piston diameter perpendicular to piston
pin central line at the place 38.1mm away from the piston top (Figure 2-7-33).

Forward mark
Mark position of
weight grade

Fig. 2-7-32
Fig. 2-7-33

The piston diameter is as follow:

Standard type
～
69.673 69.687mm
(b) Measure the internal diameter of cylinder
hole.
(c) Subtract the piston diameter value from the
cylinder hole internal diameter value.
Standard oil film clearance: 0.023 ~ 0.047mm
Maximum oil film clearance: 0.07mm
If oil clearance is larger than the maximum,
replace all four pistons, and resize 4 cylinders.
Replace the crankshaft if necessary.
Note (when using new crankcase): Use pistons
which have the same mark as that of the
cylinder hole (Figure 2-7-34). Fig. 2-7-34
 Engine 11-59
(2) Check backlash of the piston
Measure the clearance between the new piston ring and ring slot with a feeler gauge.
(Figure 2-7-35).
Piston ring side clearance
Top compression ring: 0.01 ~ 0.03mm
The 2nd ring: 0.01 ~ 0.03mm
Maximum value: 0.05mm
If the backlash is greater than the specified value, replace the piston.
3. Check piston ring gap
(a). Insert piston ring into cylinder hole.
(b) Use piston to push the piston ring to the position slightly over the piston ring journey, 85mm
from the crankcase top (Figure 2-7-36).

- 11 -

85 mm

Fig. 2-7-35 Fig. 2-7-36

(c) Use feeler gauge to measure the opening

clearance (Figure 2-7-37).
Maximum open clearance:
Top compression ring:0.60mm
The 2nd ring: 0.60mm
Oil ring (plate ring +bushing ring): 0.90mm
Standard open clearance:
Top compression ring: 0.250 ~ 0.350mm
Fig. 2-7-37
The 2nd ring: 0.250 ~ 0.450mm

Oil ring (plate ring +bushing ring): 0.200-0.700mm

If the clearance is greater than the specified value, replace the piston ring.
If the opening clearance still exceeds the maximum value after using new piston ring, resize the
four cylinders or replace the crankcase.
11. Check connecting rod
(1) Use connecting rod collimator and feeler gauge to check the torsion resistance and inclination
between the large hole and the small hole of the connecting rod
(a) Check the torsion resistance between the large hole and the small hole of the connecting rod
(Figure 2-7-38)
11-60 Engine
Torsion resistance standard value: 0.06mm/100mm
Torsion resistance maximum value: 0.08mm/100mm
If the torsion resistance exceeds the maximum value, replace the connecting rod piston
components.
(b) Check the inclination between the large hole and the small hole of the connecting rod (Figure
2-7-39).
Inclination standard value: 0.03mm/100mm
Inclination maximum value: 0.05mm/100mm
If the inclination exceeds the maximum value, replace the connecting rod piston component.

- 11 -

Fig. 2-7-39
Fig. 2-7-38

(2) Check the connecting rod bolts

(a) Install the lock nuts of the connecting rod bolts Check whether the lock nut can be easily
rotated to the thread end with hands (Figure –7-40).
(b) If the lock nuts fail to rotate smoothly, use dial caliper to measure the external diameter of the
connecting rod bolt (Figure 2-7-41).
Standard outer diameter:7.860-8.000mm
Minimum outer diameter: 7.60mm
Tip:
● If this part can not be visually checked, measure the external diameter at the shown position.
● If the outer diameter exceeds the minimum, replace the whole set of connecting rod bolts and
nuts.

Fig. 2-7-40 Fig. 2-7-41

 Engine 11-61
12. Process cylinder hole
● Process 4 cylinder holes to match the enlarged 0.5 type piston external diameter.
● Replace all prison rings to match the enlarged 0.5 type piston.
(1) Measure the diameters D of 4 enlarged pistons.
Diameter range of enlarged 0.5 type piston: 70.175-70.189mm.
Measure the specific value D of 4 extended 0.5 type of piston diameters
Measure with screw micrometer at the position 38.1mm away from piston top, with the measuring
direction vertical to piston pin axles.
(2) Calculate the diameter of the 4 processed cylinder holes.
The processed cylinder diameter=D+0.035, tolerance:±0.01mm
(3) Confirm the working allowance M of the 4 cylinder holes.
Working allowance M=diameter of cylinder after processing – diameter of cylinder before
processing=resizing value + grinding value, grinding value=0.01-0.02mm.
Caution: Excessive polishing will destroy roundness of the finished product. - 11 -
(4) bore and polish the cylinder to the calculated size
Check the radius run-out of the crankshaft
(1) Put the crankshaft on the V-block (Figure 2-7-42).
(2) Use the dial indicator to measure the radial skip of the countershaft journal.
Radial skip standard value: 0.02mm
Radial skip maximum value: 0.04mm
If the radius run-out exceeds the maximum, replace the crankshaft.

Fig. 2-7-42 Fig. 2-7-43

14. Check the main shaft journal and the connecting rod journal
(1) Use spiral micrometer to measure the diameter of each main shaft journal and the connecting
rod journal (Figure 2-7-43).
Main journal diameter:
Standard type
Mark "1": ＞48.994～49.000mm
Mark "2": ＞48.988～48.9939mm
Mark "3": ＞48.982～48.9879mm
11-62 Engine
Enlarged 0.25 type (main bearing bush thickened by 0.25mm): 48.73-48.75mm.
Connecting rod journal diameter:
Mark "1": ＞38.000～37.994mm
Mark "2": ＞37.988～37.939mm
Mark "3": 37.9879～37.982mm
Enlarged 0.25 type (connecting rod bearing bush thickened by 0.25mm):37.73-37.75mm.
If the diameter is disqualified, check the oil film clearance; Replace the crankshaft if necessary.
(2) As shown in the figure, check the cylindricity of every main journal and connecting rod journal.
Cylindricity standard value of the main journal and connecting rod journal: ≤0.01mm
Maximum value: 0.02mm
If the cylindricity exceeds the maximum value, replace the crankshaft.

15. Polish the main journal/connecting rod journal if necessary. - 11 -

Polish the main shaft journal:
(1) Measure the diameters D of 4 main shaft holes.
(2) Measure the thickness T of the 4 thickened main bearing bushes.
The thickness range of the thickened 0.25 main bearing bush: 2.253-2.237mm.
Measure the thickness value T of the 4 thickened main bearing bush
(3) Calculate the diameter of the main shaft journal after processing.
The diameter of the processed main shaft journal=D-2T-0.024, tolerance: ±0.009mm.
(4) Confirm the processing allowance M of the 4 main shaft journals.
Working allowance M=diameter of the main shaft journal before processing- diameter of the
processed main shaft journal
(2) Polish the main shaft journal to the calculated size
Grinding connecting rod journal:
The method is the same as above, the thickness scale of thickened 0.25 connecting rod bearing
bush is: 1748-1760mm
The diameter of processed connecting rod journal =D-2T-0.037, tolerance: ±0.017mm
Install new shaft bushing that matches the main shaft journal/connecting rod journal

III. Replace crankcase parts

1 Replace timing cover oil seal

Note: There are two oil seal replacement methods A and B as follow
A. If the timing cover has been removed from the crankcase.
(a) Use straight screwdriver to lift the oil seal (Figure 2-7-44).
(b) Use special tool to knock in the new oil seal, until its surface is of the same level as the timing
cover (Figure 2-7-45).
(c) Apply grease to the oil seal edge.
 Engine 11-63

Engine
Mounting tool for
crankshaft rear oil seal

Crankshaft

Front oil seal of

crankshaft
Fig. 2-7-44
Fig. 2-7-45

B. If the timing cover installed to the crankcase

(a) Use knife to cut off oil seal edge.
- 11 -
(b) Use straight screwdriver to lift the oil seal.
Caution: be careful not to damage camshaft. Wrap the adhesive plaster on the tip of the
screwdriver.
(c) Apply grease to the new oil seal edge.
(d) Use special maintenance tool to knock in the oil seal, until its surface is of the same level of the
pump shell edge (Figure 2-7-45).

2. Replace crankshaft rear end cover

Note: There are two oil seal replacement methods A and B as follow
A If the rear end cover of the crankshaft has been removed from the crankcase

(a) Use straight screwdriver and hammer to

knock out the oil seal lightly (Figure 2-7-45).
(b) Use special tool or hammer to knock in the
new oil seal, until its surface is of the same
level of the rear oil seal edge (Figure 2-7-45).
(c) Apply lithium grease to the oil seal edge.
B. If the rear end cover of crankshaft has been
installed on the crankcase
(a) Use knife to cut the off the oil seal edge.
(b) Use straight screwdriver to lift the oil seal. Fig. 2-7-46

Caution: be careful not to damage camshaft.

Wrap the adhesive plaster on the tip of the
screwdriver.

(c) Apply grease to the new oil seal lips.

(d) Use special tool to knock in the new oil seal, until its surface is of the same level of the rear end
cover edge.
11-64 Engine
IV Assemble the crankcase

Tip:
● Completely clean all parts and components to be installed.
● Before installing components, apply new engine oil to all sliding and rotating surfaces.
● Use new sealing gasket, O-ring and oil seal to replace all old ones.

1. Install piston and connecting rod

(1) Apply engine oil to piston pin and piston pin hole.
(2) Put the piston and the front end mark of the connecting rod on the same side, push in the
piston pin with thumb (Figure 2-7-47).
(3) Use special tool to press in piston pin (Figure 2-7-48).

2 Install the piston ring.

- 11 -
(1) Manually install plate ring and lining ring

Front end mark

(concave)

Front end mark

(bumped)

Fig. 2-7-47 Fig. 2-7-48

(2) Use piston ring expander to install 2 gas rings, with the character mark upwards (Figure
2-7-49).
(3) The opening position after installing piston ring is as shown in the figure (Figure 2-7-50).

Piston ring
expander Clearance of oil
ring gasket
Exhaust
Oil ring rail Clearance of
clearance the 2nd ring
Front mark

Clearance of Oil ring rail

the 1st ring Intake clearance

Fig. 2-7-49
Fig. 2-7-50
 Engine 11-65
3 Install the connecting rod bearing bush
(1) Align the bumped part of the bearing bush with the groove on the connecting rod/connecting
rod cover (Figure 2-7-51).
(2) Install bearing bush in the connecting rod/connecting rod cover.

4 Install main bearing bush

Note: The upper main bearing bush has oil groove and oil hole, while the lower main bearing bush
does not them(Figure 2-7-52).

Upper main
bearing bush

Lower main
bearing bush - 11 -

Fig. 2-7-51 Fig. 2-7-52

(1) Align the bumped part of the main bearing bush with the groove on the crankcase, and push
the 5 upper main bearing bushes (Figure 2-7-53).
(2) Align the bumped part of the main bearing bush with the groove on the main bearing cover,
and push the 5 lower main bearing bushes (Figure 2-7-54).

Fig. 2-7-53 Fig. 2-7-54

5. Install the upper thrust plate

Install 2 thrust plates on the two sides of the main shaft hole of No.3 crankcase, with oil groove
outwards (Figure 2-7-55).
6 Put the crankshaft to the main shaft hole of crankcase.
7. Install main bearing cap and the lower thrust plate
(1) Install the 2 thrust plates on the two sides of the main bearing cover No.3, with oil groove
outward (Figure 2-7-56).
11-66 Engine

Fig. 2-7-55 Fig. 2-7-56

(2) Install 5 main bearing covers to the corresponding positions (Figure 2-7-57).
Note: Each bearing cover has number mark and front mark.
(3) Apply a thin layer of engine oil to the thread
- 11 -
(4) Install and tighten the 10 main shaft bolts evenly by several times according to the sequence
shown in the figure (Figure 2-7-58).
Torque: 55-60N•m
(5) Check whether the crankshaft rotates smoothly.

Fig. 2-7-57 Fig. 2-7-58

8. Check the crankshaft axial clearance

Axial clearance: 0.11-0.31mm

9. Install connecting rod piston components

(1) Use tube to cover the connecting rod bolts to protect the cylinder hole and crankshaft journal
from damage (Figure 2-7-59).
(2) Use piston ring compressor to push the connecting rod pistons matched with corresponding
cylinder into the cylinder, with the front end mark of piston forwards (Figure 2-7-60).
 Engine 11-67

Front end mark

(concave) Push down

Fig. 2-7-59
Fig. 2-7-60

10. Install the connecting rod cover

(1) Connect the connecting rod cover to the connecting rod
(a) Match the connecting rod cover with the corresponding connecting rod according to the
- 11 -
number.
(b) Install connecting rod cover, with front end mark forward (Figure 2-7-61).
(2) Install connecting rod cover nuts
Tip:
● The connecting rod cover nuts shall be gradually screwed up by 2 steps (Figure 2-7-62).
● If the connecting rod cover bolts break or deform, replace them.

Front end mark

(bumped)

Fig. 2-7-61 Fig. 2-7-62

(a) Apply a thin layer of engine oil to the bottom surface of the connecting rod cover nut.
(b) Install and alternately tighten locking nuts by several times.
Torque: 30 - 35N•m
If any locknut fails to meet the specified torque, replace the whole set of connecting rod bolts and
nuts.
(c) Use painting to mark on the connecting rod bolts and locking nuts (Figure 2-7-63).
(d) Check whether the crankshaft rotates smoothly.
11. Check the axial clearance of the connecting rod
12. Installation of crankshaft rear end cap
11-68 Engine
(1) Install new sealing gasket and oil seal
(2) Use 6 bolts to install crankshaft rear end cover (Figure 2-7-63).
Torque: 9 - 11N·m

Front side

Paint mark

Fig. 2-7-63 2-7-64

- 11 -
13. Install the knock sensors.
Install the knock sensor with the special tool (Figure 2-7-65)
Torque: 18 – 20N.m.
14 Install the oil pressure alarm switch
(1) Apply Darbond 2567 thread sealant to the 2nd-3rd threads of the alarm switch.
(2) Use special tool to install the oil pressure switch.
15. Installation of oil filter
16. Installation of cylinder head
17. Re-installation of water pump
(1) Install a new O-ring to the crankcase.
(2) Use 2 bolts to install water pump.
Torque: 18 – 20N.m.

Fig. 2-7-65
Fig. 2-7-66
 Engine 11-69

18. Install oil pan and timing cover

19. Install alternator support (Figure 2-7-66)
20 Install the front and rear lifting hooks of
the engine
21. Install timing pulley and belt
22. Lift engine from support special for
engine
23. Install the transmission partition
24. Installation of flywheel
Fig. 2-7-67
(1) Install flywheel on the crankshaft.
(2) Install and tighten mounting bolts evenly by
several times according to the sequence shown
in the figure (Figure 2-7-67).
Torque: 55-60N.m
- 11 -
11-70 Engine
Cooling System

I. Check and replacement of antifreeze coolant

1. Inspection of antifreeze coolant

1. Check the engine antifreeze coolant level in the radiator tank (Figure 3-1-1).
When the engine is cold, the coolant level should be between the LOW and FULL marks.
Check any leakage if it is low, and add coolant to bring it to the FULL mark.
2. Check the quality of engine antifreeze coolant.
(1) Remove the radiator cover.
Removing the radiator cap while the engine and radiator are hot can cause the coolant to spray
out, seriously scalding you. - 11 -
No excessive rust or scale deposition around the radiator cap or the water filling opening of the
radiator is permitted. No engine oil in the coolant is permitted. If the coolant is dirty, replace it.

(3) Reinstall radiator cover.

Fig. 3-1-1

II Replace antifreeze coolant

1. Discharge the antifreeze coolant

Engine drain plug
(1) Remove radiator cap
Note: To prevent burns, never dismantle the
radiator cap when the engine and radiator are
also rather hot, because the liquid and steam
will spray out under pressure.
(2) Screw out the crankcase drain plug (at the
front left side of the crankcase) (Figure 3-1-2)
and radiator drain plug (at the right side of the Radiator drain plug

water tank below the radiator) (Figure 3-1-3),

discharge the antifreeze coolant.
(3) Screw in water drain plug. Fig. 3-1-2
 Engine 11-71
Torque: engine drain plug 12.7N.m

2. Fill antifreeze coolant

(1) fill antifreeze coolant to cooling system
slowly.
Specification of antifreeze coolant: ethylene
glycol antifreeze coolant having freezing point
below the lowest local temperature 5-10 ℃
and meeting the SH0521 standard.
Note: Never use alcohol antifreeze coolant.
Capacity: 5.3L
Fig. 3-1-3
(2) Install radiator cap.
•Start the engine to discharge the air in the
cooling system.
(4) Fill antifreeze coolant to antifreeze coolant
reservoir to - 11 -
“FULL” line.
3. Check antifreeze coolant for leakage

3.2 Disassembly, maintenance and assembly of water pump

I. Remove the water pump

1. Discharge the antifreeze coolant

2. Remove the pump alternator belt
3. Remove the 2 water pipes
4. Remove inlet pipe of the water pump
5. Remove the alternator bracket
6. Remove the water pump (Figure 3-2-3)
(1) Remove the 2 pump inlet mounting bolts.
(2) Remove 4 pump mounting bolts.
(3) Remove the pump and pump inlet
(4) Take off the O-ring from the crankcase.
11-72 Engine

Fig. 3-2-2 Fig. 3-2-3

II. Check the water pump

1. Check the air hole and water hole visually for coolant leakage. If any, replace the water pump.
- 11 -
2. Rotate the belt wheel, the rotation of pump bearing shall be smooth and silent, replace the
pump if necessary.

III. Install the water pump

1. Re-installation of water pump

(1) Put a new O-ring in the pump sealing groove (Figure 3-2-4).

Bumped part

New O-ring

Fig. 3-2-5
Fig. 3-2-4

(2) Install the pump with 4 bolts (Figure 3-2-5)

(3) Tighten the bolt
Torque: 20-25N•m
3. Install the water pump water inlet hose
4. Install alternator bracket.
5. Install water pipe
6. Install the water pump alternator belt
 Engine 11-73
7. Fill antifreeze coolant
8. Starting engine and checking for leaks

3.3 Check and replacement of thermostat

I. Remove the thermostat

Without thermostat, the cooling efficiency will

fall. Don't remove the thermostat even if the
engine tends to overheat.
1. Discharge the antifreeze coolant
2. Remove the connectors of water
temperature sensor
3. Remove the thermostat cover and the
thermostat - 11 -
(1) Remove 2 bolts and the thermostat cover
(Figure 3-3-1). Fig. 3-3-1
(2) Remove the thermostat cover.
(3) Remove the seal ring from the thermostat.

II. Check the thermostat

Note: there is valve open temperature on

thermostat (Figure 3-3-2)
(1) Immerse the thermostat in water Heat the
water slowly (Figure 3-3-3)
(2) Check the opening temperature of the
valve.
Valve opening temperature: 82±2°C
If the valve opening temperature does not
conform to regulations, replace the thermostat. Fig. 3-3-2

(3) Check valve lift (Figure 3-3-4).

Valve lift :The lift is at least 8mm or more at 95 °C.
11-74 Engine

Valve lift

Fig. 3-3-3 Fig. 3-3-4

If the thermostat valve lift is inconsistent with the specified value, replace the thermostat.
℃
(4) When the thermostat is in low temperature (below 40 ), check whether the valve is fully
closed. If the valve cannot close, replace the thermostat.
- 11 -
III. Install the thermostat

1. Install the thermostat in the thermostat seat.

(1) Install the new seal ring to the thermostat. (Figure 3-3-5).
(2) Install the thermostat in the thermostat seat. (Figure 3-3-6).
2. Install the thermostat cover
Install the thermostat cap with two bolts.
Torque: 9-11N•m
3. Connect the connector of water temperature sensor
4. Fill antifreeze coolant
5. Start the engine and check the antifreeze coolant for leakage

New gasket

Bypass-valve

Fig. 3-3-5 Fig. 3-3-6

3.4 Check and replacement of cooling fan

I. Check the cooling fan on vehicle

 Engine 11-75

1. Check the performance of cooling fan in low temperature (below 83 ). ℃

(1) Connect the ignition switch (ON) (Figure 3-4-1)
(2) Check whether the cooling fan can stop running.
If it does not stop, check cooling fan relay and water temperature switch.
Check whether the connectors or the conductor between the cooling fan relay and water
temperature switch are disconnected.

Below 83 ℃ “ON” start Ammeter

Battery - 11 -

Fig. 3-4-1 Fig. 3-4-2

2. Open the water temperature switch joint.

(1) Remove the water temperature switch joint.
(2) Use a length of wire. Connect the water switch connector with the ground electrode.
(3) Check whether the cooling fan can rotate.
If it fails to rotate, check the cooling fan relay, cooling fan, fuse, and engine main relay, and check
whether there is short circuit between the cooling fan relay and the water temperature switch.
3. Reconnect water temperature switch connector.
4. Check the performance of cooling fan at high temperature
(1) Start the engine to raise the temperature of cooling liquid to 93 ℃ or above.
(2) Check whether the cooling fan can rotate.
If the fan fails to rotate, replace the water temperature sensor.

5. Check the cooling fan.

Screw
Nut
(1) Open the connector of cooling fan.
(2) Connect the battery and ammeter to the
connector of cooling fan (Figure 3-4-2).
(3) Check whether the cooling fan can rotate
smoothly. And check the reading of ammeter.
Standard current intensity: 5.7~7.7A Screw

(4) Reconnect the cooling fan connector.

Fig. 3-4-3

II. Dismantle the cooling fan

11-62
11-76 Engine
1. Remove the fan cover
Remove mounting nut and fan (Figure 3-4-3).
2. Remove the fan motor
Remove the leads from the fan cover.
Remove 3 screws and fan motor (Figure 3-4-3).

III. Re-assemble cooling fan

1. Install the fan motor

(1) Install the fan motor with 3 screws (Figure 3-4-3).
Torque: 26 N.m
(2) Connect the wire to the fan cover.
2. Install the fan
- 11 -
Install fan with nuts.
Torque: 6.2N.m

35 Check and replacement of cooling fan relay

1. Remove the relay box cover.

2. Remove the cooling fan relay, which is in the central control box of the engine (Figure 3-5-1).

No continuity Conductive
Cooling fan relay

Ohmmeter Ohmmeter

Fig. 3-5-1 Fig. 3-5-2

3. Check the conductivity of the cooling fan

relay. Conductive

(1) Check with ohm gauge. Terminal 1 and

terminal 3 shall be conducted.
If not, replace the relay. Ohmmeter Battery
(2) Check between terminal 2 and terminal 4 It
shall be not conductive.
If so, replace the relay.
4 Check working condition of cooling fan relay
 Engine 11-77
(Figure 3-5-3): Fig. 3-5-3

(1) Apply positive voltage of battery to terminals

1 and 3
(2) Check terminals 2 and 4 with ohm gauge for
conductivity.
If not, replace the relay.
5. Re-installing the cooling fan relay
6. Reinstall relay box cap

Lubrication system

I. Oil and filter

- 11 -
(1) Inspection

1 Check the engine oil quality

Check the oil for deterioration, water, black or thinning.
If the oil quality is deteriorated, replace the oil.
Suggested viscosity is as shown in the figure (Figure 4-1-1).

Recommended use viscosity (SAE)

Within the predicted temperature scale before

replacing engine oil

Fig. 4-1-1 Fig. 4-1-2

2. Check engine oil level

Warm up the engine and shut down for 5 minutes, the oil level on the ground shall be between the
upper marking hole and lower marking hole of the oil level gauge. If it is lower Then check whether
there is leakage and fill engine oil to the upper mark hole.
Caution: Do not fill engine oil over the mark hole.
3. Removing oil pressure alarm switch and installing oil pressure gauge
(1) Remove the oil pressure alarm switch with special tools (Figure 4-1-2).
(2) Install oil pressure gauge (Figure 4-1-3).
11-78 Engine

Adhesives

Fuel
pressure
gauge

Fig. 4-1-4
Fig. 4-1-3

4. Preheating engine
(c). Preheat the engine to its normal working temperature.
- 11 -
5. Check oil pressure
： ～ ，
Oil pressure 750r/min is 100 200kPa 4000r/min is 280-360 kPa
6. Removing oil pressure gauge and re-installing oil pressure alarm switch
(1) Remove the oil pressure gauge.
(2) Apply Darbond 2567 thread sealant to oil pressure alarm switch (Figure 4-1-4).
(3) Install oil pressure alarm switch with special tool.
Torque: 18±1N•m
7.Starting engine and checking for leaks

II. Replacement

Precautions:
Prolonged and repeated contact with mineral oil will remove the natural fat of the skin, resulting in
dryness, irritation and dermatitis. In addition, the used engine oil contains harmful pollutants
possible to cause skin cancer.
Take special care and try your best to minimize the time and frequency for your skin to contact
with the used oil. Wear blue protective clothing and gloves. Use soap and water to wash your skin
thoroughly or use any anhydrous skin cleanser to dismantle the any used engine oil. Do not use
gasoline, thinner or solvent.
To protect the environment, you must dispose the used engine oil and filter at designated place.
 Engine 11-79

1. Drainage of engine oil

(1) Unscrew the oil filler cap.
(2) Remove the oil drain plug and drain off the
oil to the container.
2. Replacement of oil filter
(1) Remove the oil filter with special tool (Figure
4-1-5).
(2) Check and clean the mounting surface of
crankcase filter.
Fig. 4-1-5

(3) Check whether the parts numbers of the

new oil filter are the same as those of the
previous ones.
(4) Coat clean engine oil onto the sealing ring
of the new oil filter.
- 11 -
(5) Screw in the oil filter slightly; screw up when
the seal ring touches the base.
(6) Screw another 3/4 circle with special tool
(Figure 4-1-6).

Fig. 4-1-6

3. Refilling of engine oil

(1) Clean the drain plug, replace the seal gasket and install the drain plug back.
Torque: 30-35N•m
(2) Refill new engine oil.
Volume
After reinstalling engine: 2.7L
Replace the oil filter: 2.7L
Not replacing oil filter: 2.5L
(3) Install oil filler cap
4. Starting engine and checking for leaks
5. Check the engine oil level again.
11-80 Engine
II. Disassembly, maintenance and assembly of timing cover

I. Remove timing cover

Note: When repairing oil pump, remove and

clean the oil pan and oil strainer.
1. Drain off engine oil.
2. Remove the water pump alternator belt.
3. Remove the tensioning wheel
4. Remove the water tube
5. Remove crankshaft timing pulley.
6. Remove the dipstick and guide pipes (Figure
4-2-1).
- 11 -
(1) Remove mounting bolts.
Fig. 4-2-1
(2) Pull out the oil dipstick and the guide pipe.

(3) Remove the O-ring from the oil dipstick guide pipe.
7. Remove oil pan
(1) Remove 18 bolts (Figure 4-2-2).
(2) Insert special blade between the crankcase and the oil pan, cut the sealant and remove the oil
pan (Figure 4-2-3).

Fig. 4-2-3
Fig. 4-2-2

Note:
● Take care not to damage the flange of the oil pan.
8. Remove the oil strainer.
Unscrew 2 bolts and remove the oil strainer and O-ring (Figure 4-2-4).
 Engine 11-81

Fig. 4-2-4 Fig. 4-2-5

9. Remove the timing cover

(1) Remove 15 bolts (Figure 4-2-5).
- 11 -
(2) Tap the oil pump body with a small rubber hammer. Remove the oil pump.

II. Disassemble the oil pump

1. Remove reducing valve

(1) Take down the snap ring with the pliers
(Figure 4-2-6)
(2) Remove the limiting stopper and driven
rotor
2. Remove the drive and driven rotors
Remove the 8 screws, pump external cap,
O-ring and drive and driven rotors.

Fig. 4-2-6

IIII. check the oil pump

1. Check the reducing valve

Apply engine oil to reducing valve Check whether it can fall into the valve hole by its own weight.
If not, please replace the reducing valve. If necessary, replace the oil pump.
11-82 Engine

Fig. 4-2-7 Fig. 4-2-8

2. Check inner and outer rotors

(1) Check the clearance of the rotor body.
Measure the clearance between the outer rotor and pump body with a feeler gauge (Figure 4-2-7)
～
Standard Clearance: 0.10 0.14mm - 11 -
Maximum clearance 0.18mm
If the clearance is larger than the maximum, please replace the complete set of rotors. If
necessary, replace the oil pump.
(2) Check the clearance of the rotor tip.
～
Standard tip clearance: 0.050 0.10mm
Maximum tip clearance:0.20mm
Use a feeler gauge to measure the clearance between the internal and external rotor ends (Figure
4-2-8).
If tip clearance is larger than the maximum, replace a completed set of rotors.
(3) Check the rotor clearance.
Use precision straight edge (or knife straight edge) and feeler gauge to measure the clearance
between rotor and the precision straight edge (Figure 4-2-9).
～
Standard backlash: 0.045 0.10mm
Maximum clearance: 0.15
If the backlash exceeds the maximum value, replace the whole set of rotors. If necessary, replace
the oil pump.

Mark

Fig. 4-2-9 Fig. 4-2-10

 Engine 11-83
IV. Replace components

Replace the crankshaft front oil seal

V. Assemble oil pump

1. Install the inner and outer rotors

(1) Install the inner and outer rotors into the body, with the mark facing the oil pump cover (Figure
4-2-10)
(2) Install the oil pump cover with 8 screws
Torque: 9 - 11N·m
2. Install reducing valve
(1) Insert the pressure relief valve, spring an stopper into the pump hole.
(2) Install the snap ring with the pliers.
- 11 -

VI. Install timing cover

1. Install the timing cover

(1) Apply Darbond 2599 sealant on the joint surface of the timing cover
(2) Align the keyway of inner rotor for oil pump with the key teeth of the crankshaft and then slip it
into (Figure 4-2-11)

Fig. 4-2-12
Fig. 4-2-11
11-84 Engine
(3) Install the timing cover with 15 bolts.
Torque: short bolt 9-11N.m; long bolt 20-25N.m
Length of the long bolts: 38mm, 40mm, 42mm
(Figure 4-2-12) Sealing width
3-5mm
Length of short bolt: 25mm
(4) Scrap off the gasket higher than the lower
end face of the crankcase.
2. Installation of oil strainer
Install new seal gasket and oil strainer with 2
bolts.
Torque: 9-11N•m
3. Install oil pan 6mm (0.24 inch)

(1) Eliminate all old plane sealant on the

crankcase and oil pan. Be careful not to drop
the engine oil on the contact surfaces of the oil
- 11 -
pan and crankcase. Fig. 4-2-13

● Remove all used plane sealant from the

gasket surface and the sealing grooves with the
blade and the gasket remover.
● Thoroughly clean all parts Remove all
loosened materials.
● Clean both sides of sealing surface with
residue-free solvent.
Don't use the solvent which may affect the paint
surface.

(2) Apply Darbond 2599 plane sealant to the oil

pan (Figure 4-2-13).
● Ensure to assemble the parts within 5
minutes after applying the plane sealant.
Otherwise, make sure to remove the sealant
and re-coat it.
(3) Install the oil pan with 18 bolts.
Torque: 9-11N•m
4. Install oil dipstick and the guide pipe
(1) Install the new O-ring to the oil dipstick
guide pipe (Figure 4-2-14). New O-ring

(2) Apply the suds to O-ring.

Fig. 4-2-14
(3) Push the oil dipstick guide pipe and oil
dipstick in and install them with bolts.
Torque: 9-11N•m
5. Install the crankshaft timing pulley
6. Install the tensioner temporarily
7. Install the water pump alternator belt
 Engine 11-85
8. Install water pipe
9. Fill engine oil
10. Start the engine and check for oil leakage.
11. Reinspection of engine oil level

- 11 -
11-86 Engine
Exhaust Emission Control

I. Overview:

Purpose
The exhaust emission control system is equipped to reduce the CO, HC compound content in the
engine emissions, to prevent the HC compound-containing gas leaking out of the crankcase
from discharging to the atmosphere, and to prevent the HC compound-containing fuel vapor
escaped from the fuel tank from discharging to the atmosphere.
For the function of such system, see the table below:
System Abbreviation Purpose
1. Positive crankcase Reduce the crankcase gas (HC compound)
PCV
ventilation system leakage.
2. Fuel evaporative emission - 11 -
EVAP Reducing the HC compound evaporation
control system
3. Electronic fuel injection Adjusting the working conditions of various engine
EFI
system components to reduce exhaust emissions
4. EGR valve EGR Control the emission of NOx
 Engine 11-87
Principle diagram for exhaust emission control

Fuel steam emission control

is realized through vacuum
channel valve

Engine
harness

Crankcase - 11 -

Activated carbon
filtering valve

EGR control valve

Exhaust pipe
11-88 Engine
5.2 Positive crankcase ventilation (PCV) system

Check
Cylinder head side
1. Removing PCV valve
(a). Remove the PCV hose from the PCV valve.
(b). Remove the PCV valve. Cleaning hose
2. Mount a clean hose on the PCV valve.
3. Check the working status of the PCV
valve.
(a) Blow the air from the cylinder head to PCV
valve to check whether the air circuit is smooth Fig. 5-2-1
(Figure 5-2-1)

Note:
- 11 -
· Do not blow the air through PCV valve.
· The petroleum and other substances in the PCV valve are harmful.
(b) Blow the air from the intake side to the PCV valve to check whether the air circuit is smooth
(Figure 5-2-2).
If the performance fails to meet the specified requirement, replace the PCV valve.

Intake manifold side

Fig. 5-2-2 Fig. 5-2-3

II. Positive crankcase ventilation (PVC) system

Check
1. Removing PCV valve
(1) Remove the PCV hose from the PCV valve.
(2) Remove the PCV valve.
2. Mount a clean hose on the PCV valve.
3. Check the working status of the PCV valve.
(1) Blow the air from the cylinder head to the PCV valve to check whether the air circuit is smooth
(Figure 5-2-1).
If it is blocked, replace PCV valve.
 Engine 11-89
Note:
Do not blow air through PCV valve, where the petroleum substances are noxious.
(2) Blow the air from the reverse direction to the PCV valve to check whether the air circuit is
smooth (Figure 5-2-2)
If yes, replace the PCV valve.
4. Remove the clean hose from the PCV valve.
5. Reinstall PCV valve
6. Visually checking the hose and clamp
Check for breakage. Leakage or damage (Figure 5-2-3).

III. EVAP control system

Check (Figure 5-2-4)

- 11 -
1. Visually check the pipes and the connector.
Find whether the connectors are loosened,
sharply bended or damaged.
2. Visually check the fuel tank.
Check for deformation, cracking or fuel
leakage.
3. Visually check the fuel tank cover.
Check whether the fuel tank cap and the gasket Fig. 5-2-4
are deformed or damaged. Repair or replace
the fuel tank cover if necessary.

4. Check of activated carbon filtering tank (Figure 5-2-5)

A. Visually check activated carbon filtering tank cover
B. Check whether filter is blocked and whether check valve is stuck (Figure 5-2-6)
(a) Blow the low-pressure compressed air into the fuel tank pipeline and check whether the air can
smoothly flow out from other pipelines.
(b) Blow the air into the scavenging pipeline and check whether the air can smoothly flow out from
other pipelines.
11-90 Engine

Fig. 5-2-5

Fuel tank pipeline

- 11 -
Sweep the pipeline

Fig. 5-2-6
Fig. 5-2-7

In case of any problem, replace this activated carbon filtering tank.

C. Clean filter in activated carbon filtering tank
Close other pipes at the upper part of the activated carbon canister, and blow in air via the fuel
tank pipes to clean the filter.
D. Install activated carbon canister
5. Check the vacuum gallery valve used for controlling oil evaporative emission (Figure 5-2-7).

IV. Exhaust gas recirculation (EGR valve) control system (Figure 5-2-8)
 Engine 11-91

1. Remove 2 EGR valve nuts, EGR valve and

the gasket.
2. Visually check whether there is carbon
deposit on valve and valve seat, clean if any.
Eliminate the carbon deposit on the EGR valve
and valve seat and grind them with the abrasive
paste. The EGR valve can be used after being
tested without leakage. If necessary, please
replace the EGR valve.

Fig. 5-2-8

- 11 -
11-92 Engine
Electrical System

I. Electronic fuel injection (EFI) system

1. Precautions
Before repairing the fuel system, please disconnect the cable from the battery negative.
Note: Each fault code stored by ECU will be deleted when the battery negative (-) cable is
disconnected. Thus, please read DTC before disconnecting the battery negative cable (-) if
necessary.
(a) When repairing the fuel system, do not smoke or carry out the maintenance nearby the
obvious flame;
(b) Do not make the rubber or leather parts contact the gasoline;
(c) Repair one group of parts once to avoid mixing the parts with similar appearance;
(d) The repair site shall keep clean to avoid polluting other parts; - 11 -
(e) Pay attention not to mix to install or miss loading clamps or spring.
2. Precautions before maintenance
(a) The battery is used as the power supply of the timing lights and tachometer.
(b) If the engine cannot be started, please follow the precautions below during check.
(1) Check the correctness of the battery cable.
(2) Carefully pull out the high-voltage coil.
(3) After repairing, please check whether the terminal of ignition coil and conductor line of other
ignition systems are connected firmly.
(4) When cleaning the engine compartment, please pay special attention to avoid water
penetration for the electronic system.
(c) Precautions of removing the oxygen sensor.
(1) Do not drop the oxygen sensor or crash the oxygen sensor with other objects.
(2) Do not contact the oxygen sensor with the water.
(d) Connect the harness to the connector plug.
(1) Insert the harness terminal into the connector clip until it is safely locked in the connector
mouth.
(2) Check whether the external harness is locked firmly.
3. Intake system
(a) Once the engine oil dipstick, engine oil filler cap and PCV (crankcase forced ventilation) hose
are loosened, the engine will run disorderedly.
(b) Once the parts in the intake system between the throttle section and cylinder are disconnected,
loosened or cracked, the air will be sucked in and the engine will run disorderedly.
 Engine 11-93
II. Ignition system

Precautions

1. Connect a tachometer in the ignition system and connect the test line of the tachometer with the
terminal lG (-) of the connector.
2. As some tachometers and the ignition system are incompatible, please confirm whether all
tachometers and ignition system are compatible before the use.
3 Do not connect the ground terminal of tachometer with the ground electrode; otherwise it will
cause damage to igniter and/or ignition coil.
4. When the engine is running, never disconnect the battery.
5 Check whether the ignition system is properly grounded to the vehicle body.

Inspection on the vehicle

- 11 -

1. Spark test
Check the production of sparks
(1) Disconnect the high-pressure damper from the spark plug.
(2) Remove the spark plug.
(3) Install spark plug for each high-pressure damper.
(4) Make the spark plug ground.
(5). Check whether the spark is generated when the engine starting.
During the test, in order to prevent the gasoline spraying out from the fuel injector, each time shall
not exceed 1~2 seconds for starting of the engine. Or remove the connector of injection nozzle of
a cylinder to make it not work.
11-94 Engine
If there is no spark, perform the following tests:

No spark

Check the connection of ignition coil and ECM connector

Abnormal
Spark test Normal Connect tightly

Abnormal
Check the impedance of ignition cable Replace the damper
Max.impedance: every damper is 16+3.2kΩ

Normal
Check the ignition coil power supply Abnormal
1. Put the ignition switch in the "ON" position Check the wire from ignition - 11 -
2. Check whether the ignition coil positive (+) switch to ignition coil
has the battery voltage
Normal
Check the resistance of ignition coil
Resistance: Cold state Abnormal
Replace ignition coil
Primary 0.52±0.05Ω
Secondary 9.84±0.98kΩ

Normal
Check the resistance of crankshaft position
Abnormal Replace the crankshaft
sensor
Resistance: Cold state position sensor
Terminal B-C 560±56Ω
Normal
Abnormal "Check the wire of ECM and
Check IGT signal from ECM. ignition coil, then try another
ECM."
Normal
Try another ignition coil

2. Inspection of ignition cable

(1) Remove the high-pressure damper form the spark plug.
Disconnect the high-pressure damper from rubber protection cover. Do not pull damping cable.
Precautions:
Pull or curve the damping line and its internal conductor will be damaged.
After removing the high-pressure damper, please do not wipe all oil stains on the cable. Or swipe
the dirt lightly, in case of damage to the internal conductor of damper line.
(2) Check the impedance of the high-pressure damper.
Measure the impedance of the high-pressure damper with an ohmmeter.
 Engine 11-95
Maximum impedance: 16±3.2KΩ for each damper
If the damping line impedance is greater than the maximum value, check the wiring terminals.
If necessary, replace the ignition cable.
(3) Re-connect the high-pressure damper to the spark plug.
Ensure the high-voltage damper line and the clamp is installed in place.

3. Inspection of spark plug

Ohmmeter
(1) Disconnect the high-pressure damper from
the spark plug.
Refer to Step (1) for the check of the
high-pressure damper.
(2) Remove the spark plug.
Remove the spark plug with a wrench special
for 16mm spark plug (Figure 6-2-2). - 11 -
(3) Clean the spark plug
Fig. 6-2-1
Use spark plug cleaner or wire brush to clean
spark plug (Figure 6-2-3).

16mm spanner for

ignition plug

Spark plug cleaner

Fig. 6-2-2

Fig. 6-2-3

(4) Visually check the spark plug.

Check the spark plug electrode for wear, check
its thread and insulator for damage.
If abnormal, replace the spark plug.
Spark plug type: K7RTC
(5) Adjust the electrode clearance (Figure
6-2-4)
Be careful to bend the external electrode to
achieve a correct electrode gap.
Fig. 6-2-4
Correct electrode gap: 0.7~0.8mm
6. Installation of spark plug
Install the spark plug with a special spark plug
11-96 Engine
wrench of 16mm.
Torque: 25 N.m
(7) Re-connect the high-pressure damper to the
spark plugs.
Refer to Step (2) for the check of the
high-pressure damper.

4. Inspection of ignition coil

(1) Check the impedance of the primary coil.
Measure the impedance between the terminals A and C with ohmmeter
Impedance of primary winding:
Cold state 0.52-0.05Ω
If the resistance measurement value is too bad, replace the ignition coil.
(2) Install the secondary coil impedance
- 11 -
Use an ohmmeter to measure the impedance between the positive pole (+) and the terminal of
ignition cable.
Secondary coil impedance: cold state: 9.840±0.98KΩ
If the resistance measurement value is too bad, replace the ignition coil.

5. Inspection of crankshaft position sensor

Precautions:
The cold and hot hereinafter are referred to the temperature of the sensor itself. “Cold state” is
℃ ℃ ℃
from -10 to 50 and “hot state” is from 50 to 150 . ℃
(1) Remove the crankshaft position sensor
(Refer to the removal of crankshaft position sensor in crankshaft position sensor section)
Check the resistance of crankshaft position sensor
Check the impedance of terminals A and B with an ohmmeter.
Impedance:cold 560±56KΩ
If the impedance is out of tolerance, replace the crankshaft position sensor.
(3) Re-install the crankshaft position sensor. Installation of crankshaft position sensor (the
installing and the removing sequences of the crankshaft position sensor are opposite). The
maintenance shall be standardized.
Repair data
Item Data
Ignition order 1—3—4—2
Ignition cable Maximum resistance Each damper line is of 25KΩ
Spark Plug Model DK7RTC
Spark plug
Correct electrode gap 0.7～0.8mm
Ignition coil Primary coil impedance Cold state 0.36～0.55Ω
 Engine 11-97

Secondary coil
impedance
Cold state ～15.4KΩ
9.0

Crankshaft position
sensor
Cold-state resistance －
B C 1630～2740Ω

III. Starting system

Inspection on the vehicle

Note: Check the following items once again before operating the starter:
(1) Connection of connectors
(2) Installation of accessories, such as anti-theft system.

1. Dismantling of the starter - 11 -

(1) Remove the nut and disconnect the wire of the magnetic switch terminal; And use high
impedance multimeter to test the voltage on the wire connector, the reading shall be no less than
10.5V (note that the terminal can not contact the engine to avoid discharging danger).
(2) Unscrew the 2 nuts used to fix the magnetic switch on the starter housing;
(3) Pull up the magnetic switch and release the plunger hook of the drive shaft while lifting the
front of the magnetic switch, and then release the magnetic switch;
(4) Remove the plunger cover.

2. Remove the magnetic frame and armature

(1) Remove the connecting wires between the solenoid switch and the motor. Remove the nut and
disconnect the wires from the terminal, with a torque of 5.9Nm;
Torque:5.9N.m
(2) Remove 2 through bolts.
Torque: 1.5N • m for 1.2kW model
(3) Removing the magnetic pole frame and the armature from the solenoid switch assembly;
(4) Remove the O-ring.
Assembly notes:
● Use a new O-ring.
● Align the lug of the magnetic frame to the notch of the electromagnetic switch.

3. Removal of starter housing, clutch assemble and gears

(1) Remove the two screws.
Torque:5.9N.m
(2) Remove the following components from the electromagnetic switch assembly: starter housing,
lever spring, bearing and clutch assembly.
(3) Remove the steel balls, using the magnetic needle suck out the balls from the clutch shaft
11-98 Engine
hole.

4. Remove the brush rocker

(1) Remove the two screws and the end cover from the pole frame.
Torque: 1.5N.m
(2) Remove the O-ring form the magnetic frame.
Note for assembly: use new O-ring.
(3) Press the return spring with the screwdriver to remove the brushes from the brush carrier.
Disconnect the 4 brushes and remove the brush carrier.

5. Remove armature from the pole frame

6. Armature coil
- 11 -
(1) Checking the commutator for continuity
Check whether two commutator bars of Conductive
commutator are conducted with an ohmmeter
(Figure 6-3-1).
If any commutator bar is not conductive, Ohmmeter
replace the armature winding.

Fig. 6-3-1

(2) Checking the commutator for grounding

Check whether the commutator and armature No continuity
coil core shaft are on or off with an ohmmeter.
They shall be not conductive (Figure 6-3-2).
If it is conductive, please replace the armature Ohmmeter
winding.

Fig. 6-3-2

7. Commutator
(1) Checking the commutator for contamination and surface scorch
If any, treat the commutator with sand paper or on a lathe.
(2) Check the ring gear runout of the commutator
(a) Place the commutator on a wooden V-shaped wedge mat.
 Engine 11-99
(b) Measure the ring gear runout with a dial indicator
Maximum gear ring runout: 0.05mm
Correct the run-out difference of the ring gear on a lathe if it is higher than the maximum.

(3) Check the diameter of the commutator

Measure the diameter of the commutator with
dial calipers (Figure 6-3-3).
Standard diameter: 30mm
Minimum diameter: 29mm
If the measured diameter less than the
minimum one, replace the armature.

Fig. 6-3-3

(4) Check the undercut depth (Figure 6-3-4)

- 11 -
Make sure that the undercut area is clean and
free of impurities and its edges are smooth.
Standard undercut depth: 0.6mm
Minimum undercutting depth: 0.2mm
If the measured undercut depth less than the
minimum value, correct it with a hacksaw
blade. Do not finish fillet on kerf.
Fig. 6-3-4

8. Field frame (Field coils)

(1) Check the open circuit condition of the Conductive
magnet exciting coil.
Check whether the conductor and carbon brush
magnet exciting coil are conductive. If they are Ohmmeter
conductive, they are normal (Figure 6-3-5)
If it is not conducted, replace the field frame.

Fig. 6-3-5

(2) Check the grounding connection of the

magnet exciting coil.
Conductive
Check to make sure that the end of the
magnetic exciting coil and the magnetic frame
are not conductive (Figure 6-3-6).
Ohmmeter
If they are conductive, repair or replace the field
frame.
11-100 Engine
Fig. 6-3-6

9. Electric brush
Electronic brush
Checking the brush length frame side

Measure the length of the electronic brush with

dial calipers (Figure 6-3-7)
Standard length:15.5mm
Minimum length: 10.0mm
If the measured length less than the minimum,
replace the brush carrier and pole frame. Length

Pole frame side

- 11 -

Length

Fig. 6-3-7

10. Electronic brush spring (Figure 6-3-8)

Fig. 6-3-8

11. Electronic brush frame

Check the insulation situation of the electronic No continuity
brush frame (Figure 6-3-9)
Check whether the positive (+) and negative (-)
electrodes of the electronic brush frame are Ohmmeter
conductive with an ohmmeter. Both shall not be
conductive.
If the positive and the negative electrodes are
conductive, repair or replace the electric brush
carrier.
Fig. 6-3-9
 Engine 11-101

12. Clutch and gear (Figure 6-3-10)

1) Check the gear Move flexibly
Check the gear teeth of the planetary pinion
and idler gear and the clutch assembly for wear
or damage.
If any damage, replace the gear or the clutch Lock
assembly.
Check if the ring gear of the flywheel is
damaged as well.
Fig. 6-3-10

(2) Check clutch planet pinion

Hold the starter clutch and turn the pinion clockwise to check the pinion can be free to rotate. Then
try to turn the pinion counterclockwise to make sure that it cannot be rotated.
Replace the clutch assembly if necessary.
- 11 -
(3) Check gear teeth
Check the gear teeth of the planetary pinion and idler gear and the clutch assembly for wear or
damage.
If any damage, replace the gear or the clutch assembly.
Check if the ring gear of the flywheel is damaged as well.
(4) Check clutch planet pinion
Hold the starter clutch and turn the pinion clockwise to check the pinion can be free to rotate. Then
try to turn the pinion counterclockwise to make sure that it cannot be rotated.
Replace the clutch assembly if necessary.

IV. Charging system

Precautions
1. Check whether the battery cables are connected to the right terminals.
2. Disconnect the battery cable and rapidly discharge the battery.
3. During the test, never use any high-voltage insulation impedance detector.
4. Don't disconnect the battery when the engine running.
11-102 Engine
Special tool
Special tool
Sketch Name Remarks
Injection pump camshaft cone bearing Rotor rear bearing
inner race replacer cover

Commutator end
Injection pump spline shaft puller
bracket

Alternator rear bearing puller

Engine bearing replacer Rotor rear bearing

Alternator belt device nut spanner kit - 11 -

Front rotor
Replacer kit
bearing

Replacer 26

Replacer 50

Adapter

Equipment
Equipment
Device name Remarks
Ammeter (A)
Battery proportion meter
Belt tension meter
Torque wrench
Dial caliper Rotor (slip ring), electric brush
 Engine 11-103

I. On-vehicle check

1. Check the battery.

(1) Check the battery electrolyte
position/density.
(a) Maintenance-free battery: (Figure 6-4-1)
If less than the lower limit, replace the battery Upper limit
(or if possible, add distilled water) and check
the discharge system.
Lower limit
(b) Maintenance battery:
Check the electrolyte density: Fig. 6-4-1
Check the electrolyte density of each battery. If
less than the lower limit, add distilled water.
- 11 -
℃ ～
Standard density: 20 : 1.25 1.29
If the density is less than the specified value,
discharge the battery.

(2) Check the battery voltage

(a) After a vehicle is started and within 20min after the engine shuts down, please set the ignition
switch in the ON position and electric system (headlamp, blower rotor and rear defroster etc.) for
60s to remove the surface load.
(b0Turn the ignition switch to the "OFF" position and turn off the electrical system.
(c) Measure the voltage of battery positive (+) and negative (-) electrodes.
℃
Standard voltage: 20 (68oF): 12.5-12.9V
If the voltage is less than the specified value, please charge the battery.
(3) Check the battery electrode, fusible wire or fuse.
(a) Check to make sure that the battery electrodes should be free of looseness or corrosion.
If the electrode is corroded, clean it.
Check the continuity of fusible wire and fuse.

2. Check the generator belt

(1) Visually check whether the belt is
excessively worn, extended and broken etc.
(Figure 6-4-2).
If finding any defects, replace the alternator
belt.
Note: the belt side with teeth is allowed to have
cracks. If the tooth ribs have no block, replace
the generator belt.
Fig. 6-4-2
11-104 Engine
(2) Press in the position shown in the figure Water pump pulley
(Figure 6-4-3) with 98N to check the alternator
belt deflection. 98 N

Alternator pulley

Tension pulley Driving pulley

Fig. 6-4-3

Deflection of alternator belt:

New belt:7-9mm
Old belt:11.5-13.5mm
Adjust deviation of the alternator belt.
- 11 -
Reference: check the tension of the alternator belt with a tensiometer.
Generator belt tension
New belt:685-785mm
Old belt:295-440mm
If the tension of the alternator belt is poor, adjust it.

Note:
The “new belt” refers to the alternator belt that
is not used on a running engine for more than
5min. Correct Error Error

The “old belt” refers to the alternator belt that is

used on a running engine for 5min or more than
5min.
After installing alternator belt, check whether it Fig. 6-4-4
is properly matched with the groove (Figure
6-4-4).

Check by hand to confirm that the belt does not slide out of the pulley grooves.
After installing a new belt, please run the engine for about 5min and check the belt tension.

3. See whether the generator wiring is reliable and hear whether there is any abnormal
noise.
(1) Check the wiring for good state.
(2) When the engine is running, check whether the generator has any abnormal noise.

4. Check the charging indicator lamp circuit.

(1) The ignition switch is in the ON position. Check whether the charging indicator comes on
(2) Start the engine. Check whether the charging indicator goes out.
If the charging indicator is not working as mentioned above, check and repair the charging
 Engine 11-105
indicator lamp circuit.

5. Check the no-load charging circuit

Note: if there is battery/alternator tester, please connect the tester and indicator as per
manufacturer’s instructions.
If there is no tester, connect the voltmeter and current with the charging circuit according to the
following description (Figure 6-4-5);

● Disconnect the circuit from the alternator B Amperemeter

terminal and connect it with the ampere meter Disconnect the
harness from
negative (-) conductor shaft. terminal B
● Connect the ampere meter positive (+)
conductor shaft with the terminal B of alternator.

Battery
● Connect the voltmeter positive (+) conductor
with the terminal B of alternator. AC alternator
Voltmeter
● Make the voltmeter negative (-) conductor - 11 -
ground.
● Check the charging circuit according to the Fig. 6-4-5
following rules:
Make engine idle at speed of 2000r/min, check
and read the ammeter and voltmeter.
Standard current: 10A or less
Standard current: 14.0 ～14.8V/25℃
～
13.5 14.3V/115 ℃
If the reading in the voltmeter is larger than the
standard voltage, replace the IC adjuster. End P
If the reading in the voltmeter is less than the
standard voltage, please check the IC adjuster
and alternator according to the following steps.
End F grounds, start the engine and check the
reading of the voltmeter on end B.
If the reading in the voltmeter is larger than the
standard voltage, replace the IC adjuster.
If the reading in the voltmeter is less than the Fig. 6-4-6
standard voltage, please check the alternator.

6. Check discharging circuit with load

(1) When the engine runs at 2000rpm, turn on the front high beam and set the heater switch to
“HI”.
(2) Check the reading of the ampere meter.
Standard current: 30A or greater
If the reading of ammeter is smaller than the standard current, replace the alternator.
Note: if the battery is completely discharged, the ampere meter reading may be less than the
standard current.
11-106 Engine
The exploded view of removal and installation of engine is as
following:

- 11 -

1. Nut 2. Pulley 3. Front end cover assembly 4. Rotor components 5. Rotor assembly 6. Rear end cover component
7. Assembly bolt 8. Rectifier 9. Regulator 10.Mounting bolts 11Electric brush carrier components 12.Cover cap

II. Removal of alternator

1. Remove the rear end cap

Remove nuts and terminal insulation sleeve (Figure 6-4-7).

Fig. 6-4-8
Fig. 6-4-7

3. Remove IC regulator
Remove 3 bolts and IC adjustor (Figure 6-4-8).
4. Remove the rectifier frame
(1) Remove 4 screws and rectifier frame (Figure 6-4-9).
(2) Remove 4 rubber insulators
 Engine 11-107
11-85

Rotate

Fig. 6-4-9 Fig. 6-4-10

5. Remove the pulley

(1) Hold special tool A with torque wrench, and then tighten special tool B to the designated torque
clockwise (Figure 6-4-10). - 11 -
Torque: 39N.m
Check special tool (A) which shall be fixed on the rotor shaft tightly.
(2) Install special tool C to a pair of pliers (Figure 6-4-11).
(3) Install alternator to special tool C (Figure 6-4-11).

Rotate

Fig. 6-4-11 Fig. 6-4-12

(4) Loosen the pulley nut, and rotate the special tool A in the direction as illustrated (Figure
6-4-12).
Note: Do not loosen the pulley nut more than half a circle to avoid damaging the rotor shaft.
(5) Remove alternator from special tool C.
(6) Rotate special tool B and remove special tools A and B (Figure 6-4-13)
Remove the pulley nut and the pulley.
11-108 Engine

Rotate

Fig. 6-4-13 Fig. 6-4-14

6. Remove the rectifier frame

(1) Remove 4 nuts (Figure 6-4-14).
(2) Remove rectifier frame with the special tool (Figure 6-4-15).
- 11 -

Ohmmeter

Conductive

Fig. 6-4-15 Fig. 6-4-16

7. Remove Rotor from Drive End Bracket.

(1) Check and maintenance of rotor

(a) Check conductivity of rotor
Check conductivity between slip rings with
ohmmeter (Figure 6-4-16). Ohmmeter
Standard resistance (cold): 2.1-2.5Ω
Once it is not conductive, please replace the
rotor. No continuity

Check the grounding of the rotor. Fig. 6-4-17

Check whether the slip ring and rotor are
conductive. If not, it is correct (Figure 6-4-17).
Once it is not conductive, please replace the
rotor.
 Engine 11-109

(c) Check slip rings

● Check if the slip ring is rough or if there is
scratch on the slip ring.
Replace the rotor if the slip ring is rough or
there is scratch.
● Measure diameter of slip ring with dial
calipers (Figure 6-4-18)
Standard diameter: 14.2-14.4mm
Fig. 6-4-18
Minimum diameter: 12.8mm
Replace the rotor if the diameter measured is
smaller than the minimum.

(2) Check and Repair of Stator (Drive End

Bracket)
(a) Check open circuit condition of stator
- 11 -
Check whether the coil conductors are correctly
conducted with ohmmeter (Figure 6-4-19).
Ohmmeter
Replace the drive end bracket assembly if the
lead is not conducted.
Conductive

Fig. 6-4-19

(b) Check the grounding of the rotor.

Check to make sure that the coil conductor and
drive end frame shall be not conductive with an
ohmmeter (Figure 6-4-20).
Replace the drive end bracket assembly if the Ohmmeter
lead is not conducted.

No continuity

Fig. 6-4-20

(3) Check and Repair of Rotor

(a) Check the exposed length of the brush
Use a dial caliper to measure the exposed length of the brush.
Standard exposed length: 10.5mm
Standard exposed length: 1.5mm
(b) Unsolder and remove the brush and the spring.
Pull a new brush harness through the hole of the brush holder and insert the spring and the brush.
(d) Weld electric brush harness on brush rack according to specified length.
Standard exposed length: 10.5mm
(e) Check whether the electric brush can move smoothly on brush rack.
(f) Cut unwanted harness. and apply insulating paint to the welding area.
11-110 Engine
(4) Check and Repair of Rectifier (Rectifier Bracket)
(a) Check the forward rectification of rectifier.
Connect one detector probe of ohmmeter to the positive electrode (+) and the other probe to the
whole rectifier terminal (Figure 6-4-21).
Exchange the poles of the detector probes and repeat the above (a) step.
Check the two probes of the ohmmeter, one of which shall be conducted and the other of which
shall not be conducted.
Replace the rectifier bracket if the conduction is not the same as the afore-mentioned.

Ohmmeter Ohmmeter

Positive pole
(+) Negative (-)

Commutator - 11 -
end

Fig. 6-4-21 Fig. 6-4-22

(b) Check rectifier negative electrode

Connect one detector probe of ohmmeter to the negative electrode (-) and the other probe to the
whole rectifier terminal (Figure 6-4-22).
Exchange the poles of the detector probes and repeat the above (a) step.
Check the two probes of the ohmmeter, one of which shall be conducted and the other of which
shall not be conducted. Replace the rectifier if the conduction is not the same as the
afore-mentioned.
(5) Check and Repair of Bearings
(a) Check front bearing
Check roughness or abrasion of the bearing.

Fig. 6-4-23 Fig. 6-4-24

(b) Replace the front bearing if necessary.

Remove four screws, bearing support and bearing (Figure 6-4-23).
Press out bearing with special tool and press tool (Figure 6-4-24)
 Engine 11-111
Press in a new bearing with special tool and press tool.
Install shaft bearing and 4 bolts (Figure 6-4-25).
Torque: M/T: 2.6N.m

Fig. 6-4-25 Fig. 6-4-26

(c) Install rear bearing

Check roughness or abrasion of the bearing.
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Replace the rear bearing if necessary.
Remove bearing cap and bearing with special tool (Figure 6-4-26).
Note: Do not damage the fan.
Place the bearing cap on the rotor.

Bearing
cover

Fig. 6-4-27 Fig. 6-4-28

Use special tool and press to press in new

bearing (Figure 6-4-27).
Push the bearing cap with special tool (Figure 29mm
socket
6-4-28). wrench
(6) Alternator assembly
(a) Put drive end frame on the pulley
(b) Install rotor to drive end frame
Install rectifier end bracket
Use a 29mm sleeve wrench and press to press Fig. 6-4-29
to the rectifier bracket slowly (Figure 6-4-29).
Install 4 nuts.
Torque: 4.5N.m

(d) Install the pulley

11-112 Engine
● Manually tighten the pulley nuts and install the pulley to the stator shaft.
● Hold special tool A with torque wrench and tighten the special tool B clockwise to the designated
torque (Figure 6-4-30).
Torque: 39N.m
● Check whether the special tool A is fixed to the pulley shaft.
● Install the special tool C to a pair of pliers (Figure 6-4-31).
● Install alternator to special tool C (Figure 6-4-32).

Rotate

- 11 -
Fig. 6-4-30 Fig. 6-4-31

● Rotate special tool A in the direction shown in figure to make pulley nut rotate (Figure 6-4-33).
Torque: 110.5N.m
● Remove alternator from special tool C.
● Rotate special tool (B) and remove special tool (A) with special tool (B).

Rotate
Rotate

Fig. 6-4-32 Fig. 6-4-33

(e) Install rectifier frame

● Install 4 rubber insulators to conductor (Figure 6-4-34) and (Figure 6-4-35).
Note: Pay attention to the installation direction of the rubber insulators.
● Install rectifier frame and 4 screws.
 Engine 11-113

Inwards
Push

Fig. 6-4-34 Fig. 6-4-35

(F) Install IC regulator and brush rack

(g) Install the rear end cover
B. Install the terminal insulating sleeve and nuts.
Torque: 4.1N.m
7. Check whether the rotor rotates smoothly - 11 -

8. Maintenance specification and maintenance data

Maintenance specification and maintenance data

Name Index Conditions Parameters
Battery Specific gravity At 20°C 1.25-1.29
New 5～7mm
7～8mm
Inclination
Old
Alternator belt
New 685-785N
Tension
Old ～
295 440N
Nominal output M/T 12 V 7A
Rotor coil impedance M/T 2.1 ～2.5Ω
STD 14.2-14.4mm
Alternator Slip ring diameter
Min 12.8mm
STD 10.5mm
Exposed length of brush
Min 1.5mm
IC regulator Regulating voltage ～
13.2 14.8V

Torque Specification
Components to be tightened N.m
Bearing support × Drive end bracket M/T 2.6
Rectifier end bracket × Drive end bracket 4.5
Alternator-rotor 110.5
Rectifier end bracket × Brush holder － IC regulator 2.0
Rectifier bracket × Coil lead on the rectifier end bracket M/T 2.0
11-114 Engine
Rear end cover × Rectifier bracket 4.4
Plate terminal × Rectifier bracket Bolt 3.8
Terminal insulator × Rectifier bracket 4.1

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