Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
LF 1025 1,3
- 11 -
CAPITULO: MOTOR
Engine 11-1
Engine
Parameters of Engine .......................11-2
Lubrication System.........................11-77
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
1. Piston mechanism of crank connecting rod Option of mass, size and clearance of the parts
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
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
Note: This check is only used for ensuring whether the idling exhaust emission meets the
regulations of law.
Note: If the engine is powerless or has bad fuel economy, measure the compression pressure of
the cylinder.
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.
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
- 11 -
Fig. 2-5-6
- 11 -
Fig. 2-5-11
(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
Fig. 2-5-18
- 11 -
Engine 11-27
Exploded view of cylinder head assembly
- 11 -
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.
- 11 -
III. Check and clean
Fig. 2-6-12
Fig. 2-6-13
Cylinder
block side
Fig. 2-6-19
Intake
manifold side
Exhaust
manifold side
- 11 -
Full length
Width
(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).
(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.
Deviations
(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.
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.
- 11 -
Exhaust
Fig. 2-6-44
Fig. 2-6-43
- 11 -
Fig. 2-6-45
13.2mm
Fig. 2-6-55
Fig. 2-6-54
Length
Fig. 2-6-56 - 11 -
Fig. 2-6-57
(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
Fig. 2-6-61
Timing mark
Front cover shell upper
surface
Mark groove
Fig. 2-7-2
- 11 -
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
Mark 1, 2
or 3
Mark 1, 2
or 3
Front end mark
(bumped)
Fig. 2-7-12
- 11 -
(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. 2-7-18
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
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
Fig. 2-7-21
Fig. 2-7-24
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
Fig. 2-7-27
Forward mark
Mark position of
weight grade
Fig. 2-7-32
Fig. 2-7-33
- 11 -
85 mm
- 11 -
Fig. 2-7-39
Fig. 2-7-38
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.
Engine
Mounting tool for
crankshaft rear oil seal
Crankshaft
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.
(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
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.
Upper main
bearing bush
Lower main
bearing bush - 11 -
(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).
(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. 2-7-59
Fig. 2-7-60
(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
- 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
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.
Fig. 3-1-1
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.
Bumped part
New O-ring
Fig. 3-2-5
Fig. 3-2-4
Valve lift
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
New gasket
Bypass-valve
Battery - 11 -
No continuity Conductive
Cooling fan relay
Ohmmeter Ohmmeter
Lubrication system
- 11 -
(1) Inspection
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
Fig. 4-1-6
(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. 4-2-6
Mark
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)
- 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
Engine
harness
Crankcase - 11 -
Activated carbon
filtering 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.
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).
Fig. 5-2-5
Fig. 5-2-6
Fig. 5-2-7
IV. Exhaust gas recirculation (EGR valve) control system (Figure 5-2-8)
Engine 11-91
Fig. 5-2-8
- 11 -
11-92 Engine
Electrical 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.
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
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
Fig. 6-2-2
Fig. 6-2-3
Secondary coil
impedance
Cold state ~15.4KΩ
9.0
Crankshaft position
sensor
Cold-state resistance -
B C 1630~2740Ω
Note: Check the following items once again before operating the starter:
(1) Connection of connectors
(2) Installation of accessories, such as anti-theft system.
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
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.
Fig. 6-3-3
Fig. 6-3-5
9. Electric brush
Electronic brush
Checking the brush length frame side
- 11 -
Length
Fig. 6-3-7
Fig. 6-3-8
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
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
Alternator pulley
Fig. 6-4-3
Note:
The “new belt” refers to the alternator belt that
is not used on a running engine for more than
5min. Correct Error Error
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.
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.
- 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
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
Rotate
(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
Ohmmeter
Conductive
Fig. 6-4-19
No continuity
Fig. 6-4-20
Ohmmeter Ohmmeter
Positive pole
(+) Negative (-)
Commutator - 11 -
end
Bearing
cover
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
Inwards
Push
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
- 11 -