SERVICE MANUAL OF

GW4G15/GW4G13 GASOLINE
ENGINES
Written by Great Wall Engine Company

GREAT WALL MOTOR COMPANY LIMITED

I
 Maintenance Manual of GW4G13/GW4G15 Gasoline Engines

Brief Introduction

This manual introduces the technical features, maintenance, dismantling and installation,
adjustment, repair etc. in detail of GW4G15/GW4G13 gasoline engine. It can be used for
reference for those who use, maintain and repair gasoline engines.

SERVICE MANUAL 0F GW4G15/GW4G13 GASOLINE ENGINES

Written by Great Wall Engine Company

*
Compiled by Automobile Book Editorial Office of China Academy of Agriculture Mechanization
Add: No. 1, Beishatan, Deshengmenwai, Beijing Postcode: 100083
Tel: 010—64882616·E-mail: [email protected]
Editor in charge: Gao Hai Wang Xinxin

Designed by Automobile Book Editorial Office of China Academy of Agriculture Mechanization

Designers: Xu Lianying Liu Xiaoli Cover Designer: Yu Shuying
Printed by Baoding Zhonghuameikai Printing Co., Ltd.
*
Format: 880 mm×1230 mm l/16·Printed sheet: 8.75·Number of words: l60,000
Baoding 1st Edition, Nov.2008·Baoding 1st Printing, ----.-----

CAAMS-1060-123/G · 374-QC-08~09-28.00

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 Maintenance Manual of GW4G13/GW4G15 Gasoline Engines

Foreword
GW4G15/GW4G13 gasoline engine adopts multi-point fuel injection and electronic control system. The
4G15/4G13 engine has reached the world advanced level for the time being in such performances as
dynamic property, economical efficiency and reliability, superior to the requirements in China’s existing
environmental protection standards, laws and regulations in emission, noise and radio interference
suppression, fuel evaporation control. Moreover, the engine features compact structure, small volume,
lightweight, and easy operation, maintenance, etc.
GW4G15/GW4G13 gasoline engine is a high-level modernized power driven mechanism of complex
construct. Thanks to the strictly-fitted materials, workflow and components, there are high requirements
on use, maintenance and repair accordingly.
Service Manual of GW4G15/GW4G13 Gasoline Engines is a comprehensive manual for engine service,
which incorporates the main technology, structure, dismantling, assembly, adjustment, test and others of
GW4G15/GW4G13 gasoline engines. Read carefully and act strictly in accordance with each provision
of the manual, so that you can master the maintenance and repair ways in order to ensure the engine to
be in good condition and to meet ideally the indexes on power and economy performance.
For vehicle and chassis to be dealt with during the maintenance of GW4G15/GW4G13 gasoline engine
or components supplied by vehicle and mechanical manufacturers, please refer to the Maintenance
Manual of assembled vehicles and mechanics.
In consideration of your life and property safety, use and operate with the engine strictly according to
pertinent regulations in this manual. Otherwise, the accidents on person, machine/vehicle will occur.
As science and technology develops unceasingly and with the requirements put into practical use,
GW4G15/GW4G13 gasoline engine will improve continuously, and the construct and accessories will
vary as well. There will be amended and complemented contents covering maintenance, repair in terms
of the changed components in the new edition. We would like to ask your close attention to these.
We reserve the right of revision in terms of supply scope, equipment and technology. Therefore, users
shall not put forward any demand on the prerequisite of the data, illustration and description hereto. The
product structure, equipment and technology can be altered without notice.
Oversight and mistakes are unavoidable for extensive contents involved in this manual, and time limited.
Valuable suggestion will be appreciated. This manual is only for reference to users in work. As to the
loss caused by the operation not conforming to the manual, we assume no direct or indirect
responsibility.
We welcome your suggestions about quality, performance, structure as well as experiences with respect
to use, maintenance and repair of our GW4G15/GW4G13 gasoline engine. Your precious comments will
help us to improve our products and develop our technologies on utilization, maintenance and repair.
Please send your letter to: No. 2299, South Chaoyang Street, Baoding, Hebei Engine Company of Great
Wall Motor Company Limited
Postcode: 071000.
We have authorized service stations all around the world. If there is anything wrong with your engine
GW4G15/GW4G13 or you need technical maintenance, troubleshooting, repair or component
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 Maintenance Manual of GW4G13/GW4G15 Gasoline Engines
replacement, you can get handy consultation or services.

This manual shall not be copied or published without the permission of Great Wall Motor Company
Limited. All rights are reserved for Copyrights provided by the law, and for alteration and interpretation
as well.

Great Wall Motor Company Limited

------ -------

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 Maintenance Manual of GW4G13/GW4G15 Gasoline Engines

Contents
Chapter 1 Introduction.......................................................................................................................................................1
Section 1 How to Use This Manual ..............................................................................................................................1
Section 2 Identification .................................................................................................................................................3
Section 3 Service Instruction ........................................................................................................................................3
Section 4 Precautions ....................................................................................................................................................4

Chapter 2 Specifications and Parameters.........................................................................................................................5

Chapter 3 Preparations for Maintenance .........................................................................................................................7
Chapter 4 Repair Data and Specifications........................................................................................................................9
Section 1 High Strength Bolts.......................................................................................................................................9
Section 2 Repair Data .................................................................................................................................................10
Section 3 Torque Specifications of Fasteners..............................................................................................................13

Chapter 5 Regular Inspections and Maintenance ..........................................................................................................16

Chapter 6 Exterior Engine Accessories...........................................................................................................................17
Section 1 Components of Exterior Accessories ..........................................................................................................17
Section 2 Alternator Assembly....................................................................................................................................18
Section 3 Starter ..........................................................................................................................................................19
Section 4 Other Exterior Accessories..........................................................................................................................20

Chapter 7 Air Intake and Exhaust Systems....................................................................................................................22

Section 1 Components of Air Intake and Exhaust Systems ........................................................................................22
Section 2 Air Intake Systems ......................................................................................................................................23
Section 3 Exhaust Systems .........................................................................................................................................26

Chapter 8 Electronically Controlled Fuel Injection System..........................................................................................29

Section 1 Repair Knowledge on Electronic Fuel Injection System (EFIS).................................................................29
Section 2 On-board Diagnostic (OBD)System Overview...........................................................................................31
Section 3 Fault Diagnosis Principles and Examples ...................................................................................................40
Section 4 Structure Principles and Fault Analyses of Electronic Fuel Injection System (EFIS) ................................42

Chapter 9 Cooling System ................................................................................................................................................71

Section 1 Components of Cooling System..................................................................................................................71
Section 2 Coolant ........................................................................................................................................................71
Section 3 Water Pump Assembly ................................................................................................................................73
Section 4 Thermostat ..................................................................................................................................................76
Section 5 Heating-system Water Return Pipe .............................................................................................................79

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 Contents
Chapter 10 Lubrication System.......................................................................................................................................81
Section 1 Components and Oil Passage of Lubrication System .................................................................................81
Section 2 Oil and Oil Filter Assembly ........................................................................................................................82
Section 3 Oil Trap and Oil Sump Assembly ...............................................................................................................85
Section 4 Oil Pump .....................................................................................................................................................89

Chapter 11 Cylinder Head and Valve Timing.................................................................................................................94

Section 1 Components of Cylinder Head and Valve Timing.......................................................................................94
Section 2 Cylinder Head Cover Assembly..................................................................................................................95
Section 3 Cylinder Head Assembly and Valve Actuating Mechanism........................................................................98
Section 4 Timing Mechanism ...................................................................................................................................112

Chapter 12 Cylinder Block Assembly............................................................................................................................ 117

Section 1 Components of Cylinder Block Assembly ................................................................................................117
Section 2 Piston Connecting Rod Assembly .............................................................................................................118
Section 3 Crankshaft Flywheel Assembly.................................................................................................................122
Section 4 Upper/Lower Cylinder Blocks ..................................................................................................................129

Chapter 13 Clutch Assembly..........................................................................................................................................133

VI
 Chapter 1 Introduction

Chapter 1 Introduction

Section 1 How to Use This Manual

1. Index
The Contents (Index) of this manual guides you to look up the service items you need for repair. For easy to look up,
the title of each chapter has been printed on the header of odd pages.

2. Preparations
This part lists special service tools (SST), special maintenance materials (SSM) and lubricating oil, you should prepare
before operation and indicate their purposes.

3. Repair Procedures
Most repair procedures begin with a general schematic diagram of components, showing the components and how to
assemble them together.
Example: for the schematic diagram of the oil pump components assemblage, see Figure1-1-1.

Figure1-1-1 Schematic diagram of Oil Pump Components Assembly

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 Maintenance Manual of GW4G13/GW4G15 Gasoline Engines

The repair procedures are as follows:

(1) The Schematic diagram shows what and where to do, as Figure 1-1-2.
(2) The title of work task indicates what to repair.
(3) Describe how to do the job in details and furnish other information, such as specifications, notices, tips.
For instance,

The title of work task: Repair Items

Install real oil seal of the crankshaft.
Install real oil seal of the crankshaft with special
repair tool (SST).
SST：CC2008010

Tool code
Explanation: How to do the job.

Figure1-1-2 Install Real Oil Seal of Crankshaft

This form offers a short cut for the experienced technician. The work task on the top is clear at a glance and the
contents on the lower part gives detailed description. The important specifications, notices and warnings are printed
with Times New Roman font (bold) strikingly.

4. Cross Reference
This manual adopts few cross references, but if any, the page of cross references will be given.

5. Specifications
If necessary, the specifications are listed separately without job halt to look for them. The specifications are listed at the
last of each section for quick review.

6. Warnings, Notices and Hints

“Warning” is expressed by Times New Roman font, reminding that injuries may occur to you and other persons.

“Notice” is expressed by Times New Roman font, reminding that the damaged parts are being repaired.
“Hint” is expressed by Times New Roman font and separated form the official text, providing additional data so
that you can repair the part efficiently.

7. Measuring Unit
The unit adopted in the Maintenance Manual is SI unit (Standard International Unit).
For example:
Torque: N·m;
Force: N;
Power: w, kw;
Length: mm;
Rotary speed: r/min;
Pressure and intensity of pressure: Pa, kPa.

2
 Chapter One Introduction

Section 2 Identification
Serial number of engine
The serial number of engine is stamped on the cylinder block, as
shown in Figure 1-2-1.

Section 3 Service Instruction

1. During maintenance, use baffle plate, base and floor mat to
keep them clean and sound, and prevent from damage.
2. When dismantling, place the components in proper order so
as for easy re-installation.
3. Service rules:
Figure 1-2-1 Mark of Engine Serial Number
3.1 The negative cable must be disconnected prior to electrical
equipment maintenance, as shown in Figure 1-3-1.
3.2 When a inspection and maintenance work needs to
disconnect the connection with battery, always detach the battery
terminal negative cable, which is connected with vehicle body as
ground.
3.3 To prevent battery terminal from damaging, loosen the
retaining nut, lift the terminal up and not turn or pry it forcibly.
3.4 Use a special rag to clean the terminals of the battery and
cable. Do not use files or other rough pieces to scratch them.
3.5 When the cable terminal is connected to the battery, loosen
the nut. After installation, tighten the nut. Do not use a hammer
to knock them inside.
Figure 1-3-1 Dismantling Battery Negative Cable 3.6 Tighten the cover of positive terminal of the battery.
4 Check the connections of host and lead to ensure reliability
and correction.
5 Do not re-use parts: cotter pin, gasket, O-ring and oil seal
must be new.
6 Pre-coated parts: Pre-coated parts refer to bolts, nuts and so
on that have been coated with fluid sealant in the factory, as
shown in Figure 1-3-2.
6.1 If the pre-coated part is tightened again or released, smear
the fluid sealant again.
6.2 When the pre-coated parts are re-used, clean out the fluid
Figure 1-3-2 Pre-coated Parts
sealant on the surface of the parts or in screw hole and purge
them by compressed air. Then smear the sealant on the specified
position, as shown in Figure 1-3-2.

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 Maintenance Manual of GW4G13/GW4G15 Gasoline Engines

7. Apply fluid sealant on the gasket to prevent leakage

necessary.
8. Observe all specifications on tightening torque of bolts and
use the torque wrench strictly in accordance with the technical
requirements, as shown in Figure 1-3-3.

9. Based on service requirements, use the special service tools

Figure 1-3-3 Torque Wrench
(SST) and special service material (SSM) strictly in line with the
Operation Specifications. The special service tools and special
service materials are listed in Chapter 3 – Maintenance
Preparations of this manual.
10. Abide by the following precautions in order to avoid
damaging parts:
10.1 Non-professional person cannot open the cover and house
of the electronic control unit (ECU).
10.2 When pulling out the vacuum tube, you should hold the
terminal of the tube. Do not pull the middle part, as shown in
Figure 1-3-4 Pull out Vacuum Tubes Figure 1-3-4.
10.3 When separate the terminals of the plug connector in the
circuit, you should pull the plug connector itself. Do not pull the
wire, as shown in Figure 1-3-5.
10.4 Do not fall off the elements (such as sensors) of electronic
fuel injection system (EFIS), as shown in Figure 1-3-6. If it falls
off, use a new one instead of it.
10.5 It is forbidden to use an impact wrench to dismantle or
mount temperature sensors and so on, which have torque
stipulation.

Figure 1-3-5 Inspect Lead Terminal

Section 4 Precautions

If the vehicle is equipped with mobile communication

systems, such as bidirectional wireless communication
equipment and cell phone handset, the following precautions
should be observed:
(1) The communication wire shall be far from the ECU and the
sensors of the electronic system.
(2) The antenna feeder shall be fitted more than 20 cm away
Figure 1-3-6 Elements of Electronic Fuel Injection from the ECU and sensors of the electronic system. For the
System (EFIS) position of the ECU and sensors, refer to the section of the
relevant parts.

4
 Chapter 2 Specifications and Parameters

Chapter 2 Specifications and Parameters

Main Specifications and Parameters of Gasoline Engine

Items Specifications and Basic Parameters
Model GW4G15 GW4G13

4-stroke, water-cooled, in-line, electrical start, pent roof combustion chamber,

Type multi-point EFI, 16-valve,DOHC, chain drive, variable valve timing, pressure
and splash combined lubricant.

Number of cylinders 4

Core×stroke (mm) 75×84.7 75×73.5

Overall displacement (L) 1.497 1.298

Compression ratio 10.5:1

Rated power (kW/r/min) 77±3/6000 68±3/6000

Max. torque (N·m/r/min) 138+4/(4000-5000) 1 18±4/~000-5000)

Min. fuel consumption rate (g/kW·h) ≤265

800±25 (the idle speed may be slightly different as required by the vehicle
Stable idle speed (r/min)
model, please refer to the whole vehicle requirements for specific value)
Fuel rating (RON) ≥93# (GB 17930-2006)

Air intake valve clearance (cold status) (mm) O.2±0.05

Exhaust valve clearance (cold status ) (mm) 0.3±0.05

Cylinder compression pressure [(260 ± 10) r/min]
1550±50 1450±50
(kPa)
Ignition order 1-3-4-2
Rotary direction (Visually checked from the vibration
Clockwise
damping pulley end)
Fuel pressure of engine (kPa) 380±20

Ignition control Distributorless, direct ignition by electronic control

Spark plug gap (mm) 0.75±0.05

Oil pressure of main oil passage (kPa) At idle: ≥ 80; at 3000 r/min, ≥ 300
Above grade SJ, the viscidity of lubricating oil: 10W-30 (Winter）, 20W-40
Oil rating
(Summer）
Oil capacity (first filled) (L) 3.5

Coolant High grade glycol coolant

Start temperature of thermostat (℃) 80～84

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 Maintenance Manual of GW4G13/GW4G15 Gasoline Engines

(continued)
Items Specifications and Basic parameters

Net mass of engine(excluding harness, A/C

compressor, power steering pump, transmission) 96 93
(kg)

Dimensions (L×W×H) (mm) w/o transmission 600.5×589×632 600.5×589×622

HC(ppm) ≤80
800 r/min
Dual idle speed
CO(％) ≤0.30
pollutant
emission
HC(ppm) ≤60
2000 r/min
CO(％) ≤0.20

CO≤1.0, HC≤0.1, NOx≤0.08,

Exhaust pollutant limit (g/km)
Comply with GB 18352. 3 -2005 (IV)

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 Chapter 3 Preparations for Maintenance

Chapter 3 Preparations for Maintenance

1. Special Service Tools（SST)

Special Tool Name of Tool Tool Code Operation guide

Knock down the oil filter,

Wrench of oil filter CC2008013
see P84.

Knock down the spark

Wrench of spark plug CC2008014
plug, see P99、P111.

Knock down the valve

Valve spring compressor CC2008015 spring compressor, see
P100, P107.

Mount a valve oil seal, see

Valve oil seal compressor CC2008012
P107.

Special tool of the rear oil seal of Mount the rear oil seal of
CC2008010
crankshaft crankshaft, see P127.

Mount clutch friction

Positioning tool of friction plate CC2008011
plate, see P134.

Alignment tool kit of engine gap General tool

Bosch electrical testing instrument

General tool
set

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 Maintenance Manual of GW4G13/GW4G15 Gasoline Engines

2. Special Service Materials (SSM)

Material
Material Name Direction for Use
code

Le Thai 243 anaerobic type Water drain valve, see P72 and P131; oil pressure sensor,
23962
thread locker sealant or equivalent see P83; PCV valve assembly, see P97; flywheel bolt, see P127.

Flange face of oil sump, see P87; Sealing face of oil pump assembly,
Le Thai 5699 silicon rubber
33964 see P92; joints of cylinder head and cover of cylinder head, and see
plane surface sealant or equivalent
P96; joint face of upper and lower cylinder blocks, see P130.

3. Lubricating Oil

Items Capacity Rating of Lubricating Oil

Engine oil
3.5 L Over SJ grade, the viscidity: 10W-30 (Winter), 20W-40 (Summer)
Change oil filter 3.3 L Over SJ grade, the viscidity: 10W-30 (Winter), 20W-40 (Summer)
Not change oil filter

8
 Chapter 4 Maintenance Data and Specifications

Chapter 4 Repair Data and Specifications

Section 1 High Strength Bolts

1. Tightening Torque of High Strength Bolts

Tightening Use Frequency
No. Part No. Part Name and Spec. Bolt Grade Assembly Position
Torque Limitation
Bolts of main bearing cap
l 1002133A-EG01 8.8 Main bearing cap 22N·m-t-90° 2
M10×1.5×70.5
Bolts of cylinder head 23N·m+90°
2 1003011 一 EG01 10.9 Cylinder head 4
M9×1.5×144 +90°
Bolts of Connecting rod Connecting rod
3 1004303 一 EG01 12.9 15N·m-I-90° 3
M8×1×37.5 assembly
Flywheel bolts Flywheel ring gear
4 1005011 一 EG01 10.9 30N·m+45° 3
M10×1.25×20 assembly
Bolt unit of damping belt
5 1005400 一 EG01 pulley 10.9 Damping belt pulley 50N·m+65° 2
M12×1.25×47
Bolt of exhaust camshaft
Exhaust camshaft
6 1021012 一 EG01 sprocket wheel 10.9 30N·m-I-65° 1
sprocket wheel
M10×1.25×22
VVT phase bolts
7 1021014 一 EG01 12.9 VVT phaser 30N·m+65° 3
M12×1.25×34

Caution: If the frequency limit is exceeded, there might be a serious accident.

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 Maintenance Manual of GW4G13/GW4G15 Gasoline Engines

Section 2 Repair Data

Main Repair Data

Items Data
1550kPa±50kPa(GW4G15)
260 r/min±10 r/min Normal value
Compression pressure 1450kPa±50kPa(GW4G13)
Pressure difference between cylinders ≤98kPa

Air intake valve cold status 0.15～0.25 mm

Valve clearance
Exhaust valve cold status 0.25-0.35 mm

800 r/min±25 r/min (the idle speed may

be slightly different as required by the
Idling speed vehicle model, please refer to the
complete vehicle requirements for
specific value)

Cylinder block Limit 0.07 mm

Warp
Manifold side Limit 0.10 mm
Cylinder block
Sealing angle 45°
Valve seat
Contact width 1.0～1.4 mm

Valve guide Inner diameter 5.000～5.015 mm

Valve length Normal valve Air intake valve 88.99～89.39 mm

Exhaust valve 87.55～87.95 mm
Face angle of valve 45°
Diameter of valve rod 4.960～4.975 mm
Air intake valve
Exhaust valve 4.945～4.960 mm
Oil clearance of valve rod
Air intake valve 0.025～0.055 mm
Normal valve
Valve Exhaust valve 0.040～0.070 mm
Air intake valve 0.08 mm
Limit
Exhaust valve 0.10 mm
Air intake valve 1.10 mm
Thickness of edge
Exhaust valve 1.20 mm
Normal valve
Air intake valve 0.50 mm
Exhaust valve 0.50 mm
Limit

Vertical deviation (ref.) Limit 2°

Valve spring Free length 45.10 mm
Mounting elasticity with the length of 32.2mm 162 N±10 N

Axial clearance Normal valve Air intake camshaft 0.060～0.115 mm

Exhaust camshaft 0.060～0.115 mm
Limit 0.130 mm
Camshaft Air intake camshaft 0.130 mm
Exhaust camshaft 0.035～0.072 mm
Fit clearance of journal Normal valve 0.080 mm
Limit

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 Chapter 4 Maintenance Data and Specifications

(Continued)
Items Data

Diameter of journal 1# journal 34.444～34.460 mm

Other journals 22.949～22.965 mm
Height of cam “cam-tip” Nornal valve Air intake cam cam-tip 44.64～44.74 mm(GW4G15)
Exhaust cam cam-tip 44.68～44.78 mm(GW4G15)
Air intake cam cam-tip 44.62～44.72 mm(CW4G13)
Camshaft
Exhaust cam cam-tip 44.05～44.15 mm(GW4G13)
Height of cam “cam-tip” Limit Air intake cam peach cam-tip 44.53 mm(CW4C15)
Exhaust cam cam-tip 44.57 mm(GW4G15)
Air intake cam cam-tip 44.51 mm(CW4G13)
Exhaust cam cam-tip 43.95 mm(GW4G13)

Diameter of tappet 30.956～30.966 mm

Diameter of tappet hole 31.000～31.025 mm
Valve tappet
Oil clearance Normal value 0.034～0.069 mm
Limit 0.100 mm

Warp of cylinder head contact surface Normal value 0.040 mm

Cylinder block
Diameter of cylinder bore Limit 75.000～75.010 mm

Diameter of piston Normal value 74.940～74.955 mm

Clearance between the piston and cylinder Normal value 0.045～0.070 mm
Side clearance of piston ring groove Normal value 1st-stage 0.03-0.07 mm
2nd-stage 0.02～0.06 mm
Oil ring
0.04-0.15 mm
Piston and piston Piston ring gap Normal value 1st-stage
ring 2nd-stage 0.20～0.35 mm
Oil ring 0.35-0.50 mm
Limit 0.20～0.70 mm
1st-stage 0.91 mmm
2nd-stage 1.06 mm
Oil ring 0.82 mm

Piston and piston Gap between piston pin and seat hole Normal value 0.008～0.015 mm
ring Limit 0.050 mm

0.18-0.37 mm
Axial clearance Normal value
Central thickness of connecting rod bush Normal value Blue 1.488～1.492 mm
Colorless 1.492～1.496 mm
Yellow 1.496～1.500 mm
Connecting rod
Clearance between connecting rod bushes Normal value 0.016～0.042 mm
Limit 0.060 mm
Bending of connecting rod Limit 0.06/100
Distortion of connecting rod Limit 0.10/100

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 Maintenance Manual of GW4G13/GW4G15 Gasoline Engines

(continued)
Items Data

Axial clearance Normal valve 0.10～0.29 mm

Limit
0.35 mm
Fit clearance of main journal
Normal valve 0.014～0.037 mm
Limit 0.070 mm
Diameter of main journal 45.985～46.000 mm
Crankshaft
Normal valve 1.989～1.993 mm
Central thickness of main shaft bushing Normal valve
Yellow 1.993～1.997 mm
Colorless
1.997～2.001 mm
Red
Connecting rod journal Normal value 39.985～40.000 mm

Valve-opening temperature 80 ℃～84 ℃

Thermostat
Valve lift Coolant temperature ≥8mm

Oil pressure Rev. of engine 3000 r/min ≥300 kPa

Main oil passage Rev. of engine 800 r/min ≥80 kPa
Axial clearance Normal valve
Limit 0.250～0.322 mm
0.425 mm
Axial clearance Normal valve
0.05-0.10 mm
Oil pump Limit
0.28 mm
Back lash 0.02-0.07 mm
End clearance of rotor Normal valve 0.15 mm
Limit

Ignition order 1-3-4-2

Model of spark plug RC8YC

Spark plug
Electrode gap 0.75 mm±0.05 mm

Primary coil resistance 0.65～0.83 Q

Ignition coil
Secondary coil resistance 8.89 一 11.31 kQ

Flexivity New belt 6～8 mm

Belt of engine
Downforce New belt 98 N

Rated voltage and output 12V，1.2 kW

Boot parameters 8.5 V
Starter Voltage ≤350 A
Current 10 N·m
Torque ≥1100 r/min

Rated output current 90 A/6000 r/min

Rated voltage
Alternator 14.55 V
At 25℃
14.235 V
At 115℃

12
 Chapter 4 Maintenance Data and Specifications

Section 3 Torque Specifications of Fasteners

Torque Specifications of Main Components

Fastener Installation Site Name and Spec. of Fastener Tightening Torque Tightening Method

Alternator regulating arm -- Hexagon bolt M8×30， Hexagon flange nut

24 N·m±2 N·m See P19.
timing cover cap M8

Alternator -- upper cylinder

Hexagon flange bolt M10×1.25×72 60 N-m±2 N·m See P19.
block

Starter -- lower cylinder block Hexagon flange bolt M10×1.25×60 60 N·m±2 N·m See P19.

Front engine mount -- upper Hexagon flange bolt M10×1.25×50，

55 N·m±2 N·m See P21.
cylinder block M10×1.25×55

A/C conditioner -- lower

Hexagon flange bolt 24 N-m±2 N·m See P21.
cylinder block
Vacuum power pipe conponent
Hexagon flange bolt M6×12 12 N-m±1 N·m See P21.
-- cylinder head
Hexagon bolt and flat washer assembly
Air intake manifold -- cylinder
M8×35， Hexagon flange nut M8, Double end 22 N-m±2 N·m See P25.
head
stud M8×30
Throttle valve assembly -- air Double end stud M6×50， Hexagon flange
12 N·m±1 N·m See P25.
intake manifold bolt M6×50， Hexagon flange nut M6
Lower thermal shroud Hexagon bolt and flat washer assembly
component -- upper cylinder 22 N·m±2 N·m See P27.
M8×16
block
Hexagon bolt and flat washer assembly
Exhaust manifold -- cylinder
M8×20， Double end stud M8×20， Hexagon 22 N·m±2 N·m See P28.
head
flange nut M8
Bracket of exhaust manifold -- Hexagon bolt and flat washer assembly
30 N-m±2 N·m See P28.
upper cylinder block M10×1.25×22
Bracket of exhaust manifold -- Hexagon bolt and flat washer assembly
30 N-m±2 N·m See P28.
exhaust manifold M10×1.25×22
Thermal shroud component --
Hexagon flange bolt M6×12 10 N·m±1 N·m See P28.
exhaust manifold
Oxygen sensor -- exhaust
Oxygen sensor 50 N·m±10 N·m See P28, P51.
manifold
Knock sensor -- upper cylinder
Knock Sensor 20 N·m±5 N·m See P47.
block
Water temperature sensor --
Water temperature sensor 14 N·m±1 N·m See P70.
cylinder head
Water drain valve assembly --
Water drain valve assembly 15 N·m±2 N·m See P72, P131.
upper cylinder block
Water pump assembly -- upper Hexagon flange bolt M6×35， Hexagon
11 N-m±1 N·m See P75.
cylinder block flange nut M6
Water pump pulley – water
Hexagon flange bolt M6×12 12 N·m±2 N·m See P75.
pump

Thermostat -- upper cylinder Double end stud M6×22， Hexagon flange

11 N-m±1 N·m See P78.
block nut M6

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 Maintenance Manual of GW4G13/GW4G15 Gasoline Engines

(Continued)
Fastener Installation Site Name and Spec. of Fastener Tightening Torque Tightening Method

Warm air return pipe assemblies Hexagon flange nut M6， Hexagon
10 N·m±l N·m See P80.
-- upper cylinder block flange bolt M6×14
Oil pressure sensor -- upper
Fuel tank pressure sensor 15 N·m±2 N·m See P83.
cylinder block
After contact,
Oil filter -- lower cylinder block l filter: tightening 3/4～l See P84.
turn.
Oil sump -- oil drain plug oil drain plug 18 N·m±2 N·m See P84, P87.
Oil Collector -- lower cylinder Hexagon flange bolt M6×12 ，
8 N·m±1 N·m See P87.
block Hexagon flange nut M6
Hexagon flange bolt M6×12 ，
Oil sump -- lower cylinder block 8 N·m±1 N·m See P87.
Hexagon flange nut M6
Oil level gauge tube -- cylinder
Hexagon flange bolt M6×12 7 N·m±1 N·m See P88.
head
Spring seat of pressure limiting
Spring seat of pressure limiting valve 30 N·m±l N·m See P91.
valve -- oil pump cover
Hexagon flange bolt M6×30，Cross
Oil pump cover -- timing cover 10 N·m±l N·m See P91.
recessed countersunk screw M6×14
Oil pump assembly -- upper Hexagon flange bolt M8×30, 24 N·m±2 N·m
See P92.
cylinder block M6×20.M6×35 1l N·m±l N·m
Oil pump assembly -- cylinder Double end studs M8×30，
24 N·m±2 N·m See P92.
cover Hexagon flange nut M8
Cylinder cover module -- oil
Hexagon flange bolt M6×25 10 N·m±1 N·m See P92.
pump assembly
Cylinder cover module -- cylinder
Hexagon flange bolt M6×25, M6×60 10 N·m±1 N·m See P96.
head
Washer assembly -- cylinder head Hexagon flange bolt M6×60 10 N·m±1 N·m See P96.
PcV valve assembly -- cylinder
PCV valve 1l N·m±l N·m See P97.
head cover module
Ignition coil -- cylinder head
Ignition coil 7 N·m±1 N·m See P97.
cover module
Bearing cap of camshaft -- Hexagon bolt and flat washer assembly Tighten two times.
12 N·m±1 N·m
cylinder head M6×38 See P105, P110.

Cylinder head -- upper cylinder Tighten two times.

Bolt of cylinder head M9×1.5×144 23 N·m+90°+90~
block See P109.
Tighten two times.
Bearing cap of front camshaft -- Hexagon bolt and flat washer assembly See P110.
23 N·m±2 N·m
cylinder head M8×42 Tighten two times.
See P109.
See P111.
Greasy blockage -- cylinder head Greasy blockage 30 N·m±2 N·m Tighten two times.
See P109.
VVT-i control valve -- cylinder
Hexagon flange bolt M6×12 7 N·m±1 N·m See P111.
head
Spark plug -- cylinder head Spark plug 27 N·m±2 N·m See P111.

Sprocket wheel of exhaust Bolt of exhaust camshaft sprocket wheel Tighten two times.
30 N·m+65°
camshaft -- camshaf M10×1.25×22 See P115.

Bolt of VVT phaser Tighten two times.

VVT Phaser 30 N·m+65°
M12×1.25×34 See P115.

14
 Chapter 4 Maintenance Data and Specifications

(Continued)
Fastener Installation Site Name and Spec. of Fastener Tightening Torque Tightening Method

chain shock absorber assembly -

Hexagon flange bolt M6×14 10 N·m±1 N-m See P115.
upper cylinder block

tensioner assembly - upper cylinder

Hexagon flange bolt M6×25 10 N·m±l N·m See P115.
block

Connecting rod cap -- connecting Tighten twice.

Connecting rod bolt M8×1×37.5 15 N·m+90°
rod See P120, P126.

Main bearing cap -- upper cylinder Bolt of main bearing cap Tighten two times.
22 N·m+90°
block M10×1.5×70.5 See P126.

Tighten two times.

Flywheel assembly -- crankshaft Flywheel bolt M10×1.25×20 30 N·m+45°
See P127.

Bolt assembly of damping belt pulley

Damping belt pulley -- crankshaft 50 N·m+65° See P127.
M12×1.25×47

Upper cylinder block -- lower Hexagon bolt and flat washer assembly
24 N·m±2 N·m See P130.
cylinder block M8×45，M8×80，M8×140

Hexagon bolt and spring washer

Clutch assembly -- flywheel 24 N·m±2 N·m See P134.
assembly M8×18

Hanging hook component --

Hanging hook component 55 N·m±2 N·m
cylinder head

15
 Maintenance Manual of GW4G13/GW4G15 Gasoline Engines

Chapter 5 Regular Inspections and Maintenance

When using GW4G15/ GW4G13 gasoline engine, inspect and change the components according to the actual conditon
and the stipulated change frequency.

Table 5-1 Regular Inspections and Maintenance Period of Gasoline Engine

Judge according to Driving mileage

2.5 10 20 30 40 50 60 70 80 90 100
driving mileage or (×1000km)
No. service life cycle,
whichever comes
Using life cycle
first. 1 6 12 18 24 30 36 42 48 54 60
(month)

Inspect, adjust and replace every 40000 km driving,replacing

l Timing chain aned tension device I
it within 200000 km.

Ignition cable: Check GND for damage and Joint

2 for loose I I I

3 Spark plug I I R I R I R I R I R

Inspect the fluid level and add it every 300-500 km, replacing it within
4 Coolant
2 years.

5 Fuel filter: R R R R R R R R R R

Inspect and clean every 5000 km driving,replacing it every 10000 km

6 Air filter core③
driving.

7 Various sensors I I I I I I I I I I

8 Ventilation system of crankshaft I I I I I I I I I I I

9 PCV valve assembly I Inspect every 5000 km.

10 Engine oil ④ R Replace every 8000～10000 km.

11 Oil filter ④ R Replace every 8000～10000 km.

12 Belt of alternator I Inspect every 20000 km or 12 months.

13 Common bolts and nuts I Inspect and tighten every 5000 km.

14 Valve clearance I I I I I I

The meaning of symbols in the table:

① “I” is for inspection. If necessay, regulate, calibrate and clean the engine or replace the components.
② “R” is for replacement.
③ If it is used in the area with serious wind and sand, the vehicle can be maintained in advance according to the actual
condition.
④ Under the severe conditions, the vehicle needs to be replaced every 2500 km driving.

16
 Chapter 6 External Engine Accessories

Chapter 6 Exterior Engine Accessories

Section 1 Components of Exterior Accessories

Assembly Schematic Diagram of External Gasoline Engine Accessories

1 一 Alternator mouting assembly;2 一 Front engine mounting assembly;
3 一 Rubber hose mounting assembly for positive ventilation of crankcase;
4 一 Vaccum booster hose module mounting assembly;5 一 Starter mounting assembly;
6 一 A/C compressor assembly

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 Maintenance Manual of GW4G13/GW4G15 Gasoline Engines

Section 2 Alternator Assembly

1.Disassembly
1.1Dismantle alternator assembly
Release the hexagon bolt (M8×30) -- component of alternator
adjusting arm, take off the belt, dismantle the alternator
assembly, as shown in Figure 6-2-1.
1.2 Dismantle the alternator adjusting arm
Dismantle hexagon flange nut(M8) at alternator adjusting arm,
take off its components, as shown in Figure 6-2-1.

Figure 6-2-1 Dismantle Alternator Assembly 2. Inspection

2.1 Inspect alternator belt
alternator 2.1.1 Visually inpsect the alternator belt for excessive abrasion
and rope for loose. If any problem, replace the belt.
Notice: The crack at wedge side on alternator belt is allowed,
but if there are flakes on the surface of belt, replace it.
2.1.2 Check the rate of tension of the alternator belt.
water pump Under the pressure of 98 N, flexility is 6-8 mm. Inspect the
pulley middle part between alternator belt and damper pulley, as shown
in Figure 6-2-2.
air conditioning
If necessary, adjust the rate of tension of the alternator belt.
compressor
Notice:
(1) After the alternator belt is mounted, inspect the match
between belt and wheel groove.
(2) Inspect by hand to confirm if the alternator belt slide away.
damper pulley
(3) After a new genarator belt of engine is mounted and the
engine runs for 5 minutes, reinspect the rate of tension of the
Figure 6-2-2 Inspect Alternator Belt
alternator belt.
2.2 Inspect the alternator rotor rotated by hand for stable rotaiton,
as shown in Figure 6-2-3.
2.3 Inspect the running state of the engine
2.3.1 Check the engine for good wiring.
2.3.2 Inspect if the alternator noise is abnormal when the engine
is running. Replace the alternator assembly if any.
2.3.3 Inspect the alternator assembly for normal work. If there is
any problem, replace the engine.

Figure 6-2-3 Inspect Alternator Rotor

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 Chapter 6 External Engine Accessories

3. Mounting
3.1 Mount the alternator arm on the timing cover shell (Air
intake side).
3.2 Assembe the alternator assembly and fix the alternator
assembly and ajusting arm together, as shown in Figure 6-2-4.
3.3 Place the belts into the outer groove of the damper pulley,
A/C compressor belt pulley and alternator belt pulley. The
coiling direction of the belt is shown in Figure 6-2-2.
Notice: Do not mount the belt in the improper groove.
3.4 Adjust the position of alternator assembly Check the belt
flexility and confirm it meets the requirements. Then tighten the
bolts and nuts.
Tighten the bolts (M8×30) of adjusting arm of the alternator.
24 N·m±2 N·m。
Tightening torque: 24 N·m±2 N·m.
Figure 6-2-4 Mount Alternator Hexagon flange bolt of engine: M10×1.25×72。
Tightening torque: 60 N·m±2 N·m。
Check the belt flexility:
Under the pressure of 98 N, flexility is 6-8 mm. Inspect the
middle part between alternator belt and damper pulley, as shown
in Figure 6-2-2.

Section 3 Starter
1. Dismantle
1.1 Loosen the starter, mount the Hexagon flange bolt
(M10×1.25×60) and take off the starter assembly, as shown in
Figure 6-3-1 Starter Figure 6-3-1.
1.2 Remove the dustproof sheet of the starter.
2. Inspection
2.1 Inspect the clutch of starter for abrivision or damage. If any,
replace the starter assembly.
2.2 Inspect if the starter runs normally and if the driving gear
can flex freely. If it can not, replace it.
3. Mounting
3.1 Assembe the dustproof sheet of the starter.
3.2 Using two hexagon flange bolts, M10×1.25×60, tighten the
starter assembly to the lower cylinder block, as shown in Figure
6-3-2.
Tightening torque: 60 N·m±2 N·m。
Notice: The starter should be installed after the transmission is
mounted.

Figure 6-3-2 Mount Starter

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 Maintenance Manual of GW4G13/GW4G15 Gasoline Engines

Section 4 Other Exterior Accessories

1. Dismatling
1.1 Dismantle the front engine mount
1.1.1 Remove the whole engine from the vehicle.
1.1.2 1.1.2 Dismantle the 4 hexagon flange bolts (M10×1.25×50)
and take the front engine mount off from the lower cylinder
block, as shown in Figure 6-4-1.

Figure 6-4-1 Dismantle Front Engine

Mount
1.2 Dismantle the A/C compressor
Dismantle the four-hexagon bolts module with flange and take
A/C compressor off, as shown in Figure 6-4-2.

Figure 6-4-2 Dismantle A/C

Compressor

1.3 Dismantle the hose for positive ventilation

Loosen the 2 steel band type ring clamps, take off the hose for
positive ventilation, as shown in Figure 6-4-3.

Figure 6-4-3 Dismantle Hose for

Positive Ventilation

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 Chapter 6 External Engine Accessories

1.4 Take down the vaccum booster hose and booster hose
1.4.1 Loosen 2 steel band type ring clamps and take off the
booster hose, as shown in Figure 6-4-4.
1.4.2 Take down 2 hexagon flange bolts (M6×12) and remove
the vaccum booster hose, as shown in Figure 6-4-4.

2. Inspection
Inspect the rubber hose for aging and cracking, the mount for
welding damage and loosening. If any, replace it.

Figure 6-4-4 Take down Vaccum Booster Hose 3. Mounting

and Booster Hose
3.1 Mount front engine mount
Mount the front engine mount by 2 hexagon flange bolts
(M10×1.25×55) and 2 hexagon flange bolts (M10×1.25×50) to
the upper cylinder block, as shown in Figure 6-4-5.
Tightening torque: 55 N·m±2 N-m。

Figure 6-4-5 Mount Front Engine Mount

3.2 Mount A/C compressor
By 4 hexagon flange bolts mount the A/C compressor to the
lower cylinder block, as shown in Figure 6-4-6.
Tightening torque: 2 4 N·m±2 N·m。

3.3Mount the vaccum booster hose and booster hose

3.3.1 By 2 hexagon flange bolts mount the vaccum booster hose
assemblies to the cylinder head.

Tightening torque: 12 N·m±1 N·m。

Figure 6-4-6 Mounr A/C Compressor
3.3.2 Tighten the two ends of booster hose by 2 steel band type
ring clamps.
3.4 Mount hose for positive ventilation
Tighten the hose for positive ventilation by 2 steel band type
ring clamps, as shown in Figure 6-4-7.

Figure 6-4-7 Mount Hose for Positive

Ventilation

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 Maintenance Manual of GW4G13/GW4G15 Gasoline Engines

Chapter 7 Air Intake and Exhaust Systems

Section 1 Components of Air Intake and Exhaust Systems

Figure 7-1-1 Component Assembly Diagram of Air Intake and Exhaust System of Gasoline Engine
1 一 Exhaust system；2 一 Air Intake System

22
 Chapter 4 Maintenance Data and Specifications

Section 2 Air Intake Systems

1. Component Assembly Diagram

Component Assembly Diagram of Air Intake System

1 一 Stud (M8×30，2 peices)；2 一 Hexagon flange nut(M8，2 pieces)；3 一 Hexagon bolt and plain washer assembly (M8×35，
3 pieces)；4 一 Engine hood support(2 pieces)；5 一 Assembling bolt of support (2 pieces)；6 一 Hexagon flange bolt (M6×50,2
pieces);7 一 Stud (M6×50，2 pieces)；8 一 Hexagon flange nut(M6，2 pieces)；9 一 Throttle valve assembly; 10 一 Throttle valve
gasket; 11 一 Air Intake manifold assembly；12 一 Gasket of air intake manifold

2. Disassembly
Disassemble other hoses on the air intake manifold and
throttle valve. The air intake system after disassembly is
shown in Figure 7-2-2.
2.1 Dismatle the throttle valve.
2.2 Dismantle the pressure sensor for air intake.
2.3 Dismantle the air intake manifold.
2.4 Take off the gaskets of the air intake manifold.
2.5。Take off the gaskets of throttle valve.
Figure 7-2-2 Dismantle Air Intake Manifold

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 Maintenance Manual of GW4G13/GW4G15 Gasoline Engines

3. Inspection
3.1 Inspect the air intake for sealing condition and leakage.
The air intake should have good sealing and no leakage. If
leakage occurs, the power of engine will reduce and exhaust
becomes worse, replace timely the relative components.
3.2 Inspect the throttle valve assembly for breakage or other
damages. Rotate throttle valve according to the direction marked
in Figure 7-2-3. Check if the valve rotates flexibly.
Figure7-2-3Inspect Throttle Valve
3.3 Inspect the air intake manifold for severe diformation,
breakage or damage.
3.4 Inspect the gaskets of air intake manifold and throttle valve
for breakage or corrosion.
4. Mounting
4.1 Mount the gasket of throttle valve on the flange of the air
intake manifold, as shown in Figure 7-2-4.

Figure7-2-4 Install the Ggasket of

Throttle Valve

Notice: Press the fail-safe mark on the gasket of the throttle

valve into the marking groove of throttle valve correspondingly
and evenly, as shown in Figure 7-2-5.
4.2 Mount the gasket of air intake manifold on the flange of the
air intake manifold.

Figure7-2-5 Fail-safe Mark of the

Ggasket of Throttle Valve Notice: Press the fail-safe mark on the gasket of the air intake
manifold into the marking groove of throttle valve
correspondingly and evenly, as shown in Figure 7-2-6.

Figure7-2-6 Fail-safe Mark of the

Ggasket of Air Intake Manifold

24
 Chapter 4 Maintenance Data and Specifications

4.3 By 2 studs (M8×30) on the air intake side of the cylinder

head for positioning, mount the air intake manifold assembly
on the flange for air intake of the cylinder head with 3
hexagon bolt and plain washer assies (M8×35) and 2 hexagon
flange nuts (M8), as shown in Figure 7-2-7 ① fixed air intake
manifold.
Tightening torque: 22 N·m±2 N·m。

Figure 7-2-7 Mount Air Intake

Manifold Assembly
4.4 Mount the throttle valve assembly on the air intake
manifold assembly by 2 studs (M6×50) (Figure 7-2-8 ①), 2
hexagon flange nuts(M6) and 2 hexagon flange bolts (M6×50),
as shown in Figure 7-2-9.
Tightening torque: 12 N·m±1 N·m。

Figure 7-2-8 Mount Throttle Valve Assembly

throttle

Figure 7-2-9 Mount Throttle Valve

Fasteners
4.5 Mount the air intake pressure & temperature sensor and fix
intake pressure & it by the hexagon flange bolt (M5×15) to the air intake
temperature sensor manifold, as shown in Figure 7-2-10. Connect all water pipes,
vent-pipes, hoses and wiring harness joints well.

Figure 7-2-10 Mount Air Intake Pressure & Temperature

Sensor

25
 Maintenance Manual of GW4G13/GW4G15 Gasoline Engines

Section 3 Exhaust Systems

1. Component Assembly Diagram

Figure 7-3-1 Component Assembly Diagram of Exhaust System of Gasoline Engien

1 一 Hexagon bolt and plain washer assembly (M8×16, 2 pieces)；2 一 Heat shield assembly; 3 一 Exhaust manifold support; 4 一 Exhaust
manifold assembly 5 一 Exhaust manifold gasket assembly; 6 一 Heat shield of oxygen sensor; 7 一 Oxygen sensor; 8 一 Heat shield assembly;
9 一 Hexagon flange bolt (M6×12, 3pieces); 10 一 Hexagon flange nut (M8, 2pieces)；11 一 Stud (M8×20, 2pieces)；12 一 Hexagon bolt and
plain washer assembly (M8×20, 3 pieces); 13 一 Hexagon bolt and plain washer assembly (M10×22, 3 pieces)

26
 Chapter 7 Air Intake and Exhaust Systems

2. Disassembly
2.1 Take down the oxygen sensor.
2.2 Take down the heat shield assembly of the oxygen sensor, as
shown in Figure 7-3-2.
Warning: To prevent burning, take preventive measures when the heat
shield of oxygen sensor is taken off from the hot machine.

Figure 7-3-2 Take down Heat Shield of 2.3 Take down the exhaust manifold support.
Oxygen Sensor
2.4 Take down the exhaust manifold assembly.
2.5 Take down the exhaust manifold gasket assembly.
2.6 Take down the heat shield assembly of exhaust manifold, as
shown in Figure 7-3-3.
3. Inspection
3.1Inspect the exhaust manifold assembly and exhaust manifold
gasket assembly for sealing before disassemby of the exhaust
manifold assembly. If they Leak, exhaust becomes worse, and
replace timely them.
Figure 7-3-3 Dismantle and Inspect Heat
Inspect the exhaust manifold assembly for blockage. Blockage
Shield Assembly of Exhaust Manifold
will cause difficult start, poor acceleration, poor dynamic
property, worse exhaust and so on. Replace the exhaust manifold
assembly in time.
Notice: Do not use the dismantled exhaust manifold gasket assembly. Do
use new ones.
3.2 Inspect the heat shield assembly of exhaust manifold and
exhaust manifold support, as shown in Figure 7-3-3 and Figure
7-3-4.
If the heat shield assembly of exhaust manifold, lower heat
shield assembly and exhaust manifold support have cracks or
Figure 7-3-4 Inspect Exhaust other damages, replace those parts.
Manifold Support

Warning: To prevent burning, take preventive measures when the heat

shield assembly is taken off (Inspect or replace parts after the engine is
cooled).
4. Mounting
4.1 Mount the heat shield assembly (See Figure 7-3-5) under the
exhaust manifold on upper cylinder block by 2 hexagon bolt and
plain washer assemblys (M8 × 16).
Tightening torque: 22N·m ± 2N·m。

Figure 7-3-5 Mount Lower Heat Shield Assembly

27
 Maintenance Manual of GW4G13/GW4G15 Gasoline Engines

4.2 With 2 studs (M8×20) at the exhaust side of the cylinder

head, mount the new exhaust manifold gasket assembly (See
Figure 7-3-6) on the cylinder head. Then fasten exhaust
manifolds (See Figure 7-3-7) and exhaust gasket assembly by 3
hexagon bolt and plain washer assemblys (M8 × 20) and 2
hexagon flange nuts (M8).
Tightening torque: 22 N·m ± 2 N·m.

Figure 7-3-6 Mount Exhaust Manifold

Gasket Assembly

Figure 7-3-7 Mount Exhaust Manifold

4.3 Fasten exhaust manifolds support on upper cylincer block by

3 hexagon bolts and plain washer assemblys (M10×1.25×22), as
shown in Figure 7-3-8.
Tightening torque: 30 N·m±2 N·m。

4.4 Fasten the Heat Shield of the exhaust manifold on the

exhaust manifold by 3 hexagon flange bolts (M6×12), as shown
in Figure 7-3-8.
Tightening torque: 10 N·m±1 N·m。

Figure 7-3-8 Mount Exhaust Manifold

Support

4.5 Mount the heat shield of oxygen sensor and oxygen sensor.

Put the Heat shield of oxygen sensor and oxygen sensor into
exhaust manifold, as shown in Figure 7-3-9.
Tightening torque: 50 N·m±10 N·m。

Figure 7-3-9 Mount Heat Shield of Oxygen Sensor

and Oxygen Sensor

28
 Chapter 8 Electronically Controlled Fuel Ejection System

Chapter 8 Electronically Controlled Fuel Injection System

Section 1 Repair Knowledge on Electronic Fuel Injection System (EFIS)

1. General Service Instruction
1.1 Only the high impedance digital multi-meter can be used in inspection of the Electronic Fuel Injection System
(EFIS).
1.2 Please use quality components during the operation, otherwise, the Electronic Fuel Injection System (EFIS) can not
run normally.
1.3 During service, only unleaded gasoline can be used.
1.4 Always do the servicing work according to the service diagnosis procedure in the specification.
1.5 Do not dismantle and install the components of the Electronic Fuel Injection System (EFIS) during service.
1.6 During dismantling and installation of the electronic elements (electronic control unit (ECU), sensor and so on),
always be very careful. Do not fall to the ground.
1.7 With environment protection consciousness, dispose castoffs generated in the process of service.

2. Cautions of Repair
2.1 The components and connectors of the Electronic Fuel Injection System (EFIS) dismantled from the installation
position should avoid water, oil and others entering into inside body. Otherwise, the Electronic Fuel Injection (EFIS)
System can not work properly.
2.2 During removal and installation of connectors, always turn off the ignition switch to prevent the electrical elements
from damaging.
2.3 Under the thermal state simulated condition and other maintenance work that may cause temperature to rise, never
allow the temperature of the electronic control unit (ECU) exceeded.
2.4 The oil pressure of the Electronic Fuel Injection System (EFIS) is higher (380 kPa or so) and all fuel pipes are high
pressure resistant fuel pipe. Even if the engine doesn’t run, the fuel pipe still keeps relatively high pressure. Therefore,
do not dismantle the oil pipe during maintenance. If the fuel system needs service, the pressure relief of the fuel system
should be done before the oil pipe is dismantled. The method of pressure relief is as follows: remove the fuel pump
relay, start the engine and make it rotate at idle until the engine goes out automatically. Dismantling fuel pipes and
replacing fuel filter should be done by the professional person in the condition with the good ventilation.
2.5 When the electric fuel pump is taken down from the fuel tank, the power of pump should be off to avoid generating
the electric spark and cause a fire.
2.6 The fuel pump cannot be tested under the dry state or in the water, otherwise, its life will be reduced. Moreover, the
positive and negative of the fuel pump must be connected correctly.
2.7 Only when necessary, can the jump spark detection in the ignition system be done. During testing, throttle valve
shouldn’t be open. Otherwise, a lot of unburned gasoline enters the exhaust pipe to damage three-way catalytic
converter.
2.8 The idle speed of engine is regulated by the Electronic Fuel Injection System (EFIS) without manual regulation.
2.9 The positive and negetive terminals of battery can not be connected wrongly to avoid damaging electronic
components. The Engine Electronic Fuel Injection System of GW4G15/GW4G13 gasoline engine adopts minus earth.
2.10 Disassembling the battery cable isn’t allowed when the engine running.
2.11 When welding is done in the vehicle, do remove the battery positive terminal, negative cables and electronic
control unit (ECU) from the vehicle.
2.12 Do not inspect the input/output signal of components by stabbing the lead surface.

29
 GW4G13／GW4G15Maintenance Manual of Gasoline Engine

3. Service Tool
Name of tool:
The diagnostic instrument for Electronic Fuel Injection System
(EFIS) with standard OBD function, as shown in Figure 8-1-1.
Functions:
Read/clear the fault code of Electronic Fuel Injection System
(EFIS), check datastream, test actions of components, and so on.

Figure 8-1-1 Diagnostic Instrument for Electronic Fuel

Injection System with Standard
Name of tool:
OBD Function
Digital multimeter (can not be substituted by low-impedance
Simulating multimeter), as shown in Figure 8-1-2.
Functions:
Inspect characteristic parameters in the Electronic Fuel Injection
System (EFIS), such as valtage, current, resistance.

Figure 8-1-2 Digital Multi-meter

Name of tool:
Cylinder pressure gauge, as shown in Figure 8-1-3.

Functions:
Inspect various cylinders of engine for pressure.

Figure 8-1-3 Cylinder Pressure Gauge

Name of tool:

Fuel Pressure Gauge is shown in Figure 8-1-4.

Functions:
Inspect the pressure of the fuel system and determine the
working conditions of the fuel pump and the fuel pressure
regulator of the fuel system.

Figure 8-1-4 Fuel Pressure Gauge

30
 Chapter 8 Electronically Controlled Fuel Ejection System

Name of tool:
Exhaust gas analyzer, as shown in Figure 8-1-5.

Functions:
Inspect the tail gas condition of the vehicle to help judge
malfunction of the Electronic Fuel Injection System (EFIS).

Figure 8-1-5 Exhaust Gas Analyzer

Name of tool:
Fuel injector cleaning analyzer is shown in Figure 8-1-6.
Functions:
Purge the fuel injector and analyze its running condition.

Figure 8-1-6 Fuel Injector Cleaning Analyzer

Section 2 On-board Diagnostic (OBD)System Overview

The on-board diagnostic system (OBD) refers to the system that can monitor the defective components affecting
exhaust emission in the control system of engine and it is a diagnostic system of function and state of engine. The
system has the functions of identifying , saving and displaying defaul information by self-diagnostic malfunction
indicator lamp (MIL).
In order to ensure durability of emission control performance during the vehicle service, Emission Limitation and
Measuring Method of Light Vehicle Pollutantes (China III，IV Phase) specifies definitely that all vehicles must be
equipped with OBD system, which can ensure to identify inferior and defective parts within the whole service life of
the vehicle.
When maintaining the vehicle with OBD system, the maintainer can locate the defective component quickly and
accurately by diagnostic instrument so as to improve maintenance efficiency and quality.
OBD technology involves in many brand-new concepts. In order to understand better the follow-up content, some
basic knowledge on OBD technology is introduced as follows:

31
 GW4G13／GW4G15Maintenance Manual of Gasoline Engine

1. Malfunction
Once the following conditions found in OBD system, a failure is considered to have occurred.
The converting efficiency of the catalytic converter declines and the emission exceeds OBD limit.
The engine misfires, exhaust pollutant exceeds OBD limit, or the catalytic converter is damaged due to excessive
temperature.
The oxygen sensor is so damaged or aged that the exhaust pollutant of the vehicle exceeds OBD limit.
The parts connected to electrical control unit and relating to emission lose effeciency so that the exhaust pollutant of the
vehicle exceeds OBD limit.
The current status of the parts of powertrain connected to electrical control unit, including any sensors with monitoring
functions, is not normal.

2. Malfunction Handling
When a fault is found, OBD will do the following jobs according to the fault:
In a conrresponding mode, glitter, light or put out fault indicator.
For ECU, add, renew and delete the reletive information of faults. These information can be read by the standard
diagnostic instrument via its standard interface.
2.1 Malfunction State
The mode of OBD system’s handling the fault varies with the different fault. To better understand the Fault Status, we
must define the meaning of fault confirmation and restore.
Fault confirmation refers to the course in which the fault is found and confirmed by the OBD system and then to trigger
MI lamp according to the corresponding strategy. A fault is called an accidental fault before confirmation. When
identified it is called a confirmed fault. Generally, here are two ways to confirm a fault:
(1) Inspect and find out faults in three continuous cycles:
An operating cycle includes start of engine, corresponding working condition (The fault shall be determined when it
occurs in the vehicle) and engine being stalled. This way of confirmation is used for most faults related to emission.
(2) Through inspection it is found that the fault existed for more than 2.5s.
This method is adopted on even more reliable diagnostic functions, such as the diagnosis of revolution speed sensor.
Fault correction means that the OBD system is found no fault after troubleshooting. And fault recovery requires a
confirmation process. For the accidental fault, OBD will directly clear off the fault record when it detects that the fault
has been restored. As to confirmed fault, OBD can confirm the restored fault only when no fault is found in three
continuous cycles. Then go to handle with the fault indicator and the fault memory in accordance with the fault disposal
policies.
Depending on whether a fault is confirmed or corrected and how it is confirmed and corrected in different ways, the fault
can be classified into the following states:

Confirmed bu Confirmed fault

Occurrent but Occurrent but Confirmed no
Fault Status not confirming and confirming
not confirmation restored restroation
restoration restoration
Found out or not ～ ～ ～ ～ ～
Restore or not N
Confirm or not N N N
Restored or not ～
Confirm reatoration or not N

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 Chapter 8 Electronically Controlled Fuel Ejection System

2.2 Fault Handling Policies

The following is fault-handling policies for different Fault Status, the application of which depends on rules of law,
defective components and the characteristics of the system.

Fault Status Control of MI Lamp Save of Fault Information

Occurrent but Monitor the fault code consecutively,

MI lamp state unchanged.
not confirmation Output by Mode 7.
Occurrent but Delete the appropriate fault data in the
MI lamp state unchanged.
restored ECU memorizer.

For the fault relating to emission, activize MI lamp.

The information of fault code and
Confirmed but For the fault not effecting emission but needing maintenance, do
corresponging frame is output by Mode 2.
not corrected not activize the MI lamp.
The fault code is output by Mode 3.
For the misfire fault damaging catalytic converter, MI lamp glitters.

Identified fault
before confirmed Not change the state of MI lamp.
restoration
If the same fault does not occur within 40
Identified fault engine warming cycles after restoration,
before confirmed Activate the MI lamp. clear off the fault code and driving
restoration distance during the fault, and freeze frame
information.

3. Malfunction Indicator (MI Lamp)

MI lamp is a fault indicator. It can remind the driver when a fault occurs from any emission-related components
connected to the on-board diagnostic (OBD) system or from the OBD system itself. MI lamp is an indicator that can
display on the instrument panel and have its shape in compliance with the relevant standard.
Principles of MI lamp activation are as follows:
When the vehicle ignition switch has been turned on but the engine still does not start up or rotate, the MI lamp
illuminates.
If the fault relating to emission in the system has been confirmed (unless the fault causes the catalytic converter to
damage), OBD system will light the MI lamp, reminding the driver of overhauling.
Once the engine misfires to reach the level stipulated by the manufacturer so that the catalytic converter may be
damaged, the MI lamp glitters immediately at the frequency of 1 Hz.
Principles of putting out MI lamp are as follows:
If no fault has been found after the engine starts up, the MI lamp goes out in 3s.
If the engine misfire rate which may damage the catalytic converter does not exist, or the engine misfire rate does not
damage the catalytic converter after the revolution and load is changed, the MI lamp should be changed to the original
state prior to its activation.
For all other faults, if the monitoring system of activized MI lamp does not find the fault or other faults that will
activate MI lamp separately in three continuos cycles, MI lamp will goes out.

4. Trouble code
As required by laws and regulations, the OBD system must have the function which can identify the existing fault and
save the information, in the form of fault code, in the electronic control unit (ECU) memory. SAE(American
Association of Engineers) and ISO (International Organization for Standardization) have standardnized the fault
diagnosis code. It consists of 5 characters, for example, P0112.
The first character in fault code is a letter, it refers to the system the fault belongs to:

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 Maintenance Manual of GW4G13/GW4G15 Gasoline Engines

--Pxxxx signifies the fault in the power train.

--Bxxxx signifies the fault in the vehicle body.
--Cxxxx signifies the fault in the chassis.
--Ulxxxx signifies the fault in the network.
The faults related to the OBD is expressed by P code mainly.

The second character in fault code reflects the constitutor of the fault code:
P0xxx is subject to the difination of SAE and is used by the system. The fault code can be selected freely, including the
specified fault text description (from 2000 Vehicle Model Year: P0xxx and P2xxx).
Plxxx affecting exhaust emission is supplied by the manufacturer. The additional fault code can be selected freely,
excluding the specified fault text description, but it must be registered at legislator’s office (from 2000 Vehicle Model
Year: P1xxx and P3xxx).

The third character in fault code is the classification of the fault, its difination is as follows:
--P×0××: Fuel and air measurement, emission control.
--P×1××: Fuel and air measurement.
--P×2××: Fuel and air measurement.
--Px3××: The ignition system may misfire.
--P×4××: Additional emission control.
--Px5××: Vehicle speed, idle speed and input signal.
--P×6××: Computer and output signal.
--P×7××: Transmission .
--P×8××: Transmission
--Px9××: Transmission
--P×Axx: Hybrid propulsion.

The fourth and fifth characters in fault code denote the fault component and system.
Using the standard scanning tool and diagnosis interface, the fault code of accidental fault found by continuous
monitoring will be sent out in the scanning tool Mode 7, the confirmed fault code in Mode 3 and the fault code of frozen
frame (if any) in the scanning tool Mode 2.
Decription of Scanning Tool Functions
In addition, the OBD system provides a lot of fault diagnosis information; the information has a high reference value for
the overhaul of the ElectronicFuel Injection System (EFIS). Depending on the difinitions in Is0/I)ISl503l 一 5, the
relative information of OBD system has 9 different services/modes so as to obtain the diagnosis tools required by
Is0/I)ISl5031-4. The main functions of these modes are as follows:
--01- Read the power train and disgnoze the current data.
--02- Read the frozen frame data.
--03- Read the disgnosis fault code relating to the emission in the power train.
--04- Clear and restore the disgnosis fault code relating to the the emission.
--05- Read the monitoring and testing the results of oxygen sensor.
--06- Read the results tested by non-continuously monitoring system OBD.
--07- Read the results tested by the continuously monitoring system OBD.
--08- It belongs to a suggestion and it is not the compellent requirements.
--09- Read the Vehicle Identification Number (VIN) and software code.
The information output by all modes is the same, which is explained below. It is worth to point that the different
scanning tools and diagnostic instruments may vary during design and use, but the read content must belongs to one of
the above modes.

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 Chapter 8 Electronically Controlled Fuel Ejection System

5. The Fault Code of Electronic Fuel Injection System

The Trouble Code Table of Electronic Fuel Injection System

No. Fault Code Description of Fault Code

1 P000A Air intake VVT runs unreasonablly.
2 P0010 Current open circuit fault of air intake VVT.
3 P0012 Unreasonable locked position of air intake VVT.
4 P016 Inproper relative position of Crankshaft and Camshaft.
5 P0030 Heating control circuit opening of upstream oxygen sensor.
6 P0031 Short circuit to ground of heating control circuit of upstream oxygen sensor.
7 P0032 Short circuit to power supply of heating control circuit of upstream oxygen sensor.
8 P0036 Heating control circuit opening of downstream oxygen sensor
9 P0037 Short circuit to ground of heating control circuit of downstream oxygen sensor.
10 P0038 Short circuit to power supply of heating control circuit of downstream oxygen sensor.
11 P0053 Unreasonable heating internal resistance of upstream oxygen sensor.
12 P0054 Unreasonable heating internal resistance of downstream oxygen sensor.
13 P0105 The signal of air intake pressure sensor does not change (frozen).
14 P0106 Unreasonable air intake pressure sensor.
15 P0107 Short circuit to ground of air intake pressure sensor.
16 P0108 Short circuit to power suply of air intake pressure sensor.
17 P0112 Low signal voltage of air intake pressure sensor.
18 P0113 High voltage of the air intake temperature sensor signal circuit
19 P0116 Unreasonable temperature of the engine coolant temperature sensor
20 P0117 Low voltage of the engine coolant temperature sensor circuit
21 P0118 High voltage of the engine coolant temperature sensor circuit
22 P0121 Unreasonable signal of electronic throttle valve position sensor 1.
23 P0122 Low voltage of signal circuit of electronic throttle valve position sensor 1.
24 P0123 High voltage of signal circuit of electronic throttle valve position sensor 1.
25 P0130 Unreasonable signal of upstream oxygen sensor.
26 P0131 Low signal voltage of upstream oxygen sensor.
27 P0132 High signal voltage of upstream oxygen sensor.
28 P0133 Aging of upstream oxygen sensor.
29 P0134 Circuit signal fault of upstream oxygen sensor.
30 P0136 Unreasonable signal of downstream oxygen sensor.
3l P0137 Low signal voltage of downstream oxygen sensor.

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 Maintenance Manual of GW4G13/GW4G15 Gasoline Engines

(continued)
No. Fault Code Description of Fault Code
32 P0138 High signal voltage of downstream oxygen sensor.
33 P0140 Circiut signal fault of downstream oxygen sensor.
34 P0170 Unreasonable self-study of closed-loop control of off-line inspection air/fuel ratio.
35 P0171 Thin self-study of closed-loop control of off-line inspection air/fuel ratio.
36 P0172 Thick self-study of closed-loop control of off-line inspection air/fuel ratio.
37 P0201 Control circuit opening of fuel injector of the 1st cylinder.
38 P0202 Control circuit opening of fuel injector of the 2nd cylinder.
39 P0203 Control circuit opening of fuel injector of the 3rd cylinder.
40 P0204 Control circuit opening of fuel injector of the 4th cylinder.
4l P0219 The revolution of the engine exceeds the maximum rotation speed.
42 P0221 Unreasonable signal of electronic throttle valve position sensor 2.
43 P0222 Low voltage of signal circuit of electronic throttle valve position sensor 2.
44 P0223 High voltage of signal circuit of electronic throttle valve position sensor 2.
45 P0261 Short circuit to ground of control circuit of the 1st cylinder fuel injector.
46 P0262 Short circuit to power supply of control circuit of the 1st cylinder fuel injector.
47 P0264 Short circuit to ground of control circuit of the 2nd cylinder fuel injector.
48 P3265 Short circuit to power supply of control circuit of the 2nd cylinder fuel injector.
49 P0267 Short circuit to ground of control circuit of the 3rd cylinder fuel injector.
50 P0268 Short circuit to power supply of control circuit of the 3rd cylinder fuel injector.
51 P0270 Short circuit to ground of control circuit of the 4th cylinder fuel injector.
52 P0271 Short circuit to power supply of control circuit of the 4th cylinder fuel injector.
53 P0300 Multi-cylinder misfire.
54 P0301 The 1st cylinder misfire.
55 P0302 The 2nd cylinder misfire.
56 P0303 The 3rd cylinder misfire.
57 P0304 The 4th cylinder misfire.
58 P0321 DG loses BM to rotating speed signal cogs so that the signal loses frequently.
59 P0322 No pulse signal of revolution speed sensor (opening or short circuit).
60 P0327 Low valtage of signal circuit of the knock sensor.
61 P0328 High valtage of signal circuit of the knock sensor.
62 P0340 Improper mounting position of phase sensor.
63 P0341 Poor contact of phase sensor.

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 Chapter 8 Electronically Controlled Fuel Ejection System

(continued)
No. Fault Code Description of Fault Code
64 P0342 Short circuit to ground of phase sensor.
65 P0343 Short circuit to power supply of phase sensor.
66 P0420 Oxygen-storing capacity aging (excessive exhaust) of the three-way catalytic converter.
67 P0444 Open control circuit of canister control valve.
68 P0458 Low voltage of control circuit of canister control valve
69 P0459 High volatage of control circuit of canister control valve.
70 P0480 Relay control circuit opening (low speed) of cooling fans.
71 P0481 Relay control circuit opening (high speed) of cooling fans.
72 P0501 Unreasonable signal of the vehicle speed sensor.
73 P0506 Rotating speed of idle speed control is lower than the target idle speed.
74 P0507 Rotating speed of idle speed control is higher than the target idle speed.
75 P0537 Short circuit to ground of A/C air conditioner temperature sensor.
76 P0538 Short circuit to power supply of A/C air conditioner temperature sensor.
77 P0560 Unreasonable signal of system battery voltage.
78 P0562 Low system battery voltage.
79 P0563 High system battery voltage.
80 P0571 Signal circuit fault of brake switch or out of step with stop lamp switch
8l P0602 Code fault of electronic control unit (ECU).
82 P0604 RAM fault of electronic control unit (ECU).
83 P0605 ROM fault of electronic control unit (ECU).
84 P0606 Safe monitoring function fault of electronic throttle valve.
85 P0627 Open relay control circuit of fuel pump.
86 P0628 Short circuit to ground of relay control circuit of fuel pump.
87 P0629 Short circuit to power supply of relay control circuit of fuel pump.
88 P0645 Relay control circuit opening of A/C compressor.
89 P0646 Short circuit to ground of relay control circuit of A/C compressor.
90 P0647 Short circuit to power supply of relay control circuit of A/C compressor.
9l P0650 MIL drive circuit.
92 P0688 Unreasonable output voltage of the main relay.
93 P0691 Short circuit to ground of relay control circuit of cooling fans (low speed).
94 P0692 Short circuit to power supply of relay control circuit of cooling fans (low speed).
95 P0693 Short circuit to ground of relay control circuit of cooling fans (high speed).

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 Maintenance Manual of GW4G13/GW4G15 Gasoline Engines

(Continued)
No. Fault Code Description of Fault Code
96 P0694 Short circuit to power supply of relay control circuit of cooling fans (high speed).
97 P0704 Improper signal of clutch pedal switch.
98 P1336 Restriction of safely monitored torque of electronic throttle valve.
The deviation between the actual position and target position of electronic throttle valve is out
99 P1545
of the limit.
100 P1558 Too big opening resistance of the electronic throttle valve.
101 P1559 Self-learning process fault of the electronic throttle valve.
102 P1564 The system voltage does not meet the self-study condition of the electronic throttle valve.
103 P1565 Self-learning fault of limit position initializtion of the electronic throttle valve.
104 P1568 Too big return resistance of the electronic throttle valve.
105 P1579 Self-study condition of the electronic throttle valve cannot be met.
106 P1604 Self-study of gain adjustation fault of the electronic throttle valve.
107 P1610 The anti-theft key has not been programmed.
108 P1611 The code of the anti-theft key is wrong.
109 P1612 The communication between the anti-theft immobilizer and ECU is off.
110 P1613 The communication between the anti-theft immobilizer and ECU is off.
111 P1614 The chip fault within the anti-theft key.
112 P1651 Driver circuit fault of SVS light.
113 P2088 Short circuit to ground of air intake VVT.
114 P2089 Short circuit to power supply of air intake VVT.
115 P2106 Driving fault of the electronic throttle valve.
116 P2122 Low signal voltage of Pisition Sensor 1 of electronic accelerator pedal.
117 P2123 High signal voltage of Pisition Sensor 1 of electronic accelerator pedal.
118 P2127 Low signal voltage of Pisition Sensor 2 of electronic accelerator pedal.
119 P2128 High signal voltage of Pisition Sensor 2 of electronic accelerator pedal.
120 P2138 Unreasonable signal of Pisition Sensor of electronic accelerator pedal.
Self-learning value of closed-loop control of air/fuel ratio exceeds the upper limit (medium
121 P2177
loading area).
Self-learning value of closed-loop control of air/fuel ratio exceeds the lower limit (medium
122 P2178
loading area).
Self-learning value of closed-loop control of air/fuel ratio exceeds the upper limit (low loading
123 P2187
area).
Self-learning value of closed-loop control of air/fuel ratio exceeds the lower limit (low loading
124 P2188
area).
125 P2195 Aging of upstream oxygen sensor.
126 P2196 Aging of upstream oxygen sensor.
127 P2270 Aging of downstream oxygen sensor.
128 P2271 Aging of downstream oxygen sensor.

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 Chapter 8 Electronically Controlled Fuel Ejection System

Fault Overhaul Steps

For the vehicles with OBD function to go a fault overhaul, observe generally the following steps:

Connect the diagnosis testing equipment to disgnosis port and turn it on.

Turn on the “ignition switch”.

(3)Read the related information (fault code, frozen frame, etc.), look up the
Maintenance Manual to confirm defect component and its type, and work
out the maintenance plan according to the relative information and
experiences.

(4) Fault correction.

(5) Clear fault memory, drive the vehicle and the driving mode must satisfy
the corresponding diagnosis condition, and read the fault information to
confirm the removed fault.

Connection of Diagnostic Instrument

This system adopts “K” line communication protocol
and standard diagnostic connector ISO 14230, as shown
in Figure 8-2-1.
The standard diagnostic connector is connected to the
engine harness fixedly. Pins 4, 7 and 16 on the standard
diagnostic connector are used for the engine
management system (EMS).
Pin 4 of the standard diagnostic connector connects with
the ground wire of the vehicle. Pin 7 is connected with
Figure 8-2-1 Standard Diagnostic Connector Pin 71 of the ECU, i.e., “K” line of the engine. Pin 16 is
connected to the positive terminal of the battery.

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 Chapter 8 Electronically Controlled Fuel Ejection System

Section 3 Fault Diagnosis Principles and Examples

The fault code points out the most important fault information, i.e. fault object and type. It can help the maintenance
personnel to locate the fault object quickly and accurately to know the meaning of each fault code and diagnosis
functions to decide the maintenance method.
The following is the meaning of the used fault codes, the corresponding diagnosis policy, ossible causes and handling
policy. They can be used for reference during the vehicle maintenance.
It is worth mentioning that a fault code is the result diagnosed by OBD system on the base of a certain policy for the
appropriate components and system, because the diagnosis policies adopted by the different OBD systems may vary for
the different components and systems. Even the same system may also vary after the diagnosis policy upgrades. These
contents may be changed after the OBD software and data update.
For example, P0030: heating control open circuit of upstream oxygen sensor.
Fault causes:
When the engine starts, the circuit control module in ECU will measure the heating control ciucuit voltage of the
upstream oxygen sensor. When the voltage accords with the opening mode voltage, judge and confirm it is the heating
control ciucuit opening of upstream oxygen sensor.
Schematic circuit:

For example, the heating control circuit of P0031 upstream oxygen sensor is short to ground.

Fault causes:
When the engine starts, the circuit control module in ECU will measure the heating control ciucuit voltage of the
upstream oxygen sensor. When the voltage accords with the voltage of short–to-ground mode, judge and confirm that
the heating control circuit of upstream oxygen sensor is short to ground.

Schematic circuit:

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 Chapter 8 Electronically Controlled Fuel Ejection System

For example, P0133 upstream oxygen sensor is deteriorated.

Fault causes:
The air/fuel ratio of the fuel-air mixture transforms between the rich and lean under normal conditions. Accordingly,
the signal amplitude of the oxygen sensor will jump continuously. The sensibility of the oxygen sensor after
deterioration will decline for the gas mixture, the cycle of signal fluctuation becomes slow. ECU will calculate the
average cycle according to the corresponding calculation method. If finding it slower than preset critical value, judges
and confirms the sensor has been aged.

For example, the control ciucuit of fuel injector of the 1st cylinder P0201 is open.

Fault causes:
When the engine starts, the driver module of fuel injector in ECU will measure the ciucuit voltage. If the voltage
accords with the voltage of open circuit mode, determine it is a open circuit fault.

Schematic circuit:

For example, the control circuit of fuel injector of the 1st cylinder P0261 is short to ground.

Fault causes:

When the engine starts, the driver module of fuel injector in ECU will measure the ciucuit voltage. If the voltage
accords with the voltage of short circuit mode, determine it is a short circuit fault.

Schematic circuit:

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 Maintenance Manual of GW4G13/GW4G15 Gasoline Engines

For example, the 1st cylinder P0301 misses fire.

Fault causes:
An engine misfire signifies that the burning process cannot be interrupted or burn so that the emission exceeds the limit
otherwise the catalytic converter is damaged due to overheating. Because the ignition system can not release ignition
energy effectively in the cylinder (Ignition failure), deviation of fuel ejection amount (concentration deviation of the
mixture) occurs, or the cylinder compression pressure is low or other reasons. As for the OBD system, when the times
of Cylinde 1 misfire exceeds the set value, Cylinde 1 is determined as a misfire.
Faults:
Idle shudder; ② Weak acceleration; ③ Increased fuel consumption; ④ Exceed emission limit.

Section 4 Structure Principles and Fault Analyses of Electronic Fuel Injection

System (EFIS)

The structure and principle of Electronic Fuel Injection System of GW4G15/GW4G13 gasoline engines are shown in
Figure 8-4-1.
The electrical control system of GW4G15/GW4G13 gasoline engines consists of ECU, electronic throttle valve, air
intake pressure & temperauture sensor, fuel injector, electronic accelerator pedal, electronic fuel pump, water
temperauture sensor, fuel pressure regulator, oil pump bracket, camshaft positon sensor, fuel distributing pipe, revolution
speed sensor, canister control valve, knock sensor, ignition coil, oxygen sensor, etc.

Figure 8-4-1 Structure Principle Diagram of Electronic Fuel Injection

System of GW4G15/GW4G13 Gasoline Engines

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 Chapter 8 Electronically Controlled Fuel Ejection System

1 Air Intake Pressure & Temperature Sensor

1.1 Shematic Diagrams and Pins

Skematic diagrams: Air intake pressure & temperature sensor,

as shown in Figure 8-4-2.

Pin:
The circuit of air intake pressure & temperature sensor is shown
in Figure 8-4-3.
Pin 1 is connected to ground.
Figure 8-4-2 Air Intake Pressure & Temperature Pin 2 outputs temperature signal.
Sensor Pin 3 is connected to 5v.
Pin 4 transmits pressure signal.

l 2 Mounting Position
The air intake pressure & temperature sensor consists of two
sensors: absolute pressure sensor of air intake manifold & air
intake temperature sensor, mounted on the manifolds, as shown
Figure 8-4-3 Circuit of Air Intake Pressure & in Figure 8-4-4.
Temperature Sensor
l.3 Operating Principle
The absolute-pressure sensing cell of the air intake manifold
consists of a silicon chip. On the silicon chip, a pressure
diaphragm is etched. There are 4 piezoelectric resistances on the
pressure diaphragm. These piezoelectric resistances act as strain
elements, comprising one wheatstone bridge. Except the
pressure diaphragm on the chip, a signal processing circuit is
integrated. The silicon chip and one metal shell form 1 closed
reference space. The air absolute pressure in the space
approaches zero, thus forming a microelectronics mechanical
system. The active suface of the silicon chip withstands a
presure nearing zero and its back bears the absolute pressure of
Figure 8-4-4 Mounting Position of Air Intake the air intake manifold introduced by a pipe and to be measured.
Pressure & Temperature Sensor Since the thickness of the silicon chip only has a few μm, the
change of absolute pressure of air intake manifold makes the
chip mechanical deformation and 4 piezoelectric resistances also
to deform accordingly, so that the resistance value changes. After
passing the signal disposal circuit of the silicon chip, a voltage
signal of linear relationship with the pressure is produced.

The air intake temperature sensor is a resistance with negative

temperature coefficient (NTC). The resistance varies as air
intake temperature differs. The sensor conveys a voltage
denoting the change of air intake temperature to the controller.

Figure 8-4-5 Definitions of Plug Connectors

1. Grounding 2. NTC 3. 5V 4. Pressure
signal output

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 Chapter 8 Electronic Control Fuel Injection System

1.4 Technical Characteristic Parameters

(1) Limit data
Amount Value
Unit
Min. Typ. Max.
Withstand supply voltage 16 V
Withstand pressure 500 kPa
Withstand storage temperature -40 +130 ℃

(2) Characteristic data

Value
Amount Unit
Min. Typ. Max.
Pressure testing range 10 115 kPa
Operating temperature -40 130 ¡æ
Operating supply voltage 4.75 5.0 5.25 V
Current at Us=5.0V 6.0 9.0 12.5 mA
Load current of output circuit -0.1 O.5 mA
Negative resistance to ground or Pull up 5
battery Pull down 10 kΩ

Response time 1 ms
Mass 27 g

(3) Transfer function of pressure sensor

UA=(C1 Pabs+C0)Us
Where, UA= Signal output voltage (V)
Us= Supply voltage (V)
Pabs= Absolute pressure (kPa)
C0=-0.1/105
C1=0.85/105(KPa-1)

From what can be seen above, the signal output voltage of the pressure sensor approaches the supply voltage.
If the supply voltage is 5V, the signal output voltage of the pressure sensor is equal to 4V when the throttle valve is full
open.
(4) Limit data of temperature sensor
Storage temperature: -40℃~130℃.
Loading capacity at 25℃: l00mW.

(5) Characteristic data of temperature sensor

Operating temperature: -40℃~130℃.
Rated voltage: The front end resistance 1 kΩ runs at 5 V, or runs at the testing current of ≤ lmA.
Rated resistance at 20℃: 2.5kΩ ± 5％.
air temperature/time coefficient 63: v = 6m/s: ≤ l0s.

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 Chapter 8 Electronic Control Fuel Injection System

1.5 Installation Precautions

(1) Intake pressure & temperature sensor is installed on the plane
of engine intake manifold as shown in Figure 8-4-6. Both the
pressure tube and temperature sensor protrude into the intake
manifold and an O ring is used for air sealing.
(2) Mount the intake & temperature sensor onto the vehicle in a
correct way (i.e. pressure is drawn from the intake manifold,
pressure tube inclines downwards, and so on) to ensure no
condensed water will form on the pressure sensitive elements.
(3) The drilling and fixation on the intake manifold must be
carried out as shown in the manufacturer’s drawing to ensure
that the sealing and resistance can withstand medium corrosion.
(4) Reliable electrical connection of part connector is mainly
Figure 8-4-6 Installation of Intake Pressure & affected by connector itself and also related to the material
quality and dimensional precision of its matching connector on
Temperature Sensor
the wiring harness.
1.6 Symptoms and Diagnostic Methods
Symptoms:
Engine misfire, poor idle speed, etc.
Common causes of failure:
(1) Abnormal high voltage or inverse heavy current occurs
during use.
(2) Vacuum components are damaged during repair.
Repair precautions:
(1) Never spray high-pressure gas to vacuum components when
carrying out repair.
(2) When replacing the sensor, check whether alternator output
voltage and current are normal.
Simple measuring methods:
Temperature sensor: (Disconnect the connector) set the digital
multi-meter (DMM) to Ohms and connect both styli respectively
to the sensor’s Pins 1 and 2 (as shown in Figure 8-4-3), and its
rated resistance at 20℃ is 2.5kΩ ± 5%. Other corresponding
resistance values can be measured as shown in Figure 8-4-7
NTC Resistance Characteristic Curve of Intake Temperature
Sensor. Simulation method can also be used for resistance
measurement; specifically, blow the sensor with a hair drier (do
not be close) and observe the sensor’s resistance, and the
resistance should decrease.
Pressure sensor: (Connect the connector) set digital multi-meter
to DC voltage position, ground the black stylus and connect the
red stylus respectively to Pins 3 and 4 (as shown in Figure 8-4-3).
At idle speed, there should be a 5V reference voltage at Pin 3
and about 1.3V (exact value depends on vehicle model) at Pin 4;
Figure 8-4-7 NTC Resistance Characteristic Curve of in no-load condition, the voltage at Pin 4 will not change
Intake Temperature Sensor obviously when the throttle is opened slowly, but it will rise to
about 4V (exact value depends on vehicle model) in a second
and then drop to about 1.5V (exact value depends on vehicle
model) when the throttle is opened quickly.

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2. Knock Sensor
2.1 Schematic Diagrams and Pins
Schematic diagrams: Knock sensor is shown in Figure 8-4-8 and
Figure 8-4-9.

Figure 8-4-8 Knock Sensor w/o Cable

Figure 8-4-9 Sectional View of Knock Sensor

1- vibration block; 2- shell; 3- piezoelectric ceramic body;
4- contact; 5- electrical connector
Pins:
The circuit diagram of knock sensor is shown in Figure 8-4-10.
Pins 1 and 2 connect to ECU.
2.2 Mounting Position
Knock sensor is mounted between Cylinders 2 and 3 as shown in
Figure 8-4-12.

2.3 Working Principles

Figure 8-4-10 Circuit Diagram of Knock Sensor One or more knock sensors, as vibration acceleration format, are
mounted onto the engine cylinder block. The sensitive element
of knock sensor is a piezoelectric element. The vibration of
engine cylinder block is transferred to piezoelectric crystal via
the mass block in the sensor. Thanks to the pressure arising from
mass block vibration, piezoelectric crystal generates voltage on
two pole faces and changes vibration signal into alternating
voltage signal and export it. The frequency response
characteristic curve is shown in Figure 8-4-11. The frequency of
vibration signal caused by engine knock is much higher than that
of normal vibration signal, so ECU can distinguish knock signal
Figure 8-4-11 Frequency Response Characteristic Curve from normal signal after processing the signal of knock sensor.
of Knock Sensor

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2.4 Technical Characteristic Parameters

(1) Limit data
Value
Parameter Unit
Min. Typ. Max.
Working temperature -40 +130 ℃

(2) Characteristic data

Parameter Value Unit

New sensor’s sensitivity to 9kHz signal 23-36.3 mV/g
New sensor’s sensitivity to 17kHz signal 24-45.0 mV/g
2
Linear velocity during vibration (5kHz, 20 ~ 100m/s relative
≤±10％ mV/g
to 5m/s2)
Main resonance frequency >30 kHz
Resistance >6 MΩ
Impedance
Capacitance 1150±200 pF
Leakage resistance (the resistance between the sensor’s two
4.9±20％ MΩ
output pins)
Sensitivity shift caused by temperature ≤-0.04 mV/g*K

2.5 Installation Precautions

With a hole in the middle, just use 1 hexagon flange bolt (M8 × 30)
to fasten knock sensor to the cylinder block with 20N·m ± 5N·m of
tightening torque. The mounting position should ensure that it is
easy for the sensor to receive vibration signals from all the cylinders.
The optimum mounting position should be determined through the
modal analysis on engine body. For 4-cylinder engines, the knock
sensor is usually mounted between the Cylinders 2 and 3 as shown
in Figure 8-4-12. Be careful not to leave the sensor exposed to such
liquids as engine oil, coolant, brake fluid and water for a long time.
It is not allowed to use any gasket or washer when installing. The
sensor’s metal surface must be tightly attached to the cylinder block.
When laying the sensor’s signal cable, be careful to prevent signal
cable from resonance in order to avoid breakage. Be sure not to
apply high voltage between the Pins 1 and 2, otherwise low-voltage
electric elements may be damaged.
2.6 Symptoms and Diagnostic Methods
Faults: Bad acceleration, etc.
Common fault causes: The sensor is corroded due to long-term
Figure 8-4-12 Mounting Position of Knock Sensor exposure to such liquids as engine oil, coolant, brake fluid and water,
etc.
Repair precautions: Refer to Installation Precautions.
Simple measuring methods: (Disconnect the connector) set digital
multi-meter to Ohms position and connect its two styli respectively
to the Sensors 1 and 2 and Pins 1 and 3, and the resistance at normal
temperature should be higher than 1MΩ. Set the digital multi-meter
to mV (millivolt) position and gently hit near the knock sensor, and
there should be a voltage signal output.

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3. Oxygen Sensor
3.1 Schematic Diagrams and Pins
Schematic diagrams: The structure of oxygen sensor is shown in
Figure 8-4-13.

Figure 8-4-13 Sectional View of Oxygen Sensor

1- cable; 2- butterfly washer; 3- insulating bushing; 4-
protective sleeve; 5- heating element clamping joint; 6-
heating rod; 7- contact gasket; 8- sensor seat; 9- ceramic
probe; 10- protecting tube Each oxygen sensor is provided with cable as shown in Figure
8-4-14. The other end of cable is an electrical connector.

Pins:
The electrical connector of oxygen sensor has 4 pins (see Figure
8-4-15):
1# pin connects to heating power supply positive terminal
(white).
2# pin connects to heating power supply negative terminal
(white).
3# pin connects to signal negative terminal (grey).
Figure 8-4-14 Oxygen Sensor 4# pin connects to signal positive terminal (black).

3.2 Mounting Position

Oxygen sensor is mounted at the front end of exhaust pipe.

3.3 Working Principles

The sensing element of oxygen sensor is a ceramic tube with
pore, and the tube’s outer wall is surrounded by engine exhaust
while air flows through its inner wall. The ceramic tube wall is
of solid electrolyte and embedded with electric heating tube as
shown in Figure 8-4-13.
The function of oxygen sensor is achieved by changing oxygen
ion concentration difference between the inner and outer walls of
Figure 8-4-15 Circuit Diagram of Oxygen Sensor
the sensing ceramic tube into voltage signal output. The sensing
ceramic tube will have the characteristics of solid electrolyte
upon its temperature reaching 350℃. Its special material enables
oxygen ions to pass freely. Just for this characteristic,
concentration difference is changed into potential difference to
form electric signal output. In case of rich mixture, oxygen ion
concentration difference between inner and outer walls of
ceramic tube and potential difference will be relatively high, and
large numbers of oxygen ions will move out and the output
voltage will be relatively high (close to 800mV ~ 1,000mV); in
case of lean mixture, oxygen ion concentration difference
between inner and outer walls of ceramic tube and potential
difference will be low, whilst only a few oxygen ions will move
Figure 8-4-16 Characteristic Curve of Oxygen from inside to outside, and the output voltage will be low (close
Sensor at 600℃ to 100mV). The signal voltage changes abruptly at a theoretical
equivalent air/fuel ratio (λ=1) as shown in Figure 8-4-16.

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3.4 Technical Characteristic Parameters

(1) Limit data

Value
Parameter Unit
Min. Typ. Max.
Ceramic tube end (exhaust temperature) 150 930 ℃
Housing hexagon head (exhaust
≤570 ℃
Working temperature temperature)
Cable retaining ring and connecting cable ≤250 ℃
Connecting plug ≤120 ℃
Random vibration (peak) ≤1000 m/s2
Simple harmonic vibration (vibration
Permissible housing ≤0.3 Mm
displacement)
vibration
Simple harmonic vibration (vibration
≤300 m/s2
acceleration)
Continuous DC current at 350℃ Absolute value≤10 μA
Maximum continuous AC current when exhaust temperature ≥ 350℃
≤10 μA
and f≥1Hz
Permissible fuel additives Additives conforming to DIN EN 228 for commercial use
Permissible value and data must be determined through a proper
Oil consumption and combustion
scale of test by customers. Guideline value: ≤0.7L/1,000km

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(2) Electrical data

Parameter Value Unit

Insulation resistance between new sensor Room temperature, heating element
≥30 MΩ
heating element and sensor connector powerdown
Rated voltage 12 V
Continuous working voltage 12 ~ 14 V
Be able to keep working voltage for at most
1% of total life (exhaust temperature 15 V
Supply voltage of plug
≤850℃)
Be able to keep working voltage for at most
18 V
75s (exhaust temperature ≤350℃)
Test voltage 13±0.1 V
Maximum heating current 2.1 A

(3) Service life

The service life of oxygen sensor is related to gasoline lead content.

Relationship between the Service Life of Oxygen Sensor and Gasoline Lead Content

Service Life
Gasoline Lead Content (g/L)
(km)
≤0.6 20000
≤0.4 30000
≤0.15 60000
≤0.005 (unleaded gasoline) 160000

3.5 Installation Precautions

(1) Oxygen sensor is mounted on the exhaust pipe and the
mounting position should represent exhaust composition and
meet specified temperature limit. The installation point should
be as much close to the engine as possible. The exhaust pipe
should have screw thread for tightening the oxygen sensor as
shown in Figure 8-4-17

Figure 8-4-17 Mounting Position of Oxygen sensor

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(2) Mounting configuration of oxygen sensor: As shown in

Figure 8-4-18, oxygen sensor should be mounted in such a way
that it makes an angle not less than 10° with horizontal plane and
its tip is downward to avoid condensate accumulation between
sensor shell and sensing ceramic tube during cold start.
(3) Requirements for exhaust pipe: It is required to make the
exhaust pipe in the zone before oxygen sensor be heated rapidly.
If possible, exhaust pipe should be designed to tilt down to avoid
condensate accumulation before oxygen sensor.
(4) Do not make the cable retaining rings at the side of oxygen
sensor be heated improperly, especially after engine cutoff.
Figure 8-4-18 Mounting Configuration of Oxygen Sensor (5) Do not use cleaning liquid, oily liquid or volatile solid on the
plug of oxygen sensor.
(6) The screw thread of oxygen sensor is M18 × 1.5 × 30.

(7) The hexagon wrench of oxygen sensor is 22

(8) The tightening torque of oxygen sensor is 50N·m ± 10N·m.

3.6 Symptoms and Diagnostic Methods

Faults:
Bad idle speed, poor acceleration, excessive emissions, high fuel
consumption, and more.

Common fault causes:

(1) Moisture and vapor entry into oxygen sensor, temperature
shock and probe breakage.
(2) Oxygen sensor “poisoning” (poisoning elements Pb, S, Br
and Si).
Repair precautions:
It is prohibited to use cleaning liquid, oily liquid or volatile solid
Figure 8-4-19 Mounting Diagram of Oxygen Sensor on oxygen sensor during repair.
Simple measuring methods:
(Disconnect the connector) set the digital multi-meter to Ohms
position and connect its two styli respectively to the sensor’s
Pins 1 (white) and 2 (white) (as shown in Figure 8-4-15), and the
resistance value at normal temperature should be about 9Ω.
(Connect the connector.) at idle speed, wait until oxygen sensor
reaches its working temperature 350℃, then set the digital
multi-meter to DC voltage position and connect its two styli
respectively to the sensor’s Pins 3 (grey) and 4 (black) (as shown
in Figure 8-4-15), and the voltage should fluctuate rapidly within
the range of 0.1V ~ 0.9V.

4. Inductive Revolution Speed Sensor

(Only for distributorless ignition system)
Figure 8-4-20 Inductive Revolution Speed Sensor

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4.1 Schematic Diagrams and Pins

Schematic diagrams: Inductive revolution speed sensor is shown
in Figure 8-4-20 and Figure 8-4-21.

Figure 8-4-21 Inductive Revolution Speed Sensor

1- permanent magnet; 2- sensor shell; 3- mounting
bracket; 4- soft magnet core; 5- coil; 6- air gap; 7- ring
gear
The circuit diagram of inductive revolution speed sensor is
shown in Figure 8-4-22.

Pins: The inductive revolution speed sensor used for electronic

control system adopts the connector as showed in Figure 8-4-23.
Figure 8-4-22 Circuit Diagram of Revolution Speed
Sensor 4.2 Mounting Position
Inductive revolution speed sensor is mounted on the
transmission housing at the rear of engine.

4.3 Working Principles

Inductive revolution speed sensor works together with the pulse
disc to provide engine speed information and crankshaft TDC
(top dead center) information for distributorless ignition system.
It is composed of 1 permanent magnet and the coil on its surface.
The pulse disc is a toothed disc originally with 60 teeth but 2
teeth vacant. The pulse disc is mounted on and rotates with the
crankshaft. When tooth tips pass close to the end of inductive
Figure 8-4-23 Connector of Inductive Revolution Speed
Sensor revolution speed sensor, the pulse disc made of ferromagnetic
material will cut the magnetic lines of force of the permanent
magnet in the inductive revolution speed sensor and generate
induced voltage in the coil, which is exported as revolution
speed signal.

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4.4 Technical Characteristic Parameters

(1) Limit data

Value
Parameter Unit
Min. Typ. Max.
Coil zone -40 +150 ℃
Endurable temperature of Transition zone -40 +130 ℃
inductive revolution speed Storage temperature -20 +50 ℃
sensor Ambient temperature when not in
-40 +120 ℃
operation
Permissible magnetic field intensity of external magnetic field ≤2 kA/m
Insulation resistance (5s, test voltage New state ≥0.8 MΩ
500V) Expiry of service life ≥100 kΩ
Withstand voltage (1 ~ 3s, 400V AC)
Connection points:
Not be punctured
1. Between DG surface and plug conducting strip
2. Between pole pin and plug conducting strip

(2) Characteristic data

Parameter Value Unit

Resistance at room temperature 23℃ 1200±15％ W
Inductance (1,000HZ series circuit) 750±15％ mH
Output voltage when crankshaft RPM (revolutions per minute) is 416 >500 mV

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4.5 Installation Precautions

(1) Be sure to unpack the inductive revolution speed sensor just
before mounting it on the vehicle or test device.
(2) Mount the inductive revolution speed sensor by pressing not
by knocking.
(3) It is recommended to use partially microencapsulated bolt
(M6 × 12) for fastening the inductive revolution speed sensor.
(4) Tightening torque should be 8N·m ± 2N·m.
(5) The air gap between inductive revolution speed sensor and
pulse disc tooth tip should be 0.5 ~ 1.5mm.
Figure 8-4-24 Three Temperature Zones of Revolution (6) Central offset (see Figure 8-4-25): ≤1.0mm.

4.6 Symptoms and Diagnostic Methods

Faults:
Start failure, etc.
Common fault causes:
Man-made failure.
Repair precautions:
Mount the inductive revolution speed sensor by pressing not by
knocking during repair.

Figure 8-4-25 Installation of Revolution Speed Sensor Simple measuring methods:

(Disconnect the connector) set digital multi-meter to Ohms
position and connect its two styli respectively to the sensor’s 2#
and 3# pins, and the rated resistance at 23℃ is 1,200Ω ± 15%.
(Connect the connector) set digital multi-meter to AC voltage
position, connect its two styli respectively to the sensor’s 1# and
2# pins and start the engine, there should be voltage output. (It is
recommended to check using the oscilloscope for car use.)

Figure 8-4-26 Test Waveform 5. Cam Phase Sensor

(Only for distributorless ignition system)
5.1 Schematic Diagrams and Pins
Schematic diagrams: Cam phase sensor is shown in Figure
8-4-27.

Figure 8-4-27 Cam Phase Sensor

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Pins:
The circuit diagram of cam phase sensor is shown in Figure
8-4-28.
Pin 1 is to be grounded;
Pin 2 is for signal output;
Pin 3 is to connect 5V.

Figure 8-4-28 Circuit Diagram of Cam Phase Sensor

5.2 Mounting Position
Cam phase sensor is mounted at the rear end of cylinder head
and fastened by 1 hexagon flange bolt (M6 × 12) as shown in
Figure 8-4-29.

Figure 8-4-29 Mounting Position of Cam Phase Sensor

5.3 Working Principles
Cam phase sensor uses Hall principle, i.e. Hall voltage is formed
by the change of magnetic field induction intensity.
Principle of Hall sensor
When current IS passes through a semiconductor slice, Hall
voltage UH will be generated in the right-hand direction of
current and its value is in direct proportion to magnetic field
induction intensity B (at right angles to current IS) and current IS.
Hall voltage is affected by the change of magnetic field
Figure 8-4-30 Principle of Hall Sensor induction intensity B as shown in Figure 8-4-30.
5.4 Technical Characteristic Parameters
Limit data
Value
Parameter Unit
Min. Typ. Max.
Ambient
-40 +130 ℃
temperature
Mounting
0.2 1.8 Mm
clearance
Supply voltage 4.75 16 V
Figure 8-4-31 Schematic Working Diagram of Hall
Element (1)

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5.5 Installation Precautions

As shown in Figure 8-4-33, there is only one hole for fastener on
the shell of cam phase sensor.
5.6 Symptoms and Diagnostic Methods
Faults:
Emission excess and fuel consumption increase, etc.
Common fault causes:
Man-made failure.
Simple measuring methods:
(Connect the connector) turn on the ignition switch but do not
start the engine, set digital multi-meter to DC voltage position
and connect its two styli respectively to the sensor’s 3# and 1#
pins (see Figure 8-4-28), there should be 12V reference voltage.
Start the engine and check whether the signal at 2# pin is normal
Figure 8-4-32 Schematic Working Diagram of Hall with the oscilloscope for car use.
Element (2)
6. Electronic Control Unit (ECU)
6.1 Mounting Position
ECU is mounted at the side of vehicle cabin.

6.2 Working Principles

(1) Functions
Sequential multi-port injection
Ignition control
Idle speed control
Knock control
Power supply of sensor: 5V/100mA
λ closed-loop control with adaptive control
Control of canister control valve
Figure 8-4-33 Cam Phase Sensor Air-conditioner switch
Engine MIL (malfunction indicator lamp)
Fuel quantitative correction
Engine speed signal output (TN signal)
Vehicle speed signal input
Fault self-diagnosis
Receiving of engine load signal
etc.

Figure 8-4-34 External View of ECU

(2) Definition of ECU pins (for reference)

Pin Connection Point Pin Connection Point

1 Ignition coil 2 6 Fuel injector of the 2nd cylinder
2 Ignition coil 3 7 Fuel injector of the 3rd cylinder
3 Ignition ground 8 Engine speed output
4 Ignition coil 4 9
5 Ignition coil 1 10

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(Continued)
Pin Connection Point Pin Connection Point
11 47 Fuel injector of the 4th cylinder
12 Continuous power supply 48 Variable camshaft timing
13 Ignition switch 49
14 Main relay 50 Low-speed fan control
15 Engine speed sensor A 51 Electronic ground 2
16 Acceleration pedal module 1 52
17 Sensor ground 1 53 Electronic ground 1
18 Upstream oxygen sensor 54 Electronic throttle position sensor 1
19 Knock sensor A 55 Downstream oxygen sensor
20 Knock sensor B 56
21 Stop lamp 57 Medium-voltage switch
22 Air-conditioner temperature sensor 58 Brake switch
23 59 Vehicle speed sensor
24 60
25 61 Power ground 1
26 Upstream oxygen sensor heating 62
st
27 Fuel injector of the 1 cylinder 63 Non-continuous power supply
28 Downstream sensor heating 64 Electronic throttle control
29 MIL 65 Electronic throttle control
30 66 Electronic throttle control
31 EOBD detecting lamp (MIL) 67 Electronic throttle control
32 5V power supply 2 68 High-speed cooling fan relay
33 5V power supply 1 69 Air-conditioner compressor relay
34 Engine speed sensor B 70 Fuel pump relay
35 Sensor ground 3 71 Diagnostic K line
36 Sensor ground 2 72
37 Intake pressure sensor 73 Immobilizer
38 Electronic throttle position sensor 2 74 Clutch switch
39 Engine coolant temperature sensor 75 Air-conditioner switch
40 Acceleration pedal module 2 76 Electronic load 1
41 77
42 Intake temperature sensor 78 Sensor ground 4
43 79 Phase sensor
44 Non-continuous power supply 80 Power ground 2
45 Non-continuous power supply 81
46 Canister valve

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6.3 Technical Characteristic Parameters

Limit data

Value
Parameter Unit
Min. Typ. Max.
Normal running 9.0 16.0 V
Battery voltage
Limited functions 6.0 ~ 9.0 16.0 ~ 18.0 V
Maintain partial functions, can
26.0V 60 S
Limit and time of withstand perform fault diagnosis
battery over-voltage Ensure starting function, can
–13.0 V 60 S
perform fault diagnosis
Working temperature –40 +70 ℃
Storage temperature –40 +90 ℃

6.4 Installation Precautions

(1) Be sure to protect against static during installation.
(2) Be sure to protect plug pins.

6.5 Symptoms and Diagnostic Methods

Faults:
Unstable idle speed, bad acceleration, failed startup, high idle speed, excessive emission, starting difficulty,
air-conditioner malfunction, fuel injector control failure, engine misfire, etc.

Common fault causes:

(1) Overload of external device/electrical appliance causes the burnout of ECU internal parts and further results in
failure.
(2) Water intrusion into ECU causes circuit board corrosion, etc.

Repair precautions:
(1) Do not disassemble ECU without reason during repair.
(2) Disconnect battery terminals and leave them disconnected for at least 5min before disassembling ECU.
(3) Be careful to store ECU properly after disassembly.
(4) Never add any circuit onto the ECU connecting wires.

Simple measuring methods:

(1) (Connect the connector) read engine failure record through engine data cable K.
(2) (Disconnect the connector) check whether ECU connecting wires are in good condition, especially ECU power cord
and ground wire.
(3) Check whether external sensor is working normally, if output signal is reliable and its wiring in good condition.
(4) Check actuator for proper operation and for integrity of its wiring.
(5) Finally, replace ECU and perform the test.

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7. Electric Fuel Pump

7.1 Schematic Diagrams and Pins
Schematic diagrams: Electric fuel pump is shown in Figure
8-4-35.

Figure 8-4-35 Electric Fuel Pump

Pins:
The circuit diagram of electric fuel pump is shown in Figure
8-4-36.
Electric fuel pump has two pins to connect to fuel pump relay.
There are “+” and “-” marks on fuel pump shell beside the two
pins and respectively indicate “connect to positive pole” and
“connect to negative pole”.

Figure 8-4-36 Circuit Diagram of Electric Fuel Pump

7.2 Mounting Position
Electric fuel pump is mounted in fuel tank as shown in Figure
8-4-37.

7.3 Working Principles

Electric fuel pump is composed of DC motor, vane pump and
end cover (integrated with check valve, relief valve and
anti-EMI components), etc., as shown in Figure 8-4-38.
Fuel pump and motor are mounted on the same axis and
enclosed in the same casing. The fuel pump and motor in the
Figure 8-4-37 Mounting Position of Electric Fuel Pump casing are surrounded by gasoline, which is used for heat
dispersion and lubrication. Battery supplies power for electric
fuel pump via fuel pump relay. The relay makes the circuit of
electric fuel pump closed only at the time of its activation and
when the engine is running. Electric fuel pump will
automatically stop running once the engine stops running due to
any accident.
The maximum outlet pressure of the electric fuel pump depends
on the pressure relief valve and it is within 450 ~ 650kPa.
However, the pressure of the whole fuel system varies with the
fluctuation of the intake manifold pressure. The pressure
Figure 8-4-38 Sectional View of Electric Fuel Pump
1- fuel pump end cover; 2- motor; 3- oil gallery; 4- vane difference between the fuel system and intake manifold depends
pump on the fuel pressure regulator.

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7.4 Technical Characteristic Parameters

(1) Limit data
Value
Parameter Unit
Min. Typ. Max.
Working voltage 8 14 V (DC)
System pressure 380 kPa
Ambient temperature (applicable to
-40 +80 ℃
storage and transportation)
Permissible fuel temperature -30 +70 ℃
Permissible vibration acceleration 20 m/s2
(2) Characteristic data
The flow of electric fuel pump at certain fuel pressure is in direct proportion to voltage. Complete vehicle manufacturers
may use different electric fuel pumps.

7.5 Installation Precautions

The electric fuel pump should be stored in the sealed original package. It can be stored at most 6 months once it is
installed on the vehicle but at most 4 years as spare part. Beyond such time, the performance data of electric fuel pump
should be rechecked by the manufacturer before use. Electric fuel pump in its storage place must be protected against
atmospheric influence and its original package must not be damaged during storage.
Electric fuel pump is only used in fuel tank. When installing electric fuel pump, be sure to install inlet filter screen with
mesh size not larger than 60μ or mutually agreed upon negotiation with the customer. Ensure the fuel from vent hole will
not spray to inlet filter screen, electric fuel pump bracket or fuel tank. Be sure to handle electric fuel pump with care.
Ensure inlet filter screen is free from load and impact. Be sure to take out the pump carefully from plastic package and
remove its protective cover just before installation. It is strictly prohibited to remove the inlet filter screen. The foreign
bodies entering into the electric fuel pump inlet or filter screen may damage the pump.
Keep clean when installing fuel pipe. Ensure inner wall of fuel pipe is clean. Use new fuel pipe clamps and determine
their positions as recommended by the manufacturer.
Do not hold fuel pump at fuel pipe or inlet filter screen.
Do not allow electric fuel pump to run dry to avoid damage. Do not use the electric fuel pump having been damaged or
once dropped onto the ground. If fuel tank is dropped onto the ground, replace the electric fuel pump in it.
It is not allowed to apply pressure onto fuel inlet plate. There must not be mechanical stress at seams.

7.6 Symptoms and Diagnostic Methods

Faults:
Loud noise of running, bad acceleration, startup failure (starting difficulty), etc.
Common fault causes:
The use of inferior fuel results in the following consequences: 1) Gum deposit forms insulating layer; 2) Electric fuel
pump bushing and armature are locked.
Repair precautions:
(1) Due to different flow, electric fuel pump should be selected as required by the engine. Those electric fuel pumps with
same shape and proper size are not necessarily suitable for the engine. During service, be sure to use an electric fuel
pump with same part number as the original.
(2) Do not allow electric fuel pump to run dry to avoid damage.
(3) In case of replacement of electric fuel pump, please clean fuel tank and pipeline and replace fuel filter.

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(Disconnect the connector) set digital multi-meter to Ohms

position and connect its two styli respectively to the two pins of
electric fuel pump to measure internal resistance, and the value
should not be 0 or infinite (i.e. not in short-circuit and
open-circuit state).
(Connect the connector) connect fuel pressure gauge to fuel inlet
pipe, start the engine and observe whether the electric fuel pump
works; if the pump does not work, check whether there is supply
Figure 8-4-39 Electromagnetic Fuel Injector voltage at “+” pin.

8. Electromagnetic Fuel Injector

8.1 Schematic Diagrams and Pins
Schematic diagrams: Electromagnetic fuel injector is shown in
Figure 8-4-39.
The structure of electromagnetic fuel injector is shown in Figure
8-4-40.

Figure 8-4-40 Sectional View of Electromagnetic Fuel

Injector
1- O ring; 2- filter screen; 3- fuel injector body with plug;
4- coil; 5- spring; 6- valve needle with coil armature; 7-
valve seat with nozzle hole plate Pins: Each fuel injector has 2 pins. The one with “+” mark on
one side of the fuel injector housing is to connect 87# pin of
main relay output end; the other is respectively to connect the
pins 27, 7, 6 and 47 of ECU, as shown in Figure 8-4-41.

8.2 Mounting Position

Electromagnetic fuel injector is mounted on welded fuel rail
assembly as shown in Figure 8-4-42. The fuel rail assembly is
Figure 8-4-41 Circuit Diagram of Electromagnetic Fuel mounted at the air intake side of cylinder head.
Injector
8.3 Working Principles
ECU sends electrical pulses to the coil of fuel injector and forms
magnetic force. When the magnetic force rises enough to
overcome the resultant force of return spring pressure, needle
valve gravity and friction force, the needle valve will lift and
fuel injection will start. Moreover, the needle valve will close
under the return spring pressure upon fuel injection pulses being
cut off.

Figure 8-4-42 Fuel Rail and Fuel Injectors

Simple measuring methods:

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GW4G15/GW4G13 gasoline engines are equipped with EV6 electromagnetic fuel injector.

8.4 Technical Characteristic Parameters

(1) Characteristic data

Value
Parameter Unit
Min. Rated Max.
Working pressure (pressure difference) 380 kPa
Resistance of fuel injector at 20℃ 11.4 12 12.6 Ω

(2) Permissible fuel

It is recommended that fuel injector use unleaded gasoline. To obtain perfect engine performance, please select No.93
(the octane number is 93) or higher grade premium unleaded gasoline. It is required to add detergent in gasoline, because
the use of unsuitable fuel may damage the engine. It should be especially noted that gasoline would deteriorate in case of
overlong storage. Especially, the taxi, equipped with LPG/gasoline dual fuel engine, uses LPG as fuel for long time and
only uses gasoline for starting, and thus its daily gasoline consumption is quite low. However, due to long-time running
of fuel pump, the temperature of fuel tank is rather high. The gasoline in such a fuel tank is oxidized and deteriorated
easily and may clog or damage the fuel injector.

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8.5 Installation Precautions

(1) Confirm BOSCH trademark and product identification number.
(2) Be sure to use the plug specially designed for the fuel injector and do not misuse.
(3) For easy installation, it is recommended to apply silicon-free clean oil on the surface of upper O ring connected to the
fuel distributing pipe. Be careful to prevent oil from entering fuel injector and nozzle hole.
(4) Install the fuel injector into its seat vertically to the seat and then fasten it to the seat with clamps.

Notes:
1) The clamps for the fuel injector include the axial and axial-radial positioning clamps depending on the position type. 2)
When installing the fuel injector that requires axial positioning, be sure that the bayonet in the middle of clamp is locked
into the slot of fuel injector and the slot on both sides of clamp is locked into the flanging of fuel injector seat. 3) When
installing the fuel injector that requires axial and radial positioning, use axial-radial positioning clamp and make the
positioning block of fuel injector and the positioning pin of fuel injector seat respectively in the appropriate slot of the
positioning clamp. 4) If the fuel injector has two slots, use care not to misplace and refer to the mounting diagram of
original parts.
(5) Install the fuel injector manually and do not knock it with such tools as hammer or others.
(6) When disassembling and reassembling the fuel injector, be sure to replace O ring and not to damage the sealing
surface of fuel injector.
(7) Do not pull out the supporting bead of O ring from the fuel injector. When installing, be careful not to damage the
fuel inlet pipe end, O ring, support ring, nozzle hole plate and plug of fuel injector. If damaged, do not use again.
(8) After finishing the installation of fuel injector, perform seal test on fuel distributing pipe assembly and consider it as
qualified only if no leakage.
(9) Be sure to disassemble defective parts manually as follows: remove the clamp of fuel injector and then pull out the
fuel injector from its seat. Also, be sure to keep the fuel injector seat clean and avoid pollution after disassembly.

8.6 Symptoms and Diagnostic Methods

Faults:
Bad idle speed, poor acceleration and startup failure (starting difficulty), etc.
Common fault causes:
Due to inadequate maintenance, gum deposit occurs in the interior of the fuel injector and thus causes failure.
Repair precautions:
Refer to Installation Precautions.
Simple measuring methods:
(Disconnect the connector) set digital multi-meter to Ohms position, connect its two styli respectively to the two pins of
the fuel injector and select 12Ω/14.5Ω/15.95Ω as the rated resistance (at 20℃) of EV6 electromagnetic fuel injector.
Recommendation: Use special cleaning analyzer to perform periodic cleaning analysis on the fuel injector.

9. Canister Control Valve

9.1 Schematic Diagrams and Pins
Schematic diagrams: Canister control valve is shown in Figure
8-4-43.

Figure 8-4-43 Canister Control Valve TEV-2

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The structure of canister control valve is shown in Figure 8-4-44.

Figure 8-4-44 Sectional View of Canister Control Valve Pins: Canister control valve has only two pins, one connects to
main relay output end and the other connects to ECU as shown
in Figure 8-4-45.

Figure 8-4-45 TEV2 Pin Definition Diagram 9.2 Mounting Position

Canister control valve is mounted on the vacuum pipe between
the canister and intake manifold as shown in Figure 8-4-46.

9.3 Working Principles

Canister control valve is composed of electromagnetic coil,
armature and valve, etc. A filter screen is set at inlet. The air
flow through canister control valve is not only related to the duty
ratio of electrical pulses sent to canister control valve by ECU,
but also related to the pressure difference between the inlet and
Figure 8-4-46 Mounting Diagram of Canister Control
outlet of canister control valve. Canister control valve is closed
Valve
1- from fuel tank; 2- canister; 3- air; 4- canister control when there is no electrical pulse.
valve; 5- to intake manifold; 6- throttle
△P means the difference between ambient pressure (Pu)
and intake manifold pressure (Ps):
The flow at 100% duty ratio (i.e. full open) varies with the type
of canister control valve. Figure 8-4-46 shows two typical flow
curves. As shown in Figure 8-4-47, under the pressure difference
of 200mbar and at full open position, the flow of Type A and B
canister control valves is 3.0m3/h and 2.0m3/h respectively.
(Type B is selected in this project.)

Figure 8-4-47 Flow Diagram of Canister Control Valve

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9.4 Technical Characteristic Parameters

(1) Limit data
Value
Parameter Unit
Min. Typ. Max.
Working voltage 9 16 V
1min over-voltage 22 V
Minimum starting voltage 7 V
Minimum release voltage 1.0 V
Permissible working temperature -30 +120 ℃
Permissible short-time working temperature +130 ℃
Permissible storage temperature -40 +130 ℃
Permissible pressure difference between the inlet
800 mbar
and outlet
Permissible on-off times 108
Permissible vibration acceleration on the product 300 m/s2
Leakage rate at 400mbar pressure difference 0.002 m3/n

(2) Characteristic data

Item Value
TEV power off Closed
Rated voltage 13.5V
Minimum pickup voltage 7V
Resistance (at +20℃) 26Ω
Current at rated voltage 0.5A
Standard trigger pulse (type B and D) ～6ms
Leakage rate (at 400mbar pressure difference) ≤0.002 m3/h

9.5 Installation Precautions

Canister control valve is connected with canister and intake manifold as shown in Figure 8-4-46.
(1) To avoid transmission of solid-borne sound, it is recommended to suspend canister control valve from the hose.
(2) Be sure to meet the requirements for airflow direction when installing.
(3) Be sure to take proper measures (e.g. filtration, purification, etc.) to prevent such foreign bodies as particles from
entering canister control valve via canister or hose.
(4) It is recommended to mount a protective filter (mesh size < 50μm) at the canister outlet.

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9.6 Symptoms and Diagnostic Methods

Faults:
Function failure, etc.
Common fault causes:
The entry of foreign bodies into valve causes corrosion or bad
sealing performance, etc.
Repair precautions:
(1) Be sure to meet the requirements for airflow direction when
installing.
(2) When canister control valve fails to work due to black
particles in the valve body and needs to be replaced, please
check the condition of canister.
(3) Prevent such liquids as water and oil from entering the valve
as possible during repair.
(4)To avoid transmission of solid-borne sound, it is
recommended to suspend canister control valve from the hose.
Simple measuring methods:
(Disconnect the connector) set digital multi-meter to Ohms
position and connect its two styli respectively to the two pins of
canister control valve, and rated resistance at 20℃ is 26Ω ± 4Ω.

10. Fuel Pressure Regulator

10.1 Schematic Diagrams
The structure of fuel pressure regulator is shown in Figure
8-4-48 and Figure 8-4-49.
10.2 Mounting Position
Fuel pressure regulator is mounted on the electric fuel pump
bracket assembly.
10.3 Working Principles
As shown in Figure 8-4-49, a flexible membrane made of rubber
fiber separates fuel pressure regulator into upper and lower
chambers. The upper chamber with spring inside is open to
atmosphere. The lower chamber is filled with fuel flowing
through a circle of fuel inlets on the bottom face of fuel pressure
regulator. The lower surface of the membrane is subjected to fuel
Figure 8-4-48 Fuel Pressure Regulator pressure while the upper surface subjected to atmospheric
pressure and spring pressure. The membrane may deform and
drive the valve seat to open or close the valve; due to very small
deformation, however, the spring force may be considered as
constant. Therefore, the valve opening/closing mainly depends
on the difference between the fuel pressure of lower chamber
and the atmospheric pressure of upper chamber. Assuming the
valve is initially closed, with the rise of fuel pressure, the
pressure difference between upper and lower chambers increases
enough to make the membrane be jacked up by fuel pressure,
and thus the valve opens and fuel returns to the fuel tank via the
fuel return hole in the center of fuel pressure regulator, and fuel
pressure decreases until the valve closes. In this way, the
Figure 8-4-49 Sectional View of Fuel Pressure Regulator difference between fuel pressure and atmospheric pressure
basically keeps constant when the working condition of engine
changes.

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10.4 Technical Characteristic Parameters

(1) Limit data
Value
Parameter Unit
Min. Typ. Max.
Leakage rate at 280kPa pressure difference 9 cm3/min
Permissible continuous working temperature -30 +80 ℃
Maximum permissible fuel temperature +80 ℃
Maximum permissible pressure drift at -30℃ (reversible) -2％ +5％
Maximum permissible pressure drift at +80℃
-5％ +2％
(reversible)
Peak value of maximum permissible acceleration 100
Maximum permissible pressure pulsation at inlet 100 kPa

(2) Characteristic data

Value
Parameter Unit
Min. Typ. Max.
Rated pressure difference at flow Q=80 l//h 380 kPa
Working pressure variation with flow fluctuation in the
17.5 kPa
range of 15 ~ 140 l/h
Flow range 10 220 L/h
Slope of characteristic curve 0.16 kPa/L/h

(3) Fuel requirements

It is recommended that Fuel pressure regulator use unleaded gasoline. To obtain perfect engine performance, please
select No.93 (the octane number is 93) or higher grade premium unleaded gasoline.
Fuel pressure regulator is also applicable to the gasoline containing less than 15% volume of methanol or ethanol.

10.5 Installation Precautions

(1) Gently lubricate O ring with clean and silicone-free engine oil.
(2) Do not deform pressure adjusting valve when assembling and disassembling.
(3) Be sure to replace O ring with a new one when reassembling pressure adjusting valve and replace pressure adjusting
valve with a new one once it is subjected to the pressure of over 1,500kPa.
(4) The pressure adjusting valve having gone through rupture test or durability test can no longer be mounted on the
vehicle.

10.6 Symptoms and Diagnostic Methods

Faults:
Over-low or over-high fuel pressure, starting difficulty, etc.
Common fault causes:
Long-term use and failure to maintain cause the following consequences: 1) filter screen clogged; 2) serious leakage due
to granular impurities; 3) man-made mechanical damage, etc.

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Repair precautions:
During repair, it is prohibited to 1) spray high-pressure gas
towards membrane elements; 2) clean it with any highly
corrosive liquid; 3) cause deformation by external force.
Simple measuring methods:
Connect fuel pressure gauge to fuel inlet pipe, start and make the
engine run at idle speed, then check whether fuel pressure is
about 380kPa; step on the acceleration pedal until engine speed
reaches 2,500r/min and check whether fuel pressure is about
380kPa.
Figure 8-4-50 Ignition Coil Refer to characteristic data of pressure adjusting valve for
system pressure and those of fuel injector for fuel requirements.
And, the sealing performance requires no fuel leak under
working pressure.

11. Ignition Coil

11.1 Schematic Diagrams and Pins
Schematic diagrams:
Ignition coil is shown in Figure 8-4-50.
Definition of pins:
The circuit diagram of ignition coil is shown in Figure 8-4-51.
Figure 8-4-51 Circuit Diagram of Ignition Coil
Pin 1 connects to ignition control signal terminal of ECU.
Pin 2 connects to main relay power supply.
Pin 3 is grounded.

11.2 Mounting Position

Ignition coil is mounted in the engine ignition coil seat hole and
fastened by hexagon flange bolt (M6 × 20) as shown in Figure
8-4-52.

11.3 Working Principles

Primary coil will be charged when its ground circuit is closed.
Once ECU cuts off the circuit of primary coil, the charging will
stop and high voltage will be induced in secondary coil to
discharge spark plug.

Figure 8-4-52 Mounting Position of Ignition Coil

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11.4 Technical Characteristic Parameters

(1) Limit data
Value
Parameter Unit
Min. Typ. Max.
Permissible temperature at specified test points (see the
-40 +110 ℃
drawing)
0.5 h maximum temperature +120 ℃

(2) Characteristic data

Value
Parameter Unit
Min. Typ. Max.
Rated voltage 6 14 16.5 V
Primary coil 0.74 0.76 0.78 Ω
Resistance (20℃ ~ 25℃)
Secondary coil 10.1 10.6 11.1 kΩ
Load 50pF 30 kV
Formation voltage
Load 50pF/1MΩ 25 kV

11.5 Symptoms and Diagnostic Methods

Faults:
Startup failure, etc.
Common fault causes:
Over-current causes burnout, damage arising from external force,
etc.
Repair precautions:
When performing repair, it is prohibited to test ignition function
through “Short-circuit Ignition Test” to prevent electronic controller
from damage.

12. Water (Coolant) Temperature Sensor

Figure 8-4-53 Water Temperature Sensor
12.1 Structural Diagrams
The structure of water temperature sensor is shown in Figure 8-4-53
and Figure 8-4-54.

12.2 Functions and Principles

Functions:
Water temperature sensor is to provide the information about engine
water temperature and hereby the controller corrects fuel injection
and ignition.
Principles:
As a NTC (negative temperature coefficient) thermistor, the
Figure 8-4-54 Structure of Water Temperature Sensor resistance of water temperature sensor decreases with temperature
1- electrical connector; 2- shell; 3- NTC resistor rise but not in linear relationship. The thermistor is installed in a
copper heat-conductive sleeve.

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12.3 Mounting Position

Water temperature sensor is mounted on the water outlet of
cylinder head as shown in Figure 8-4-55.

Mounting torque:
Max. 20N·m.

12.4 Symptoms and Diagnostic Methods

Faults:
Starting difficulty, etc.

Common fault causes:

Man-made failure.

Simple measuring methods:

Figure 8-4-55 Mounting Position of Water Temperature
Sensor (Disconnect the connector) set digital multi-meter to Ohms
position and connect its two styli respectively to the sensor’s
Pins A and C, and rated resistance at 25℃ is 1.98Kω ± 10％, as
shown in Figure 8-4-56. Simulation method can also be used for
measurement; specifically, put the working area of water
temperature sensor into boiled water (be sure to soak it for
enough time) and observe the resistance of water temperature
sensor, and the resistance value should reduce to l,600Ω ～
l,800Ω (exact value depends on the temperature of boiled water).
Characteristic data:
Resistance (kΩ)
No. Temperature tolerance ± 0.1℃ Temperature (℃)

Figure 8-4-56 Circuit Diagram of Water Temperature Min. Max.

Sensor 1 13.71 16.49 –20

2 1.825 2.155 25
3 0.303 0.326 80
4 0.1383 0.1451 110

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Chapter 9 Cooling System

Section 1 Components of Cooling System

Figure 9-1-1 Schematic Mounting Diagram of Components of Gasoline Engine Cooling System
1- water pump assembly; 2- thermostat assembly; 3- Heat water return pipe assembly

Section 2 Coolant

1. Inspection
1.1 Check of Coolant Level in Expansion Tank
When the engine is in cold state, coolant level should be
between “LOW” and “FULL” marks on the expansion tank as
shown in Figure 9-2-1.
When coolant level is close to or below the “LOW” mark, check
cooling system for leakage; if no leakage occurs, add coolant to
Figure 9-2-1 Check of Coolant in Expansion Tank the “FULL” mark.

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1.2 Check of Coolant Quality

1.2.1 Remove the radiator cap.
Warning: When the engine and radiator are at high temperature,
do not remove the radiator cap to avoid personal injury caused
by coolant and vapor spraying.

1.2.2 Check the periphery of radiator cap or radiator water filling

hole and there should not be too much rust or scale. Besides,
coolant must not contain engine oil.
Coolant should be changed once it is too dirty or has been used
Figure 9-2-2 Check of Radiator for more than 2 years.
1.2.3 After check, reinstall the radiator cap.

2. Change
2.1 Drainage of Engine Coolant
2.1.1 Remove the radiator cap.
2.1.2 Remove the radiator drain plug and open the water drain
valve on engine cylinder block to drain coolant as shown in
Figure 9-2-3.
Warning: Due to its toxicity, coolant must be stored in a proper
container to avoid contact with people. Also, liquid waste must
Figure 9-2-3 Drainage of Engine Coolant
be disposed of in a correct way for environmental protection.

2.1.3 Apply Loctite 243 anaerobic thread-locking sealant (SSM)

onto the screw thread of water drain valve assembly and then
mount the water drain valve onto upper cylinder block as shown
in Figure 9-2-4.
SSM: 23962.
Tightening torque: 15N·m ± 2N·m.

2.2 Filling of Coolant

2.2.1 Add coolant to expansion tank slowly.
Figure 9-2-4 Installation of Water Drain Valve
(1) Use famous brand ethylene glycol based coolant and mix by
following the manufacturer’s instructions.
(2) It is recommended to use the coolant containing over 50% of
ethylene glycol.
2.2.2 Mount the radiator cap.
2.2.3 Start the engine and discharge the air in cooling system.
2.2.4 Add coolant to expansion tank to the “FULL” mark as
shown in Figure 9-2-5.

2.3 Check of Coolant Leak

Figure 9-2-5 Check of Coolant Level
Start the engine and check coolant leak during engine running.
Once coolant leak is observed, clear the fault immediately.

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Section 3 Water Pump Assembly

1. Schematic Mounting Diagram of Components

Figure 9-3-1 Schematic Mounting Diagram of Components of Gasoline Engine Water Pump
1- hexagon flange bolt (M6 × 12, 3pcs); 2- water pump pulley; 3- hexagon flange nut (M6, 2pcs); 4- hexagon flange bolt (M6 × 35, 3pcs); 5-
stud (M6 × 35, 2pcs); 6- water pump assembly; 7- water pump gasket

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2. Disassembly
2.1 Drain Engine Coolant
2.2 Before disassembling water pump assembly, loosen the bolt
(M8 × 30) of alternator adjusting arm and the hexagon fastening
bolt with flange (M10 × 1.25 × 72) of alternator, then remove the
alternator belt.
2.3 Disassembly of Water Pump Pulley
2.3.1 Secure the water pump pulley with a special tool and then
screw off 3-hexagon flange bolts (M6 × 14) as shown in Figure
9-3-2.
Figure 9-3-2 Disassembly of Water Pump Pulley 2.3.2 Remove the water pump pulley.

2.4 Disassembly of Water Pump and Its Gasket

2.4.1 Screw off 3 hexagon flange bolts (M6 × 35) and 2 hexagon
flange nuts (M6) as shown in Figure 9-3-3.

Figure 9-3-3 Disassembly of Bolts and Nuts

2.4.2 Remove water pump assembly and its gasket as shown in
Figure 9-3-4.

Figure 9-3-4 Disassembly of Water Pump Assembly and

Water Pump Gasket
3. Inspection
3.1 Perform visual check on water pump overflow hole (as
shown in Figure 9-3-5) for coolant leak; and, once coolant leak
is observed, replace water pump assembly.
Check whether there is white grease on the bearing edge and
inner wall of water pump housing; and, if there is white grease,
it means grease leakage exists, please replace water pump
assembly.

Figure 9-3-5 Check of Water Pump

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3.2 Rotate flange as shown in Figure 9-3-6 and check the

rotation of water pump bearing. There should be no abnormal
noise, locking or sluggishness and obvious grease leakage,
otherwise replace water pump assembly.
3.3 Check water pump vane and cylinder block water pump
volute for serious corrosion; if so, replace coolant. Moreover, if
the vane rusts seriously, replace water pump assembly.

Figure 9-3-6 Check of Water Pump Bearing

4. Installation
4.1 Mount water pump gasket and water pump assembly onto
the 2 studs (M6 × 35) of upper cylinder block as shown in Figure
9-3-7.

Figure 9-3-7 Installation of Water Pump Assembly

4.2 Fasten 3 hexagon flange bolts (M6 × 35) and 2 hexagon
flange nuts (M6) to upper cylinder block as shown in Figure
9-3-8.
Tightening torque: 11N·m ± 1N·m.

Figure 9-3-8 Installation of Water Pump Assembly

4.3 Installation of Water Pump Pulley
Mount water pump pulley to water pump flange and then tighten
the 3 hexagon flange bolts (M6 × 12) as shown in Figure 9-3-9.
Tightening torque: 12N·m ± 2N·m.
4.4 After installation, rotate the water pump pulley. Moreover,
the pulley should be flexible without locking or sluggishness.

Figure 9-3-9 Installation of Water Pump Pulley

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Section 4 Thermostat

1. Schematic Mounting Diagram of Components

Figure 9-4-1 Schematic Mounting Diagram of Components of Gasoline Engine Thermostat

1- thermostat assembly; 2- stud (M6 × 22, 2pcs); 3- thermostat housing assembly; 4- hexagon flange nut (M6, 2pcs)

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2. Disassembly
Note: Do not remove thermostat without reason, otherwise the
cooling efficiency of engine cooling system will reduce.

2.1 Drainage of Coolant

2.2 Disassembly of Thermostat Housing Assembly and
Thermostat Assembly
2.2.1 Loosen the clamp of hose connecting to the thermostat.
Figure 9-4-2 Disassembly of Thermostat 2.2.2 Remove the hose and clamp.
2.2.3 Screw off 2 hexagon flange nuts (M6) and then remove
thermostat housing assembly as shown in Figure 9-4-2.
2.2.4 Take out thermostat assembly.

3. Check
3.1 Check of Thermostat Housing Assembly
Check thermostat housing assembly for deformation as shown in
Figure 9-4-3. If deformation is observed, replace thermostat
housing assembly.
Figure 9-4-3 Check of Thermostat Housing Assembly
3.2 Check of Thermostat Assembly
Note: Thermostat is marked with opening valve temperature as
shown in Figure 9-4-4.

Figure 9-4-4 Check of Thermostat

3.2.1 Immerse thermostat assembly entirely in water and then

heat the water slowly as shown in Figure 9-4-5. Do not heat
thermostat directly.
3.2.2 Check opening valve temperature of the thermostat by
observing temperature change via the thermometer inserted into
the water.
Opening valve temperature: 80℃ ~ 84℃.
If opening valve temperature does not meet above-mentioned
requirement, replace thermostat assembly.
Figure 9-4-5 Check of Opening Valve Temperature of
Thermostat

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3.2.3 Check thermostat valve lift as shown in Figure 9-4-6.

Valve lift: At least 8mm when water temperature is at 95℃.
If valve lift does not meet above-mentioned requirement, replace
thermostat assembly.
3.2.4 When thermostat is at relatively low temperature, check
whether the valve is closed.
If the valve is not closed, replace the thermostat.
Check the rubber sealing ring of thermostat for aging and
deformation; if it is aged or deformed, replace it.
Figure 9-4-6 Check of Thermostat Valve Lift
4. Installation
4.1 Put thermostat assembly into the mounting hole on cylinder
block and keep the position of air vent valve upwards when
installing as shown in Figure 9-4-7.

Figure 9-4-7 Installation of Thermostat Assembly

4.2 Mount thermostat housing assembly onto the 2 studs (M6 ×
22) of upper cylinder block and then fasten it with 2 hexagon
flange nuts (M6) as shown in Figure 9-4-8.
Tightening torque: 11N·m ± 1N·m.
4.3 Install hose and clamp.
4.4 Inject coolant into cooling system.
4.5 Start the engine and check whether coolant leak occurs.

Figure 9-4-8 Installation of Thermostat Assembly

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Section 5 Heating-system Water Return Pipe

1. Schematic Mounting Diagram of Components

Figure 9-5-1 Schematic Mounting Diagram of Components of Heating-system Water Return Pipe
1- hexagon flange nut (M6, 2pcs); 2- stud (M6 × 16, 2pcs); 3- heating-system water return pipe gasket; 4- heating-system water return pipe
assembly; 5- hexagon blot with flange (M6 × 14, 1pc)

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2. Disassembly
Note: Check whether water leakage occurs at the joint between
heating-system water return pipe assembly and cylinder block.

2.1 Loosen the clamp of hose connecting to the heating-system

water return pipe.
2.2 Remove the connecting hose and clamp.
2.3 Screw off 1 hexagon flange bolt (M16 × 14) and 2 hexagon
flange nuts (M6) for fastening studs (M6 × 16) on the cylinder
Figure 9-5-2 Disassembly of Heating-system Water block as shown in Figure 9-5-2.
Return Pipe
2.4 Remove the heating-system water return pipe assembly and
gasket as shown in Figure 9-5-2.

3. Inspection
Check the heating-system water return pipe for weld cracking
and flange face deformation, etc. (see Figure 9-5-3); if so,
replace it with a new one.

Figure 9-5-3 Check of Heating-system Water Return Pipe 4. Installation

4.1 Mount the heating-system water return pipe assembly and its
gasket onto the 2 studs (M6 × 16) on cylinder block as shown in
Figure 9-5-4.
4.2 Fasten the heating-system water return pipe to upper cylinder
block with 2 hexagon flange nuts (M6) and 1 hexagon flange
bolt (M6 × 14).
Tightening torque: 10N·m ± 1N·m.
4.3 Install connecting hose and clamp.

Figure 9-5-4 Installation of Heating-system Water Return

Pipe

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 Chapter 10 Lubrication System

Chapter 10 Lubrication System

Section 1 Components and Oil Passage of Lubrication System

1. Schematic Mounting Diagram of Components

Figure 10-1-1 Schematic Mounting Diagram of Components of Gasoline Engine Lubrication System
1- oil pump assembly; 2- oil collector assembly; 3- oil pan assembly; 4- oil filter assembly; 5- oil dipstick assembly; 6- oil level indicator
tube assembly

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2. Lubricating Oil Passage

Figure 10-1-2 Schematic Diagram of Oil Passage of Gasoline Engine Lubrication System

Section 2 Oil and Oil Filter Assembly

1. Check
1.1 Check of Engine Oil Quality
Check the engine for deteriorated or leaner oil; if so, change it
according to ambient temperature. Oil grade: SJ or above. It is
recommended to select oil grade as shown in Figure 10-2-1.

Figure 10-2-1 Recommended Oil Grade and Ambient

Temperature 1.2 Check of Engine Oil Level
Warm up the engine and then shut it down, 5min later, engine oil
level should be between “L” and “F” marks on the oil dipstick. If
the level is lower, check oil leak and add oil to the required level.
Note: Standard oil level should be slightly higher than the
midpoint of “L” and “F” marks on the oil dipstick and do not
allow oil level to be higher than the “F” mark, as shown in
Figure 10-2-2.

Figure 10-2-2 Oil Level Check with Oil Dipstick

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1.3 Check of Oil Pressure

1.3.1 Remove oil pressure sensor as shown in Figure 10-2-3.
1.3.2 Connect oil pressure gauge as shown in Figure 10-2-4.
1.3.3 Preheat the engine to normal working temperature (coolant
temperature at 80℃ – 90℃).
1.3.4 Check oil pressure.
Oil pressure:
Above 80kPa when the engine is at idle speed;
Figure10-2-3 Disassembly and Assembly of Oil Pressure Above 400kPa when the engine speed is over 4,200r/min.
Sensor
1.3.5 Remove the oil pressure gauge.
1.3.6 Apply Loctite 243 anaerobic thread-locking sealant (SSM)
onto 2 ~ 3 turns of screw thread of the oil pressure sensor.
SSM: 23962.
1.3.7 Mount oil pressure sensor to upper cylinder block as
shown in Figure 10-2-3.
Tightening torque: 15N·m ± 2N·m.
1.4 Check of Oil Leak
Start the engine and check oil leak during engine running.
Once oil leak is observed, clear the fault immediately.
Figure 10-2-4 Check of Oil Pressure of Lubrication
System
2. Oil Change
Warning: Be sure to wear protective clothing and gloves when
changing oil. Prevent the skin from direct contact with oil as
possible, otherwise the skin may become drier or be irritated
resulting in dermatitis.
In case of contact with oil by accident, thoroughly wash the skin
with soap and water or waterless hand cleaner to remove oil and
do not use gasoline, thinner or solvent.
Note: For the purpose of environmental protection, be sure to
Figure 10-2-5 Disassembly and Assembly of Oil Drain dispose of the used oil and oil filter at designated sites.
Plug of Oil Pan
2.1 Drainage of Engine Oil
2.1.1 Disassemble the filler cap assembly.
2.1.2 Remove the oil drain plug and its gasket of oil pan (see
Figure 10-2-5) to drain oil.

2.2 Replacement of Oil Filter Assembly

2.2.1 Disassemble the oil filter assembly with special service
tool (SST).
SST: CC2008013.
2.2.2 Apply clean engine oil onto the inlet gasket of the new oil
filter assembly as shown in Figure 10-2-6.
Figure 10-2-6 Replacement of Oil Filter

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2.2.3 In normal conditions, oil filter should be replaced every

8,000 ~ 10,000km and the replacement cycle should be
shortened as the case may be if it is used in dusty environment.
2.2.4 Slowly screw in oil filter with special service tool (SST).
Screw 3/4 ~ 1 turn again after the gasket touches the seat.
SST: CC2008013.
2.3 Filling of New Engine Oil
2.3.1 Clean oil drain plug and then reinstall the plug and its
gasket to oil pan as shown in Figure 10-2.5.
Tightening torque: 18N·m ± 2N·m.
2.3.2 Inject new engine oil via oil filler.
Figure 10-2-7 Oil Filter Oil grade: SJ or above; viscosity: 10W-30 (winter), 20W-40
(summer).
Capacity: 3.5L.
2.3.3 Mount the filler cap gasket and then mount and tighten
filler cap as shown in Figure 10-2-8.

2.4 Check for Oil Leak

Start the engine and check for oil leak during engine running;
once oil leak is observed, clear the fault immediately.

Figure 10-2-8 Installation of Filler Cap Assembly

2.5 Check of Engine Oil Level
Engine oil level should be slightly higher than the midpoint of
“L” and “F” marks on the oil dipstick as shown in Figure 10-2-9.

Figure 10-2-9 Check of Engine Oil Level

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Section 3 Oil Trap and Oil Sump Assembly

1. Schematic Mounting Diagram of Components

Figure 10-3-1 Schematic Mounting Diagram of Components of Oil Collector and Oil Pan
1- hexagon flange bolt (M6 × 12); 2- gasket; 3- oil collector assembly; 4- stud (M6 × 12, 2pcs); 5- hexagon flange nut (M6, 2pcs); 6- oil pan
assembly; 7- oil drain plug gasket; 8- oil drain plug; 9- stud (M6 × 12, 2pcs); 10- hexagon flange nut (M6, 2pcs); 11- hexagon flange bolt

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(M6 × 12, 9pcs)

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Figure 10-3-5 Check of Oil Dipstick and Oil Dipstick

2. Disassembly
Note: Drain the oil remaining in engine lubrication system
before disassembling oil pan assembly and oil collector
assembly.

2.1 Drainage of Engine Oil

2.1.1 Disassemble the filler cap assembly.
2.1.2 Remove the oil drain plug to drain oil as shown in Figure
Figure 10-3-2 Drainage of Oil in Engine Lubrication
10-3-2.
System
2.2 Disassembly of Oil Dipstick Assembly and Oil Dipstick
Funnel Assembly
2.2.1 Screw off the hexagon mounting bolt with flange (M6 × 12)
of oil dipstick.
2.2.2 Take out oil dipstick assembly and oil level indicator tube
assembly.
2.3 Disassembly of Oil Pan
2.3.1 Screw off the 9 hexagon flange bolts (M6 × 12) and 2
hexagon flange nuts (M6) as shown in Figure 10-3-3.
Figure 10-3-3 Disassembly of Oil Pan Assembly
2.3.2 Remove the oil pan assembly.

2.4 Disassembly of Oil Collector

2.4.1 Screw off 2 hexagon flange nuts (M6) and 1 hexagon
flange bolt (M6 × 12) as shown in Figure 10-3-4.
2.4.2 Remove the oil collector assembly and its gasket.

Figure 10-3-4 Disassembly of Oil Collector

3. Inspection
3.1 Check whether oil dipstick assembly and oil level indicator
tube assembly are damaged and whether O ring is aged as shown
in Figure 10-3-5; if necessary, replace relevant components.
3.2 Check whether the filter screen of oil collector is damaged; if
damaged, replace oil collector assembly.

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4. Installation
4.1 Installation of Oil Collector Assembly
4.1.1 Clean the filter screen before installing oil collector
assembly.
4.1.2 Mount the gasket and oil collector assembly to lower
cylinder block through the 2 studs (M6 × 12) on lower cylinder
block.
4.1.3 Fasten oil collector assembly to lower cylinder block with
2 hexagon flange nuts (M6) and 1 hexagon flange bolt (M6 × 12)
as shown in Figure 10-3-6.
Figure 10-3-6 Installation of Oil Collector Assembly
Tightening torque: 8N·m ± lN·m.

4.2 Installation of Oil Pan

4.2.1 Remove the sealant on oil pan flange face, wash away oil
stains and impurities in the oil pan cavity with kerosene and then
apply Loctite 5699 silicone rubber flange sealant (SSM) as
shown in Figure 10-3-7.
SSM: 33964.
4.2.2 Mount oil pan to lower cylinder block through the 2 studs
Figure 10-3-7 Sealant Coating (M6 × 12) on lower cylinder block.

4.2.3 Fasten the oil pan to lower cylinder block with 9 hexagon
flange bolts (M6 × 12) and 2 hexagon flange nuts (M6) as shown
in Figure 10-3-8.
Tightening torque: 8N·m ± 1N·m.

Figure 10-3-8 Installation of Oil Pan Assembly

4.2.4 Mount the oil drain plug and its gasket to the oil pan
assembly as shown in Figure 10-3-9.
Tightening torque: 18N·m ± 2N·m.

Note: Install the oil pan and tighten hexagon flange bolts (M6 ×
12) respectively within 3min and 15min after applying sealant
2h later, add engine oil.
Figure 10-3-9 Installation of Oil Drain Plug and Its
Gasket

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4.3 Installation of Oil Dipstick Assembly and Oil Dipstick

Funnel Assembly
4.3.1 Put the lower end of oil level indicator tube assembly into
the mounting hole of upper cylinder block as shown in Figure
10-3-10.
4.3.2 Fasten oil level indicator tube assembly to cylinder head
with 1 hexagon flange bolt (M6 × 12).
Tightening torque: 7N·m ± 1N·m.
4.3.3 Insert oil dipstick assembly into oil level indicator tube
assembly.

Figure 10-3-10 Installation of Oil Dipstick and Oil

Dipstick Funnel

Section 4 Oil Pump

1. Schematic Mounting Diagram of Components

Figure 10-4-1 Schematic Mounting Diagram of Components of Oil Pump

1- cross recessed countersunk flat head screw (M6 × 14, 3pcs); 2- hexagon flange bolt (M6 × 30, 2pcs); 3- oil pump cover; 4- outer rotor; 5-
timing cover; 6- assembling bolt; 7- hexagon flange bolt (M8 × 30, 2pcs); 8- hexagon flange bolt (M6 × 20, 11pcs); 9- stud (M8 × 30); 10-
hexagon flange nut (M8); 11- hexagon flange bolt (M6 × 35); 12- hexagon socket head tapered screw plug; 13- crankshaft front oil seal
assembly; 14- inner rotor; 15- pressure-relief valve body; 16- pressure-relief valve spring; 17- spring seat (M6 × 20)

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2. Disassembly
Note: Drain oil before disassembling oil pump.
2.1 Loosen the alternator belt and then disassemble the water
pump pulley, VVT control valve, alternator assembly and water
pump assembly.
2.2 Screw off the bolt (M12 × 1.25 × 47) of crankshaft damper
pulley and then remove the pulley.
2.3 Screw off 14 hexagon flange bolts (M6 × 20, M8 × 30), 1
hexagon flange bolt (M6 × 35) and 1 hexagon flange nut (M8) of
the timing cover.
2.4 Pry off timing cover from several positions as shown in
Figure 10-4-2.

Figure 10-4-2 Disassembly of Timing Cover

Note: Do not damage mounting surface when prying timing
cover.

2.5 Disassembly of Oil Pump Cover

2.5.1 Screw off 2-hexagon flange bolts (M6 × 30) and 3 cross
recessed countersunk flat head screws (M6 × 14) as shown in
Figure 10-4-3.
2.5.2 Remove the oil pump cover.

Figure 10-4-3 Disassembly of Oil Pump Cover

2.6 Disassembly of Pressure-relief Valve
2.6.1 Disassemble the spring seat.
2.6.2 Take out the pressure-relief valve spring and pressure-relief
valve body as shown in Figure 10-4-4.

Figure 10-4-4 Disassembly of Pressure-relief Valve

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3. Inspection
3.1 Check of Pressure-relief Valve
Apply oil onto the pressure-relief valve body and then check
whether it can rotate smoothly in valve chamber, as shown in
Figure 10-4-5.
If not, replace pressure-relief valve body; if necessary, replace
oil pump cover assembly.
3.2 Check of Inner and Outer Rotors
Figure 10-4-5 Check of Pressure-relief Valve 3.2.1 Check the radial clearance between outer rotor and timing
cover.
Measure the radial clearance between outer rotor and timing
cover counter bore with feeler gauge as shown in Figure 10-4-6.
Standard clearance: 0.250 ~ 0.322mm.
Maximum clearance: 0.425mm.
If measured clearance is larger than maximum value, replace
complete set of rotors; if necessary, replace oil pump assembly.
3.2.2 Check of the meshing clearance between inner and outer
Figure 10-4-6 Measurement of Radial Clearance between rotors.
Outer Rotor and Timing Cover
Measure the meshing clearance between inner and outer rotors
with feeler gauge as shown in Figure 10-4-7.
Standard clearance: 0.05 ~ 0.10mm.
Maximum clearance: 0.28mm.
If measured meshing clearance is larger than maximum value,
replace complete set of rotors.
3.2.3 Check of rotor end clearance.
Measure rotor end clearance with feeler gauge and precision
straight edge.
Figure 10-4-7 Check of Meshing Clearance between Standard clearance: 0.02 ~ 0.07mm.
Inner and Outer Rotors
Maximum clearance: 0.15mm.
If measured end clearance is larger than maximum value, replace
complete set of rotors; Replace oil pump assembly when
necessary.

4. Installation
4.1 Installation of Crankshaft Front Oil Seal Assembly
4.1.1 Pry out front oil seal assembly with a screwdriver.
4.1.2 Gently knock into new oil seal with proper tools and
hammer until its surface is level with timing cover edge.
Figure 10-4-8 Installation of Crankshaft Front Oil Seal
Assembly
Note: Be sure to apply engine oil onto the oil seal edge before
installation and ensure oil sealing not to tilt after installed.

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4.2 Installation of Pressure-relief Valve

4.2.1 Mount the pressure-relief valve body and spring in valve
chamber as shown in Figure 10-4-9.
4.2.2 Install the spring seat.
Tightening torque: 30N·m ± 1N·m.

Figure 10-4-9 Installation of Pressure-relief Valve

4.3 Installation of Inner and Outer Rotors
4.3.1 Mount inner and outer rotors in timing cover oil pump
chamber with the marks towards oil pump cover as shown in
Figure 10-4-10.

Figure 10-4-10 Installation of Inner and Outer Rotors

4.3.2 Fasten the oil pump cover with 2 hexagon flange bolts (M6
× 30) and 3 cross recessed countersunk flat head screws (M6 ×
14) as shown in Figure 10-4-11.
Tightening torque: 10N·m ± 1N·m.

Figure 10-4-11 Installation of Oil Pump Cover 4.4. Installation of Oil Pump
4.4.1 Replace O ring with a new one before installing the oil
pump assembly as shown in Figure 10-4-12.

Figure 10-4-12 Replacement of O Ring

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4.4.2 Apply Loctite 5699 flange sealant (SSM) onto the sealing
surface of oil pump assembly as shown in Figure 10-4-13.
SSM: 33964.
Apply engine oil onto the crankshaft front oil seal lip.

Figure 10-4-13 Loctite Sealant Coating on Sealing

Surface of Oil Pump Assembly
4.4.3 Position oil pump by positioning pin and the positioning
pin hole of oil pump and then install it as shown in Figure
10-4-14.
4.4.4 Fasten the oil pump assembly to cylinder block and
cylinder head with 14 hexagon flange bolts (M6 × 20, M8 × 30),
1 hexagon flange bolt (M6 × 35) and 1 hexagon flange nut (M8)
as shown in Figure 10-4-14.
Tightening torque:
M6 11N·m ± 1N·m
M8 24N·m ± 2N·m.

Figure 10-4-14 Installation of Oil Pump Assembly

4.4.5 Fasten the cylinder head cover assembly to oil pump
assembly with 3 hexagon flange bolts (M6 × 25) as shown in
Figure 10-4-15.
Tightening torque: 10N·m ± 1N·m.

Figure 10-4-15 Installation of Cylinder Head Cover

Assembly

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Chapter 11 Cylinder Head and Valve Timing

Section 1 Components of Cylinder Head and Valve Timing

Figure 11-1-1 Schematic Mounting Diagram of Components of Cylinder Head and Valve Timing
1- timing mechanism; 2- cylinder head assembly and valve actuating mechanism; 3- cylinder head cover assembly

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Section 2 Cylinder Head Cover Assembly

1. Schematic Mounting Diagram of Components

Figure 11-2-1 Schematic Mounting Diagram of Components of Cylinder Head Cover

1- stud (M6 × 25, 2pcs); 2- hexagon flange nut (M6, 2pcs); 3- PCV assembly; 4- hexagon flange bolt (M6 × 25, 7pcs); 5- hexagon flange bolt
(M6 × 60, 2pcs); 6- hexagon flange bolt (M6 × 20, 4pcs); 7- ignition coil assembly (4pcs); 8- filler cap assembly; 9- gasket assembly (2pcs);
10- cylinder head cover assembly; 11- cylinder head cover gasket

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2. Disassembly
2.1 Disassembly of Ignition Coil Assembly
2.1.1 Remove the rubber hose for positive crankcase ventilation
and ignition coil harness plug.
2.1.2 Screw off the hexagon flange bolts (M6 × 20) for fastening
ignition coil.
2.1.3 Screw out ignition coil assembly from the mounting hole
on cylinder head cover as shown in Figure 11-2-2.

Figure 11-2-2 Disassembly of Ignition Coil Assembly

2.2 Disassembly of Gasket Assembly
Screw off the hexagon flange bolt (M6 × 60) for fastening
cylinder head cover assembly and then remove the gasket
assembly as shown in Figure 11-2-3.
2.3 Disassembly of Cylinder Head Cover Assembly
2.3.1 Disassemble the PCV assembly.
2.3.2 Screw off the nuts and bolts for fastening cylinder head
cover assembly.
2.3.3 Remove the cylinder head cover assembly.
2.3.4 Remove the cylinder head cover gasket.

3. Inspection
3.1 Check the ignition coil assembly for oil stains.
Figure 11-2-3 Disassembly of Gasket Assembly
If oil stains exist, wipe ignition coil and cylinder head to remove
oil stains, and then investigate the source of oil stains and
replace relevant components as the case may be.
Check the rubber part and insulator at front portion of ignition
coil assembly for cracking as shown in Figure 11-2-4; if
cracking exists, replace it.
3.2 Check whether the gasket assembly is damaged; if damaged,
replace it as shown in Figure 11-2-3.
3.3 Check PCV as follows: wash clean PCV with unleaded
gasoline and dry it, then check whether the valve element moves
Figure 11-2-4 Check of Ignition Coil Assembly
smoothly by pushing it with steel wire; if it does not move
smoothly, replace it.

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3.4 Check for foreign material in the cylinder head cover

assembly and for a loose or disengaged baffle, as shown in
Figure 11-2-5.
3.5 Check the cylinder head cover gasket for cracking and aging,
etc.; if any replace it.

4. Installation
Note: Clean the cylinder head cover assembly before
installation.
Figure 11-2-5 Check of Cylinder Head Cover Assembly

4.1 Installation of Cylinder Head Cover Assembly

4.1.1 Evenly mount the cylinder head cover gasket into the
groove of cylinder head cover assembly.
4.1.2 Clean the mounting surface.
Apply the Loctite 5699 silicone rubber flange sealant (SSM)
onto the joints between timing cover, cylinder head and cylinder
head cover assembly, as shown in Figure 11-2-6.
SSM: 33964.
Mount the cylinder head cover assembly onto the cylinder head
3min after applying sealant and tighten the 2 hexagon flange
Figure 11-2-6 Application of Sealant on Joints between
Timing Cover and Cylinder Head Cover Assembly nuts (M6) and 7 hexagon flange bolts (M6 × 25), as shown in
Figure 11-2-7.
Tightening torque: 10N·m ± 1N·m.

4.2 Installation of Gasket Assembly

Fasten the cylinder head cover assembly to cylinder head using 2
hexagon flange bolts (M6 × 60) to pass through the gasket
assembly, as shown in Figure 11-2-7.
Tightening torque: 10N·m ± 1N·m.

Figure 11-2-7 Installation of Cylinder Head Cover

Assembly

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4.3 Installation of PCV Assembly

Apply Loctite 243 anaerobic thread-locking sealant (SSM) onto
the screw thread of PCV assembly and fasten it to the cylinder
head cover assembly with specified tightening torque, as shown
in Figure 11-2-8.
SSM: 23962.
Tightening torque: 11N·m ± 1N·m.

Figure 11-2-8 Installation of PCV Assembly

4.4 Installation of Filler Cap Assembly

Mount the filter cap assembly. and the sealing ring to the fuel
filler of cylinder head cover and tighten the filler cap, as shown
in Figure 11-2-9.

Figure 11-2-9 Installation of Filler Cap Assembly

4.5 Installation of Ignition Coil Assembly

Mount ignition coil into the corresponding hole of cylinder head
cover assembly by aligning it with spark plug assembly and then
tighten hexagon flange bolts (M6 × 20) with specified torque, as
shown in Figure 11-2-10.
Tightening torque: 7N·m ± 1N·m.
Reliably connect the ignition coil harness plug and the rubber
hose for positive crankcase ventilation.

Figure 11-2-10 Installation of Ignition Coil

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Section 3 Cylinder Head Assembly and Valve Actuating Mechanism

1. Schematic Mounting Diagram of Components

Figure 11-3-1 Schematic Mounting Diagram of Components of Cylinder Head and Valve Actuating Mechanism
1- spark plug (4pcs); 2- cylinder head bolt (M9 × 144, 10pcs); 3- cylinder head bolt washer (10pcs); 4- cylinder head; 5- cylinder head gasket;
6- VVT-i control valve; 7- hexagon flange bolt (M6 × 12); 8- filter screen; 9- oil plug gasket; 10- oil plug; 11- valve tappet (16pcs); 12- valve
spring seat (16pcs); 13- valve lock clamp (32pcs); 14- valve spring (16pcs); 15- valve spring gasket (16pcs); 16- valve oil seal assembly
(16pcs); 17- intake valve (8pcs); 18- exhaust valve (8pcs); 19- exhaust camshaft assembly; 20- intake camshaft assembly

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2. Disassembly
Before disassembling the cylinder head assembly, dismantle the
cylinder head cover assembly, oil pump assembly and timing
system and disconnect the rubber hose connecting to water outlet
manifold and hot water pipe.
2.1 Remove 4 spark plugs in turn with special service tool
(SST).
SST：CC2008014。
SST: CC2008014.
2.2 Disassembly of Camshaft
Figure 11-3-2 Disassembly of Bolts of Front-end 2.2.1 Disassembly of Exhaust Camshaft
Camshaft Bearing Cap
(1) Evenly loosen and remove the 3 hexagon bolt and plain
washer assemblies (M8 × 42) for mounting the front-end
camshaft bearing cap at twice, as shown in Figure 11-3-2.
(2) Remove the front-end camshaft bearing cap.
(3) Evenly loosen and remove the 8 hexagon bolt and plain
washer assemblies (M6 × 38) for mounting the camshaft bearing
cap at twice, as shown in Figure 11-3-3.
(4) Remove the 4 camshaft bearing caps and the exhaust
camshaft.
Note: Do not pry the camshaft with any tool or try to remove it
forcibly to ensure the camshaft working surface free of
scratches.
Figure 11-3-3 Disassembly of Camshaft Bearing Cap
2.2.2 Disassembly of Intake Camshaft
(1) Like the disassembly of exhaust camshaft, evenly loosen
and remove the 8 hexagon bolt and plain washer assemblies (M6
× 38) for mounting the intake camshaft bearing cap at twice.
(2) Remove 4 intake camshaft bearing caps and intake
camshaft.
Note: Do not pry the camshaft with any tool or try to remove it
forcibly to ensure the camshaft working surface free of
scratches.
2.3 Disassembly of Cylinder Head
2.3.1 Disassemble the VVT control valve, oil plug, oil plug
Figure 11-3-4 Disassembly of Cylinder Head Bolts in gasket, filter screen and other parts.
Turn and at Several Times 2.3.2 Evenly loosen and remove 10 cylinder head bolts (M9 ×
144) at several times and in the sequence as shown in Figure
11-3-4.
Note: If cylinder head bolts are not removed in correct sequence,
the cylinder head may warp or break.
2.3.3 Attract out 10 cylinder head bolt washers with a magnetic
rod, count. Put them away properly and be careful not to make
them drop into oil gallery.
2.3.4 Lift the cylinder head from cylinder block and place it onto
the wood block or rubber cushion on the worktable.
2.3.5 Remove the cylinder head gasket.
Note: Do not reuse the cylinder head gasket once it is removed.
Figure 11-3-5 Disassembly of Valve Lock Clamp

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2.4 Disassembly of Valve Actuating Mechanism

2.4.1 Take out the valve tappet.
Note: After taking out the valve tappet, mark it with uniform
number with cylinder head tappet hole and then put it into a
proper container.
2.4.2 Disassembly of Valve
(1) Compress valve spring and take out valve lock clamp with
special service tool (SST) as shown in Figure 11-3-5.
Figure 11-3-6 Disassembly of Valve Oil Seal with Nipper SST：CC2008015。
Pliers
SST: CC2008015.
(2) Dismantle the following parts: valve spring seat, valve
spring and valve.

Note: After dismantling the valve, mark it with uniform number

with cylinder head valve guide and then put it into a proper
container.
(3) Dismantle the valve oil seal assembly with nipper pliers, as
shown in Figure 11-3-6.
Note: Do not reuse the valve oil seal assembly once it is
Figure 11-3-7 Removal of Valve Spring with Magnetic
Rod
removed！
(4) Attract out the valve spring gaskets with magnetic rod, as
shown in Figure 11-3-7.
(5) Screw off the water jacket screw plug in the middle of
cylinder head with socket head wrench.

3. Check
3.1 Cleaning of Cylinder Head
3.1.1 Removal of Cushioning Material
Remove the cushioning material stuck on the bottom surface of
Figure 11-3-8 Removal of Carbon Deposit in Combustion
Chamber cylinder head with scraper.

Note: Do not scrape the bottom surface of cylinder head.

3.1.2 Cleaning of Combustion Chamber
Remove all the carbon deposit in combustion chamber with wire
brush, as shown in Figure 11-3-8.
Note: Do not scrape the surface of combustion chamber.
3.1.3 Cleaning of Valve Guide
Clean all the valve guide holes with hairbrush and solvent.

Figure 11-3-9 Cleaning of Cylinder Head 3.1.4 Cleaning of Cylinder Head

Thoroughly clean the cylinder head with hairbrush and solvent,
as shown in Figure 11-3-9.

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3.2 Check of Cylinder Head

3.2.1 Check of Flatness
Measure the bottom surface and intake/exhaust flanges with
precision straight edge and feeler gauge and determine whether
any warp exists, as shown in Figure 11-3-10.
Reference values:
Bottom surface of cylinder head: 0.05mm.
Intake/exhaust flange: 0.05mm.
Limit values:
Bottom surface of cylinder head: 0.07mm.
Intake/exhaust flange: 0.10mm.
Figure 11-3-10 Check of Flatness of Cylinder Head
3.2.2 Check for Cracks
Use dye penetrant to check the combustion chamber, air intake,
exhaust port and the bottom surface of cylinder head for cracks,
as shown in Figure 11-3-11.
If cracks exist, replace the cylinder head.

Figure 11-3-11 Check of Cylinder Head

3.3 Cleaning of Valve
3.3.1 Gently scrape off the carbon deposit on the valve big end
with scraper and be careful not to scratch the sealing strip, as
shown in Figure 11-3-12.
3.3.2 Thoroughly clean the valve with steel brush, as shown in
Figure 11-3-12.

Figure 11-3-12 Cleaning of Valve

3.4 Check of Valve Stem and Valve Guide
3.4.1 Measure the inside diameter of valve guide with calipers,
as shown in Figure 11-3-13.
Inside diameter of valve guide: 5.000 ~ 5.015mm.

Figure 11-3-13 Measurement of Inside Diameter of Valve

Guide

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3.4.2 Measure the valve stem diameter with screw micrometer

(micrometer) as shown in Figure 11-3-14.
Valve stem diameter:
Intake valve: 4.960 ~ 4.975mm.
Exhaust valve: 4.945 ~ 4.960mm.

3.4.3 Subtract the measured value of valve stem diameter from

that of the inside diameter of valve guide.
Standard oil film clearance:
Intake valve: 0.025 ~ 0.055mm.
Figure 11-3-14 Measurement of Valve Stem Diameter
Exhaust valve: 0.040 ~ 0.070mm.
Maximum oil film clearance:
Intake valve: 0.08mm.
Exhaust valve: 0.10mm.
If the oil film clearance is more than maximum value, replace
the valve and valve guide.

3.5 Check and Grinding of Valve

Grind the valve until all the pockmarks disappear and then check
Figure 11-3-15 Check of Valve Cone Angle the valve cone angle, as shown in Figure 11-3-15.
Valve cone angle: 45°.
3.5.2 Check the edge thickness of valve head as shown in Figure
11-3-16.
Standard edge thickness:
Intake valve: 1.10mm.
Exhaust valve: 1.20mm.
Minimum edge thickness: 0.50mm.
If the edge thickness is less than minimum value, replace the
Figure 11-3-16 Check of Edge Thickness of Valve Head valve.

3.5.3 Check the valve overall length as shown in Figure 11-3-17.

Standard overall length:
Intake valve: 88.99 ~ 89.39mm.
overall length Exhaust valve: 87.55 ~ 87.95mm.

3.5.4 Check the end face of valve stem for wear.

If the end face of valve stem has been worn, grind the end with
grinding wheel or replace the valve.
Figure 11-3-17 Check of Valve Overall Length

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3.6 Check and Cleaning of Valve Seat

3.6.1 Polish again the valve seat with 45° carbide ceramic tool
(as shown in Figure 11-3-18) and eliminate uneven wear,
pockmarks or pits to clean the seat ring.

Figure 11-3-18 Check and Cleaning of Valve Seat 3.6.2 Check the valve seating position.
Apply Prussian blue (or flake white) onto the valve sealing
surface. Gently press the valve to its seat and do not rotate the
valve.
3.6.3 Check the following items of valve sealing surface and
valve seat:
(1) Only if the blue pigment on the valve sealing surface is at
an angle of 360° around the valve center can indicate the valve
and its seat are coaxial, otherwise replace the valve.
(2) Only if the blue pigment on the valve seat is at an angle of
Figure 11-3-19 Check of Valve Seating Position 360° around the valve seat center can indicate the valve guide
and valve seat sealing surface are coaxial, otherwise replace the
valve seat.

(3) Check whether the contact surface of valve seat is in the

middle of valve surface. Its width is 1.0 ~ 1.4mm as shown in
Figure 11-3-20.
Otherwise, correct the valve seat as follows:
Correct the valve seat with 20° and 70° tools as shown in Figure
11-3-20.

Figure 11-3-20 Correction of Valve Seat

3.6.4 Manually grind the valve and its seat with grinding tools as
shown in Figure 11-3-21.
3.6.5 After grinding, clean the valve, valve seat and valve guide
hole.

Figure 11-3-21 Grinding of Valve and Valve Seat

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3.7 Check of Valve Spring

3.7.1 Measure the perpendicularity of valve spring with straight
steel ruler as shown in Figure 11-3-22.
Maximum angle: 2°.
If the deviation of perpendicularity is more than maximum value,
replace the valve spring.

Figure 11-3-22 Measurement of Perpendicularity of Valve

Spring 3.7.2 Measure the free length of valve spring with vernier
calipers as shown in Figure 11-3-23.
Reference value: 45.10mm.
If the measured free length does not meet the above-mentioned
requirement, replace the valve spring.
3.7.3 Measure the pressure of valve spring when in specified
mounting length with spring tester as shown in Figure 11-3-24.
The pressure when the spring is compressed to 32.2mm: 162N ±
10N.
If the pressure does not meet the above-mentioned requirement,
Figure 11-3-23 Measurement of Free Length of Valve replace the valve spring.
Spring
3.8 Check of Camshaft and Bearing
3.8.1 Check of Radial Run-out of Camshaft
(1) Put the camshaft on V-shaped block.
(2) Measure the radial run-out of journal with dial indicator.
Maximum radial run-out: 0.03mm.
If the measured radial run-out is more than maximum value,
replace the camshaft.
3.8.2 Check of Cam Cam-tip
Measure the height of cam cam-tip with screw micrometer
(micrometer) as shown in Figure 11-3-25.
Figure 11-3-24 Measurement of Pressure of Valve Spring
When in Specified Mounting Length Standard height of cam cam-tip:
Height of intake cam cam-tip: 44.64 ~ 44.74mm (GW4G15).
Height of exhaust cam cam-tip: 44.68 ~ 44.78mm (GW4G15).
Height of intake cam cam-tip: 44.62 ~ 44.72mm (GW4G13).
Height of exhaust cam cam-tip: 44.05 ~ 44.15mm (GW4G13).
Limit height of the cam cam-tip:
Height of intake cam cam-tip: 44.53mm (GW4G15).
Height of exhaust cam cam-tip: 44.57mm (GW4G15).
Height of intake cam cam-tip: 44.51mm (GW4G13).
Height of exhaust cam cam-tip: 43.95mm (GW4G13).
Figure 11-3-25 Measurement of Height of Cam If the measured height of cam cam-tip is less than limit value,
“Cam-tip”
replace the camshaft.

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3.8.3 Check of Camshaft Journals
Measure the diameter of the camshaft journals with a screw
micrometer (micrometer) as shown in Figure 11-3-26.
Diameter of camshaft journals:
First intake camshaft journal: 34.444 ~ 34.460mm.
First exhaust camshaft journal: 34.444 ~ 34.460mm.
Other journals: 22.949 ~ 22.965mm.
If the measured diameter of any camshaft journal does not meet
the above-mentioned requirement, check the oil clearance.

Figure 11-3-26 Measurement of Camshaft Journals

3.8.4 Check of Camshaft Bearing
Check whether the bearing surface is flaked or scorched; if the
bearing surface is damaged, replace the complete set of bearing
cap and cylinder head.
(1) Check the oil clearance of camshaft.
(2) Clean bearing cap, camshaft journal, cylinder head
camshaft hole.
(3) Put the camshaft on the cylinder head.
(4) Put a plastic gap gauge on each camshaft journal as shown
in Figure 11-3-27.
Figure 11-3-27 Check of Oil Clearance of Camshaft (5) Mount the camshaft bearing cap and then tighten the
hexagon bolt and flat washer assemblies (M6 × 38) of camshaft
bearing cap to the cylinder head, as shown in Figure 11-3-28.
Tightening torque: 12N·m ± 1N·m.
Note: Do not rotate the camshaft when installing the camshaft
bearing cap.
(6) Remove the camshaft bearing cap.
(7) Measure the width of the widest position of staved plastic
wire with the gauging ruler printed on the plastigauge package to
obtain the oil clearance.
Standard oil clearance: 0.035 ~ 0.072mm.
Figure 11-3-28 Installation of Camshaft Bearing Cap Maximum oil clearance: 0.080mm.
If the oil clearance is more than the maximum value, replace the
camshaft; replace complete set of bearing cap and cylinder head
when necessary.
3.8.5 Check of Axial Clearance of Camshaft
(1) Install the camshaft.
(2) Move the camshaft back and forth and measure the axial
clearance with a dial indicator as shown in Figure 11-3-29.
Standard axial clearance: 0.060 ~ 0.115mm.
Maximum axial clearance: 0.130mm.
Figure 11-3-29 Measurement of Axial Clearance of If the measured axial clearance is more than maximum value,
Camshaft replace the camshaft; replace the bearing cap and cylinder head
if necessary.

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3.9 Check of Diameter of Valve Tappet and Tappet Hole

3.9.1 Measure the diameter of cylinder head valve tappet hole
with calipers as shown in Figure 11-3-30.
Diameter of valve tappet hole: 31.000 ~ 31.025mm.

Figure 11-3-30 Measurement of Diameter of Cylinder

Head Valve Tappet Hole
3.9.2 Measure the diameter of valve tappet with screw
micrometer (micrometer) as shown in Figure 11-3-31.
Diameter of valve tappet: 30.956 ~ 30.966mm.
3.9.3 Subtract the measured diameter value of valve tappet from
that of valve tappet hole.
Standard oil clearance: 0.034 ~ 0.069mm.
Maximum oil clearance: 0.100mm.
If the oil clearance is more than maximum value, replace the
valve tappet; if necessary, replace the cylinder head.

Figure 11-3-31 Measurement of Diameter of Valve Tappet

4. Replacement
4.1 Replacement of Valve Guide
4.1.1 Immerse the cylinder head in water and gradually heat it to
80℃ ~ 100℃, as shown in Figure 11-3-32.
4.1.2 Take out the cylinder head and then gently knock out the
valve guide with proper tools.

Figure 11-3-32 Heating of Cylinder Head 4.1.3 After the cylinder head cools down, measure the inside
diameter of valve guide mounting hole as shown in Figure
11-3-33.
Standard inside diameter of valve guide mounting hole (in cold
state):
10.000 ~ 10.022mm.
Sizes of intake/exhaust valve guides:
10.053 ~ 10.068mm.

Figure 11-3-33 Measurement of Inside Diameter of Valve

Guide Mounting Hole

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4.1.4 Select a new valve guide.

4.1.5 Immerse the cylinder head in the water and gradually heat
it to 80℃ ~ 100℃.
4.1.6 Take out the cylinder head from the water and then gently
knock in the new valve guide with proper tools until the length
out of cylinder head reaches 9.0 ~ 9.4mm, as shown in Figure
11-3-34.
4.1.7 Ream the valve guide hole with Φ5mm reamer until its
diameter reaches the specified value.
Figure 11-3-34 Installation of Valve Guide
4.1.8 After replacing the valve guide, check the valve sealing
strip. If it does not meet the requirement, follow relevant
regulations.
Note: To ensure the performance of complete engine, it is
recommended to replace the cylinder head assembly directly to
avoid unnecessary consequences.

5. Installation
Note: Thoroughly clean all the parts to be installed.
Figure 11-3-35 Installation of Valve Oil Seal
5.1 Installation of Valve
5.1.1 Install water jacket screw plug and screw plug gasket.
5.1.2 Install new valve oil seal with special service tool (SST) as
shown in Figure 11-3-35.
SST: CC2008012.
5.1.3 Install the following parts in turn, as shown in Figure
11-3-36.
(1) Valve.
(2) Valve spring gasket.

Figure 11-3-36 Installation of Valve Assembly (3) Valve spring.

(4) Valve spring seat.

5.1.4 Compress the valve spring with special service tool (SST)
and place 2 valve lock clamps around the valve stem, as shown
in Figure 11-3-37.
SST: CC2008015.
5.1.5 Gently knock the valve stem end face with rubber mallet to
ensure tight fit.
Figure 11-3-37 Installation of Valve Lock Clamp

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5.2 Installation of Valve Tappet

5.2.1 Selection of Valve Tappet
Selection of valve tappet:
Intake valve tappet: A=B+(C–0.2);
Exhaust valve tappet: A=B+(C–0.3)
Where,
A- The thickness of newly selected tappet;
B- The thickness of previous tappet;
C- The measured valve clearance.
Table 11-3-1 Grouped Table of Valve Tappets (mm)

Group Group Thickness Group Thickness Group

Thickness Thickness
Figure 11-3-38 Installation of Valve Tappet No. No. No. No.
04 5.04 24 5.24 44 5.44 64 5.64
06 5.06 26 5.26 46 5.46 66 5.66
08 5.08 28 5.28 48 5.48 68 5.68
10 5.10 30 5.30 50 5.50 70 5.70
12 5.12 32 5.32 52 5.52 72 5.72
14 5.14 34 5.34 54 5.54 74 5.74
16 5.16 36 5.36 56 5.56 76 5.76
18 5.18 38 5.38 58 5.58 78 5.78
20 5.20 40 5.40 60 5.60 80 5.80
22 5.22 42 5.42 62 5.62

Figure 11-3-39 Installation of Cylinder Head Gasket 5.2.2 Apply a little oil onto the outer circular surface of the valve
tappet and then install the valve tappet. After installation, the
valve tappet should be able to rotate smoothly.

5.3 Installation of Cylinder Head

5.3.1 Check whether the cylinder block-positioning pin is
installed in place.
5.3.2 Mount the cylinder head gasket onto the top surface of
cylinder block as shown in Figure 11-3-39.

Note: Cylinder head gasket can be used only once.

5.3.3 Mount the cylinder head on the cylinder head gasket as

shown in Figure 11-3-40.

Figure 11-3-40 Installation of Cylinder Head

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5.3.4 Installation of Cylinder Head Bolts

Note: Do not use cracked or deformed cylinder head bolts.
(1) Evenly tighten 10 cylinder head bolts (M9 × 1.5 × 144) to
upper cylinder block at several times and in the sequence as
shown in Figure 11-3-41.
Tightening torque: 23N·m + 90° + 90°.

Figure 11-3-41 Tightening of Cylinder Head Bolts in Turn

Note: The length of cylinder head bolt: 144mm.

(2) Mark in the front of cylinder head bolts with paint.
(3) Tighten cylinder head bolts by 90° in sequence (as shown in
Figure 11-3-41), as shown in Figure 11-3-42.
(4) Tighten cylinder head bolts by another 90° in sequence (as
shown in Figure 11-3-41), as shown in Figure 11-3-42.
(5) Check whether the paint mark on cylinder head bolt heads
faces backward.

Figure 11-3-42 Tightening of Cylinder Head Bolts 90° +

90°

5.4 Installation of Intake/Exhaust Camshaft

Note: Due to very little axial clearance of the camshaft, be sure
to keep it level when installing. Otherwise, the part of cylinder
head under axial thrust may crack or be damaged and further
cause camshaft locking or breakage. To avoid such consequence,
take the following steps.

Figure 11-3-43 Installation of Intake/Exhaust Camshaft

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5.4.1 Installation of Intake Camshaft

(1) Install the camshaft as shown in Figure 11-3-44.
(2) Install 4 camshaft bearing caps in corresponding positions
as shown in Figure 11-3-44.
(3) Fasten camshaft bearing caps by evenly tightening 8
hexagon bolt and plain washer assemblies (M6 × 38) at twice, as
shown in Figure 11-3-45.
Tightening torque: 12N·m ± 1N·m.
5.4.2 Installation of Exhaust Camshaft
Figure 11-3-44 Installation of Camshaft and Bearing Cap
(1) Install the camshaft.
(2) Install 4 camshaft bearing caps in corresponding positions
of cylinder head.

Note: Exhaust camshaft must be installed in the required

position and direction. Refer to Installation of Intake Camshaft.
(3) Fasten camshaft bearing caps by evenly tightening 8
hexagon bolt and plain washer assemblies (M6 × 38) at twice.
Tightening torque: 12N·m ± 1N·m.

Figure 11-3-45 Even Tightening of Camshaft Bearing Cap

Bolts at Twice

5.4.3 Installation of Front-end Camshaft Bearing Cap

Evenly tighten 3 hexagon bolt and plain washer assemblies (M8
× 42) for mounting front-end camshaft bearing cap to cylinder
head at twice.
Tightening torque: 23N·m ± 2N·m.
After installation, the camshaft is shown in Figure 11-3-46.

Figure 11-3-46 Installation of Front-end Camshaft

Bearing Caps
5.4.4 Installation of Filter Screen, Oil Plug Gasket and Oil Plug
Remove the dirt and check whether the filter screen is damaged
as shown in Figure 11-3-47; if damaged, replace it with a new
one.
Note: If the VVT-i control valve is integrated with a filter screen,
the oil hole of cylinder head may not be provided with a separate
filter screen.

Figure 11-3-47 Check of Filter Screen

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Mount filter screen, oil plug gasket and oil plug to the cylinder
head as shown in Figure 11-3-48.
Tightening torque for oil plug: 30N·m ± 2N·m.

Figure 11-3-48 Installation of Filter Screen, Oil Plug

Gasket and Oil Plug

5.4.5 Installation of VVT-i Control Valve

Fasten the VVT-i control valve to cylinder head with 1 hexagon
flange bolt (M6 × 12) as shown in Figure 11-3-49.
Tightening torque: 7N·m ± 1N·m.

Figure 11-3-49 Installation of VVT-i Control Valve

5.4.6 Installation of Spark Plug
Mount 4 spark plugs to cylinder head with a 16mm spark plug
socket wrench (SST) as shown in Figure 11-3-50.
SST: CC2008014.
Tightening torque: 27N·m ± 2N·m.

Figure 11-3-50 Installation of Spark Plug

5.4.7 Install the timing mechanism (see Figure 11-3-51), oil
pump and cylinder head cover assembly, etc.

Figure 11-3-51 Installation of Timing Mechanism

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Section 4 Timing Mechanism

1. Schematic Mounting Diagram of Components

Figure 11-4-1 Schematic Mounting Diagram of Components of Timing Mechanism

1- hexagon flange bolt (M6 × 25, 2pcs); 2- tensioner assembly; 3- chain slide assembly; 4- hexagon flange bolt (M6 × 14, 2pcs); 5- chain
damper assembly; 6- VVT phaser; 7- exhaust camshaft sprocket; 8- VVT phaser bolt (M12 × 1.25 × 34); 9- exhaust camshaft sprocket bolt
(M10 × 1.25 × 22); 10- chain assembly

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2. Disassembly
2.1 Alignment of Marks
Rotate the crankshaft and make the timing marks of exhaust
camshaft sprocket and VVT phaser vertical upward as shown in
Figure 11-4-2.

Figure 11-4-2 Alignment of Timing Marks

2.2 Disassembly of Tensioner Assembly
Move up the limit stop to unlock, manually push the chain slide
assembly to make the tensioner plunger shrink and meanwhile
insert pin (or steel wire) into the holes of limit stop and tensioner,
then screw off 2 hexagon flange bolts (M6 × 25) and finally
remove the tensioner assembly, as shown in Figure 11-4-3.
2.3 Disassembly of Chain Slide Assembly and Chain Damper
Assembly
Remove the chain slide assembly. Screw off 2-hexagon flange
Figure 11-4-3 Disassembly of Tensioner Assembly bolts (M6 × 14) and then remove the chain damper assembly.
2.4 Removal of Chain Assembly
2.5 Disassembly of Exhaust Camshaft Sprocket and VVT Phaser
Screw off the bolts of exhaust camshaft sprocket and VVT
phaser and then remove the exhaust camshaft sprocket and VVT
phaser, as shown in Figure 11-4-4.

Note: Do not rotate the camshaft when disassembling the

exhaust camshaft sprocket and VVT phaser.

Figure 11-4-4 Disassembly of Exhaust Camshaft Sprocket

and VVT Phaser

3. Check
3.1 Check of Chain Assembly
Check chain rollers for such defects as breakage and spalling,
inner and outer chain plates for such defects as cracking and
breakage and pin shaft for such defects as breakage, serious wear.
If any of the above-mentioned occurs, replace the chain.
3.2 Check of Tensioner Assembly
Check the movement of tensioner plunger for retardation and the
Figure 11-4-5 Check of Chain Assembly tensioner ratchet for serious wear.
If any of the above-mentioned occurs, replace the tensioner

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assembly.

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3.3 Check of Chain Damper Assembly and Chain Slide

Assembly
Check the damper and chain slide guide face for serious wear or
damage; if any of the above-mentioned occurs, replace the chain
damper assembly or chain slide assembly.
3.4 Check of Exhaust Camshaft Sprocket and VVT Phaser
3.4.1 Check the exhaust camshaft sprocket and VVT phaser
sprocket for serious damage, knocking and tooth missing. If any
of the above-mentioned occurs, replace the exhaust camshaft
sprocket or VVT phaser.
3.4.2 Check of VVT Phaser
(1) Mount the intake camshaft together with VVT phaser, fix the
hexagonal part of intake camshaft and seal all the oil holes with
Figure 11-4-6 Check of VVT Phaser plastic adhesive tape except the oil hole with delay angle (as
shown in Figure 11-4-6).
(2) Rotate and maintain the camshaft in the direction of delay
angle as shown in Figure 11-4-7.

Figure 11-4-7 Check of VVT Phaser

(3) Aim the air gun at the reserved oil hole with delay angle to
pressurize and rotate VVT phaser shell in the direction of
advance angle (as shown in Figure 11-4-8) under the pressure of
150kPa (only for reference and may be other values sufficient to
unlock the lock pin) until it reaches the limit; repeat rotation for
2 ~ 3 times and confirm whether its rotation is steady and within
30°. If not, replace it with a new one.

Figure 11-4-8 Check of VVT Phaser

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4. Installation
4.1 Installation of Exhaust Camshaft Sprocket and VVT Phaser
When installing, align the exhaust camshaft sprocket and VVT
phaser with the positioning pins on the camshaft and push them
into the pins, then respectively tighten the exhaust camshaft
sprocket bolt (M10 × 1.25 × 22) and VVT phaser bolt (M12 ×
1.25 × 34).
Tightening torque: 30 N·m+65°.
Figure 11-4-9 Installation of Exhaust Camshaft Sprocket 4.2 Installation of Chain Damper Assembly and Chain Slide
and VVT Phaser Assembly
Mount the chain slide assembly on the cylindrical pin at the front
end of cylinder block. Fasten the chain damper assembly to
corresponding holes of cylinder block with 2 hexagon flange
bolts (M6 × 14).
Tightening torque: 10N·m ± 1N·m.

4.3 Installation of Chain Assembly

When installing the chain, be sure to align its 3 timing marks
respectively with the timing mark of exhaust camshaft sprocket,
VVT phaser sprocket and crankshaft sprocket, as shown in
Figure 11-4-10.

Figure 11-4-10 Installation of Chain Assembly

4.4 Installation of Tensioner Assembly

After finishing the installation of other parts, fasten the tensioner
assembly to upper cylinder block with 2 hexagon flange bolts
(M6 × 25).
Tightening torque: 10N·m ± 1N·m.
Then pull out the pin.
The timing system, after installation, is shown in Figure 11-4-10.

Figure 11-4-11 Installation of Tensioner Assembly

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Chapter 12 Cylinder Block Assembly

Section 1 Components of Cylinder Block Assembly

Figure 12-1-1 Schematic Mounting Diagram of Components of Cylinder Block Assembly

1- piston connecting rod assembly; 2- upper cylinder block assembly; 3- crankshaft flywheel assembly; 4- lower cylinder block

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Section 2 Piston Connecting Rod Assembly

1. Schematic Mounting Diagram of Components

Figure 12-2-1 Schematic Mounting Diagram of Components of Piston Connecting Rod Assembly
1- 1st gas ring; 2- 2nd gas ring; 3- oil ring assembly; 4- piston; 5- connecting rod bolt (M8 × 1 × 37.5, 8pcs/vehicle); 6- connecting rod cap; 7-
positioning pin of connecting rod cap (8pcs/vehicle); 8- lower connecting rod bush (4pcs/vehicle); 9- upper connecting rod bush
(4pcs/vehicle); 10- connecting rod body; 11- piston pin

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2. Disassembly
2.1 Disassembly of Piston Connecting Rod Assembly and
Connecting Rod Bush
2.1.1 Loosen the connecting rod bolts with proper tool and then
remove the connecting rod cap.
2.1.2 Insert a proper tool into cylinder bore from crankcase and
gently knock the joint face of connecting rod body and
connecting rod cap to knock out the piston connecting rod from
cylinder block, and then take out the piston connecting rod
assembly from the upside of cylinder block, as shown in Figure
Figure 12-2-2 Disassembly of Piston Connecting Rod 12-2-2.
Assembly 2.1.3 Remove upper and lower connecting rod bushes as shown
in Figure 12-2-3.
Note: Do not damage upper and lower connecting rod bushes
when disassembling. Number the disassembled piston
connecting rod assembly and upper/lower connecting rod bushes
in the sequence of cylinders and place them in groups.
2.2 Disassembly of Piston Ring Assembly
2.2.1 Dismantle the 1st and 2nd gas rings as shown in Figure
12-2-3.
2.2.2 Remove the oil ring assembly as shown in Figure 12-2-3.
3. Check
Note: Keep all the parts clean during check.
Figure 12-2-3 Disassembly of Piston Ring Assembly 3.1 Inspection of Fitting of Piston Pin
The piston pin should be able to rotate smoothly in the piston
and have no slip relative to the connecting rod, as shown in
Figure 12-2-4.
3.2 Inspection of Piston
Measure the piston diameter at the height of 10mm as shown in
Figure 12-2-5.
Measuring tool: micrometer.
Reference value: 74.940 ~ 74.955mm.
Note: The measurement should be made perpendicular to the
axial direction of piston pin hole.
3.3 Inspection of Piston Pin Boss and Piston Pin Clearance
Figure 12-2-4 Check of Fitting of Piston Pin
Calculate the clearance by measuring the diameter of piston pin
boss hole and piston pin.
Reference value: 0.008 ~ 0.015mm.
Limit value: 0.050mm.
Note: If the measured value is more than limit value, replace the
piston pin or piston; if necessary, replace both of them.
3.4 Inspection of Clearance between Piston and Cylinder
Select 3 sections in the cylinder by height (the measured depth
of the 1st, 2nd and 3rd section is respectively 10mm, 50mm and
90mm away from the top surface of cylinder block) and measure
the cylinder bore diameter in two directions perpendicular to
each other in each section.
Calculate the clearance between the piston and cylinder based on
Figure 12-2-5 Measurement of Piston Diameter at the the piston outside diameter and minimum cylinder bore
Height of 10mm
diameter.
Reference value: 0.045 ~ 0.070mm.

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3.5 Inspection of Piston Ring and Ring Groove

3.5.1 Measure the lateral clearance of piston ring groove with
feeler gauge as shown in Figure 12-2-6.
Piston Ring Reference Value
1st gas ring 0.03 ～ 0.07mm
2nd gas ring 0.02 ～ 0.06mm
Oil ring assembly 0.04 ～ 0.15mm
3.5.2 Inspection of Piston Ring Gap
Measure the clearance of piston ring with feeler gauge after
mounting it in the position 110mm away from the top surface of
cylinder block, as shown in Figure 12-2-7.
Figure 12-2-6 Inspection of Piston Ring and Ring Groove
Piston Ring Reference Value Limit Value
1st gas ring 0.20 ～ 0.35 mm 0.9lmm
2nd gas ring 0.35 ～ 0.50 film 1.06mm
Oil ring assembly 0.20 ～ 0.70 mm 0.82mm
Note: If the measured value is above the limit value, replace the
piston ring or piston connecting rod assembly.
3.6 Inspection of Connecting Road Big End Hole
After removing the connecting rod bushes, tighten connecting
rod bolts (M8 × 1 × 37.5) with the torque of 15N·m ± 3N·m,
mark on the connecting rod bolt head with paint, tighten
connecting rod bolts by another 90° and determine the angle of
Figure 12-2-7 Measurement of Piston Ring Gap rotation with paint, as shown in Figure 12-2-8.
Measure the diameter of connecting rod big end with inside
micrometer and the reference value is 43.000 ~ 43.016mm, as
shown in Figure 12-2-9.
Limit value of the diameter of connecting rod big end:
43.036mm.
Note: If the measured value is more than limit value, replace the
piston connecting rod assembly with same quality grade. The
overuse of connecting rod bolts may bring danger.
3.7 Inspection of Connecting Rod Bushes
Figure 12-2-8 Tightening of Connecting Rod Bolts Measure the diameter of connecting rod big end hole and
connecting rod journal.
The grouping of connecting rod bushes is as follows:
Color Reference Value
Blue 1.488 ～ 1.492mm
Colorless 1.492 ～ 1.496mm
Yellow 1.496 ～ 1.500 mm
Select bushes according to the measured diameter of connecting
rod big end hole and connecting rod journal, and the clearance
between the bush and connecting rod should be 0.016 ~
0.042mm.

Figure 12-2-9 Inspection of Diameter of Connecting Rod

Limit value: 0.060mm.
Big End Note: If the matching of bush fails to meet the above-mentioned
requirements, replace the crankshaft or the piston connecting rod
assembly.

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4. Installation
4. Installation of Piston Ring

Note: Remove the carbon deposit on the piston before

installation.
4.1.1 Install oil ring assembly as shown in Figure 12-2-10.
4.1.2 Install the 2nd and 1st gas ring as shown in Figure 12-2-10.

Note: The side with “ATG” mark near the opening of 1st gas ring
and the side with “A” mark of 2nd gas ring face upwards.
Figure 12-2-10 Installation of Piston Ring
Mount piston rings in place with their opening positions as
shown in Figure 12-2-11.

4.2 Installation of Piston Connecting Rod Assembly

4.2.1 Press Mounting of Piston Pin
Apply oil to piston pin boss hole and connecting rod small end
hole.
Align the Forward marks of piston and connecting rod body and
then press in piston pin with special tool.

Figure 12-2-11 Piston Ring Opening Position Note: Mount piston pin and piston as per above-mentioned
group number and do not mix.

4.2.2 Installation of Connecting Rod Bushes

Apply oil onto the inner surface (alloy layer side) of connecting
rod bushes.
4.2.3 Installation of Piston Connecting Rod Assembly
Mount piston connecting rod assembly and confirm the Forward
marks face towards the engine front end as shown in Figure
12-2-12 and Figure 12-2-13.
Figure 12-2-12 Installation of Piston Connecting Rod
Assembly and Bushes Confirm the Forward mark of connecting rod cap faces towards
the engine front end and mount the connecting rod cap onto
connecting rod body.
Tighten the connecting rod bolts with torque wrench as follows:
pre-tighten connecting rod bolt (M8 × 1 × 37.5) with the torque
of 15N·m, mark on the bolt with paint pen and then tighten it by
another 90° confirmed through the paint mark. Confirm all the
bolts are tightened.
After installing the piston connecting rod assembly in place,
confirm the crankshaft can rotate smoothly without retardance.

Figure 12-2-13 Confirmation of Marks of Piston

Connecting Rod Assembly

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Section 3 Crankshaft Flywheel Assembly

1. Schematic Mounting Diagram of Components

1- damper pulley bolt assembly (M12 × 1.25 × 47); 2- damper pulley assembly; 3- crankshaft sprocket; 4- cylindrical pin; 5- crankshaft;
6- cylindrical pin; 7- flywheel assembly; 8- flywheel bolt (M10 × 1.25 × 20, 6pcs); 9- cylindrical pin (3pcs)

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2. Disassembly
2.1 Disassembly of Damper Pulley
2.1.1 Disassemble the damper pulley bolt assembly.

Note: When disassembling the damper pulley bolt, it is strictly

prohibited to make the pulley rotate relative to the crankshaft to
prevent crankshaft cylindrical pin from breakage.

Figure 12-3-2 Disassembly of Flywheel Bolt

2.1.2 Remove the damper pulley.

Note: When disassembling damper pulley, it is strictly

prohibited to apply any tensile or compression force to the
damper pulley.

2.2 Disassembly of Flywheel

2.2.1 Fix and prevent the crankshaft rotating with proper tool,
then screw off 6 flywheel bolts (M10 × 1.25 × 20), as shown in
Figure 12-3-2 and Figure 12-3-3.
2.2.2 Remove the flywheel assembly.
Figure 12-3-3 Disassembly of Flywheel
2.3 Disassembly of Crankshaft
Note: Such components as oil pump, lower cylinder block and
connecting rod should have been dismantled before
disassembling the crankshaft assembly.

2.3.1 Screw off the 10 main bearing cap bolts (M10 × 70.5) and
then remove 5 main bearing caps, as shown in Figure 12-3-4.
2.3.2 Remove the 5 lower main bearing bushes and the 2 thrust
washers.

Figure 12-3-4 Disassembly of Main Bearing Bolts in Turn 2.3.3 Remove the crankshaft assembly and 5 upper main bearing
bushes.
Note: Mark all the disassembled main bearing bushes to avoid
confusion. Be sure to screw off main bearing bolts in the
sequence as shown in Figure 12-3-4.
2.3.4 Lift up the crankshaft assembly as shown in Figure 12-3-5.

Figure 12-3-5 Disassembly of Crankshaft

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3. Check
3.1 Check the flywheel ring gear for tooth breakage and check
both ring gear and flywheel for looseness; if any of the
above-mentioned occurs, replace the flywheel assembly, as
shown in Figure 12-3-6.
3.2 Check the outer and inner rings of damper pulley for relative
slip and axial run-out and check the rubber layer for aging and
cracking; if any of the above-mentioned occurs, replace the
Figure 12-3-6 Inspection of Flywheel Ring Gear damper pulley.
3.3 Inspection of Crankshaft and Main Bearing Bushes
3.3.1 Clean the crankshaft assembly and main bearing bushes
and then check the main bearing bushes and crankshaft journal
for pockmarks and serious scratches; if any of the
above-mentioned occurs, replace the main bearing bush or
crankshaft assembly.

Figure 12-3-7 Inspection of Crankshaft and Main Bearing

Bush

3.3.2 Measure the oil clearance of crankshaft main journal.

(1) Wipe up the oil on main journal and bush inner surface, then
mount main bearing bushes.
(2) Mount the crankshaft assembly as shown in Figure 12-3-8.

Figure 12-3-8 Installation of Crankshaft Assembly

(3) Cut the plastigauge to make its length same as bush width
and place it on the crankshaft journal in parallel with the shaft
centerline, as shown in Figure 12-3-9.

Figure 12-3-9 Installation of Plastigauge

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(4) Mount the main bearing caps and the lower main bearing
bushes, then tighten the main bearing cap bolts (M10 × 1.5 ×
70.5) in turn with a specified torque twice, as shown in Figure
12-3-10.
Tightening torque: 22N·m + 90°.
(5) Remove the main bearing caps again.

Figure 12-3-10 Installation of Main Bearing Cap and

Lower Main Bearing Bush
(6) Measure the width of the widest position of staved plastic
wire with the gauging ruler printed on the plastigauge package to
gauging ruler
obtain the oil clearance of main journal, as shown in Figure
12-3-11.
Reference value: 0.014 ~ 0.037mm.
Limit value: 0.070mm.
Note: If the measured value is more than limit value, replace the
main bearing bush or crankshaft assembly.
3.3.3 Measurement of Oil Clearance of Connecting Rod Journal
Figure 12-3-11 Measurement of Oil Clearance of Main Measure the oil clearance of connecting rod journal as described
Journal
in measuring the oil clearance of main journal.
Reference value: 0.016 ~ 0.042mm.
Limit value: 0.062mm.
Note: If the measured value is more than limit value, replace the
connecting rod bush or crankshaft assembly.

3.3.4 Measure the diameter of crankshaft journal as shown in

Figure 12-3-12.
Figure 12-3-12 Measurement of Diameter of Crankshaft Reference values:
Journal
Diameter of connecting rod journal: 39.985 ~ 40.000mm.
Diameter of main journal: 45.985 ~ 46.000mm.

3.3.5 Bush Selection Table

Table 9-3-1 Optional Connecting Rod Bush
Mark of Crankshaft Connecting Rod
Mark of Connecting Rod Bush Journal
1 2 3
Mark of 1 Colorless Blue Blue
connecting rod big
2 Yellow Colorless Colorless
end hole diameter
Figure 12-3-13 Selection of Connecting Rod Bush

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Table 9-3-2 Selection of Main Bearing Bush

Mark of Main Bearing Mark of Crankshaft Main Journal
Bush 3 2 1
0 Yellow Yellow Colorless
Mark of main
bearing hole 1 Yellow Colorless Colorless
diameter 2 Colorless Colorless Blue
3 Colorless Blue Blue

Figure 12-3-14 Selection of Main Bearing Bush

3.3.6 Measurement of Axial Clearance of Connecting Rod Big
End
Move the connecting rod big end back and forth and measure its
axial clearance with dial indicator as shown in Figure 12-3-15.
Reference value: 0.18 ~ 0.37mm.

Figure 12-3-15 Measurement of Axial Clearance of

Connecting Rod Big End
3.3.7 Measure the axial clearance of crankshaft as shown in
Figure 12-3-16. Pry the crankshaft with even force in left/right
axial direction.
Reference value: 0.10 ~ 0.29mm.
Limit value: 0.35mm.
Thickness of thrust washer: 2.40 ~ 2.45mm.
Note: Once the measured axial clearance of crankshaft is more
than limit value, replace complete set of thrust washers or
crankshaft assembly.

Figure 12-3-16 Measurement of Axial Clearance of

Crankshaft
4. Installation
4.1 Installation of Crankshaft
4.1.1 When installing main bearing bushes, do not misplace
upper and lower main bearing bushes. Upper main bearing bush
has oil hole and oil groove while lower main bearing bush does
not have, as show in Figure 12-3-17.
Note: The misplacement of upper and lower main bearing
bushes may result in the adherence and burnout of connecting
rod bush.
Figure 12-3-17 Upper and Lower Main Bearing Bushes

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Apply a little clean oil onto the inner surface of main bearing
bushes before installing them.
4.1.2 When installing the thrust washer, do not misplace and be
sure to make the side with groove of thrust face towards the
crankshaft.

4.1.3 When installing main bearing caps, be sure to note the

Forward mark and number on the caps and do not misplace them,
as shown in Figure 12-3-18.

Figure 12-3-18 Installation of Main Bearing Cap

4.1.4 When installing the main bearing cap bolts (M10 × 1.5 ×
70.5), tighten them at twice and in the sequence as shown in
Figure 12-3-19; it is strictly prohibited to rotate the crankshaft
when tightening.
Tightening torque: 22N·m + 90°.
4.1.5 After tightening 10 main bearing cap bolts, check whether
the crankshaft can rotate smoothly.
4.1.6 When installing connecting rod cap and connecting rod
bush, do not misplace upper and lower connecting rod bushes.
There is “U” mark and oil hole on the back of upper connecting
rod bush (see Figure 12-3-13) while there is “L” mark on the
Figure 12-3-19 Tightening of Main Bearing Cap Bolts in back of lower connecting rod bush. Note that there is Forward
Turn
mark on the connecting rod cap.
4.1.7 When installing connecting rod bolts (M8 × l × 37.5),
apply a little oil onto the screw thread and joint face and tighten
them at twice, as shown in Figure 12-3-20.
Tightening torque: 15N·m + 90°.

Figure 12-3-20 Installation and Tightening of Connecting

Rod Bolts at Twice

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4.2 Installation of Flywheel

4.2.1 When installing the crankshaft rear oil seal with special
service tool (SST) (see Figure 12-3-21), apply a little oil onto the
crankshaft sealing surface and oil seal lip oil groove and prevent
oil seal from scratches. After installation, make sure the end face
of the oil seal assembly. does not incline.
SST: CC2008010.
Note: Once disassembled, the crankshaft rear oil seal can not be
used again and must be replaced with a new one.

Figure 12-3-21 Installation of Crankshaft Rear Oil Seal

4.2.2 Install the flywheel assembly (see Figure 12-3-22). At this
time, be sure to keep the friction surface clean without oil stains.

Figure 12-3-22 Installation of Flywheel

4.2.3 When installing the 6 flywheel bolts (M10 × 1.25 × 20),
apply Loctite 243 anaerobic thread-locking sealant on the screw
thread and symmetrically tighten them at twice, as shown in
Figure 12-3-23.
SSM: 23962.
Tightening torque: 30N·m+45°.

Figure 12-3-23 Symmetric Tightening of Flywheel Bolts

4.3 Installation of Damper Pulley
4.3.1 Apply some lubricating oil on the damper pulley bolt
washer to prevent cylindrical pin from being broken by relative
rotation between the pulley and crankshaft.
4.3.2 Mount the damper pulley and crankshaft cylindrical pin in
the crankshaft front end, and then tighten the damper pulley bolt
(M12 × 1.25 × 47) and washer, as shown in Figure 12-3-24.
Tightening torque: 50N·m+65°.

Figure 12-3-24 Installation of Damper Pulley

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Section 4 Upper/Lower Cylinder Blocks

1. Schematic Mounting Diagram of Components

Figure 12-4-1 Schematic Mounting Diagram of Components of Upper/Lower Cylinder Blocks of Gasoline Engine
1- hexagon bolt and plain washer assembly (M8 × 80, 6pcs); 2- hexagon bolt and plain washer assembly (M8 × 45, 5pcs); 3- hexagon bolt
and plain washer assembly (M8 × 140, 2pcs); 4- dust cap of lower cylinder block; 5- lower cylinder block; 6- cylindrical pin (4pcs); 7-
cylindrical pin (2pcs); 8- upper cylinder block; 9- bowl-shaped plug (2pcs); 10- chain lubricating nozzle; 11- cylindrical pin; 12- “O” ring
(2pcs)

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2. Disassembly
2.1 Disassembly of Lower Cylinder Block
2.1.1 Dismantle the oil pan, oil filter, oil collector and timing
cover.
2.1.2 Dismantle the hexagon bolt and plain washer assemblies
(M8 × 45, M8 × 80 and M8 × 140) for fastening the lower
cylinder block, as shown in Figure 12-4-2.
2.1.3 Remove the lower cylinder block.

Figure 12-4-2 Disassembly of Fastening Bolts of Lower

Cylinder Block
2.1.4 Take out the 2 O rings of joint face between upper and
lower cylinder blocks, as shown in Figure 12-4-3.

Figure 12-4-3 Removal of 2 O rings

2.2 Disassembly of Dust cap of Lower Cylinder Block
2.2.1 Take out the dust cap by pressing its 2 bayonets, as shown
in Figure 12-4-4.

Figure 12-4-4 Removal of Dust Cap by Pressing Its Two

Bayonets

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3. Check
3.1 Inspection of Lower Cylinder Block
Visually check whether upper and lower end faces of lower
cylinder block are damaged; if damaged, repair or replace the
lower cylinder block.
3.2 Check whether the dust cap of lower cylinder block is
damaged; if damaged, replace it.
3.3 Check whether the chain lubricating nozzle is clogged.
3.4 Inspection of Top Surface Flatness of Cylinder Block
Measure the top surface warp of cylinder block with precision
Figure 12-4-5 Inspection of Top Surface Flatness of straight edge and feeler gauge and the measured value should
Cylinder Block not be more than 0.040mm, as shown in Figure 12-4-5.
3.5 Visually check whether there are vertical scratches or
grooves on the inner surface of cylinder bore; if relatively deep
scratches exist, replace the cylinder block.
3.6 Inspection of Cylinder Bore Diameter
Measure the cylinder bore diameter with inside micrometer.
Standard diameter: 75.000 ~ 75.010mm.
3.7 Check Cylinder Port for Bossing
If the wear loss of cylinder port is more than 0.2mm, ream
cylinder excess with reamer, as shown in Figure 12-4-6.

4. Installation
Figure 12-4-6 Inspection of Cylinder Port 4.1 Cleaning
4.1.1 Remove the residual sealant on the joint face of upper
cylinder block and the mounting surface of oil pan with scraper
or other tools.
4.1.2 Remove the cushioning material of upper cylinder block.
Remove the cushioning material stuck on the top surface of
cylinder block with scraper.
Note: Be careful not to damage the top surface of cylinder block
when cleaning with scraper.
4.1.3 Cleaning of Cylinder Block
Thoroughly clean the cylinder block with soft brush and solvent.
4.2 Installation of Lower Cylinder Block
4.2.1 Put the 2 new O rings into the ring groove as shown in
Figure 12-4-7.
4.2.2 Apply Loctite 5699 flange sealant (SSM) on the joint face
between the lower cylinder block and the upper cylinder block
assembly. When installing the lower cylinder block, use the 2
positioning cylindrical pins of upper cylinder block assembly for
positioning, as shown in Figure 12-4-7.
SSM: 33964.
4.2.3 Fasten the upper cylinder block assembly and lower
cylinder block with hexagon bolt and plain washer assemblies
Figure 12-4-7 Installation of Lower Cylinder Block
(M8 × 45, M8 × 80 and M8 × 140), as shown in Figure 12-4-7.
Tightening torque: 24N·m ± 2N·m.

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4.3 Installation of Dust Cap of Lower Cylinder Block

Lock the bayonets of dust cap into corresponding position of
lower cylinder block (as shown in Figure 12-4-8) and check
whether the bayonets are locked into the lower cylinder block.

Figure 12-4-8 Installation of Dust Cap of Lower Cylinder

Block
4.4 Installation of Water Drain Valve
Apply Loctite 243 anaerobic thread-locking sealant (SSM) on
the screw thread of water drain valve assembly as shown in
Figure 12-4-9, and then mount the water drain valve to cylinder
block as shown in Figure 12-4-10.

Figure 12-4-9 Application of Sealant on Screw Thread of

Water Drain Valve

Figure 12-4-10 Installation of Water Drain Valve

Assembly After installation, the water drain valve port should be
downward and within 15° as shown in Figure 12-4-11.
Tightening torque: 15N·m ± 2N·m.
SSM: 23962.
Note: If unnecessary, do not disassemble the water drain valve.

Figure 12-4-11 Installation of Water Drain Valve

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Chapter 13 Clutch Assembly

1. Schematic Mounting Diagram of Components

Figure 13-1-1 Schematic Mounting Diagram of Components of Clutch Assembly

1- clutch driven disc assembly; 2- clutch cover assembly; 3- hexagon bolt and spring washer assembly

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2. Disassembly
2.1 Fix and prevent the crankshaft rotating with proper tool, then
disassemble the 6 hexagon bolt and spring washer assemblies
(M8 × 18) for fastening the clutch cover assembly in turn, as
shown in Figure 13-1-2 and Figure 13-1-3.

Figure 13-1-2 Disassembly of Clutch

Figure 13-1-3 Disassembly of Clutch Fastening Bolts in

Turn
2.2 Remove the clutch cover assembly.
2.3 Remove the clutch driven disc assembly.

Figure 13-1-4 Disassembly of Clutch Cover Assembly

and Driven Disc Assembly
3. Inspection
Inspect the clutch driven disc assembly and clutch cover
assembly for such defects as excessive wear, loose riveting and
damage, etc. If any of the above-mentioned occurs, replace them
with new ones.

Figure 13-1-5 Inspection of Clutch Driven Disc

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4. Installation
4.1 Mount the clutch to the flywheel rear end with special
service tool (SST) as shown in Figure 13-1-6.
SST: CC2008011.

Figure 13-1-6 Installation of Clutch Cover Assembly

4.2 Symmetrically tighten 6 hexagon bolt and spring washer

assemblies (M8 × 18) to the flywheel as shown in Figure 13-1-7.

Tightening torque: 24N·m ± 2N·m.

Figure 13-1-7 Tightening of Fastening Bolt and Spring

Washer Assemblies of Clutch Cover in Turn

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