473 Engine

Page 1, Total pages 119
Engine
Catalog
Chapter 1 Gasoline Engine...................................................................3
Section 1 Overview .......................................................................................... 3
1.1 Major Technical Parameters .......................................................................................3
1.2 Technical Parameters for Maintenance ......................................................................4
1.3 BYD473QA/QB Gasoline Engine Tightening Torque Table.........................................7
1.4 BYD473Q Engine Special-purpose Part List ..............................................................9
Section 2 Cylinder Head .................................................................................. 9

2.1 Adjust Valve Clearance ..............................................................................................9
2.2 Remove/Install Crankshaft Pulley.............................................................................10
2.3 Remove/Install Silent Timing Chain.......................................................................... 11
2.4 Install Crankshaft Front Oil Seal...............................................................................19
2.5 Remove Cylinder Head Cover..................................................................................19
2.6 Remove Cylinder Head ............................................................................................20
2.7 Remove/Install Camshaft Sprocket ..........................................................................25
2.8 Replace Camshaft Phase Sensor Signal Plate ........................................................29
2.9 Check Cylinder Head Warping .................................................................................31
2.10 Remove Rocker Arm Assembly ..............................................................................32
2.11 Disassemble/Reassemble Rocker Arm and Rocker Arm Shaft...............................33
2.12 Check Rocker Arm and Rocker Arm Shaft .............................................................33
2.13 Remove Camshaft..................................................................................................34
2.14 Check Camshaft.....................................................................................................35
2.15 Remove Valve, Valve Spring and Valve Oil Seal ....................................................36
2.16 Check Valve ...........................................................................................................36
2.17 Check Valve Tappet-Valve Guide Clearance ..........................................................37
2.18 Replace Valve Guide ..............................................................................................38
2.19 Check Valve Seat ...................................................................................................40
2.20 Install Valve, Valve Spring and Valve Oil Seal ........................................................42
2.21 Install Camshaft......................................................................................................44
2.22 Install Rocker Arm Assembly ..................................................................................45
2.23 Install Cylinder Head ..............................................................................................46
2.24 Install Cylinder Head Cover....................................................................................53
Section 3 Cylinder Block ................................................................................ 54

3.1 Check Connecting Rod-Crankshaft Axial Clearance ................................................56
3.2 Replace Crankshaft Main Bearing Bush...................................................................57
3.3 Replace Connecting Rod Bearing Shell ...................................................................60
3.4 Remove Oil Pan .......................................................................................................63
3.5 Remove Crankshaft and Piston................................................................................64
3.6 Check Crankshaft.....................................................................................................67
If you find any incorrect information, or you request more details or demonstrations, please send email to
[email protected] to obtain support.
3.7 Check Cylinder Body and Piston ..............................................................................69

3.8 Replace Piston, Piston Pin and Connecting Rod .....................................................73
3.9 Check Connecting Rod Bolt .....................................................................................80
3.10 Install Crankshaft....................................................................................................80
3.11 Install Oil Pan .........................................................................................................83
Chapter 2 Lubricating System ............................................................86

1. Check Oil Pressure Warner........................................................................................87
2. Inspect Oil Pressure ...................................................................................................87
3. Change Engine Oil .....................................................................................................88
4. Replace Engine Oil Filter............................................................................................88
5. Replace Oil Filter Thread Pipe ...................................................................................89
6. Overhaul Oil Pump .....................................................................................................90
7. Install Breather Cover Plate........................................................................................93
8. Replace Oil Pressure Warner.....................................................................................94
Chapter 3 Air Intake and Exhaust System ..........................................95

1. Standard Service Value ..............................................................................................95
2. Air Intake System Parts Layout ..................................................................................95
3. Air Filter Assembly......................................................................................................96
4. Intake manifold ...........................................................................................................96
5. Intake Pipe and Muffler...............................................................................................97
6. Inspection...................................................................................................................98
7. Remove/Install intake manifold...................................................................................98
8. Remove/Install Exhaust Manifold ...............................................................................99
Chapter 4 Engine Cooling System....................................................100

1. Information on Maintenance Standard......................................................................101
2. Coolant.....................................................................................................................101
3. Sealant .....................................................................................................................101
4. On-board Maintenance.............................................................................................101
5. Thermostat ...............................................................................................................102
6. Water Pump .............................................................................................................104
7. Water Inlet/Outlet Hose ............................................................................................105
8. Radiator....................................................................................................................107
9. Check Thermostat ....................................................................................................109
10. Check Water Pump ................................................................................................109
11. Replace Water Pump.............................................................................................. 110
12. Replace Thermostat ............................................................................................... 110
13. Replace Water Temperature Sensor ...................................................................... 111
Chapter 5 Fuel and Exhaust System ................................................ 112

1. Fuel Tank.................................................................................................................. 112
2. Power Fuel Pump..................................................................................................... 113
Chapter 1 Gasoline Engine

Section 1 Overview
BYD473QA/QB gasoline engine adopts electronically controlled fuel injection system, which is
developed by BYD and featured by sequential multi-point fuel-injection and advanced
self-diagnosis function. The engine has high power per liter, low fuel consumption, low noise, low
pollution and compact profile. BYD473QA/QB engine can optimize running under all working
conditions, allowing good performance of the BYD F3 AUTO in the aspects of safety, drivability,
economic and environmental performance.
1.1 Major Technical Parameters

The major technical parameters of BYD473QA/QB are shown below:
Model
BYD473QA
BYD473QB
Configuration
In-line, water-cooled, SOHC, EFI, 4-stroke engine
Number of Cylinders
Cylinder bore (mm)
73
Piston stroke (mm)
80
Compression ratio
10.2
Ignition sequence
1-3-4-2
88.9
67
75
(5800r/min)
(5800r/min)
Maximum torque (N.m)
120 (4700 r/min)
135(4800r/min)
Declared speed (r/min)
5800
Declared power (kw)
Minimum
fuel
consumption
(g/kWh)
275
Oil pressure (kPa)
300350(3000r/min50r/min)
Minimum stable idle speed (r/min)
78050
Total displacement (L)
1.339
Oil/fuel consumption ratio (%)
0.26
Overall dimensions
(LWH) (mm)
Net weight (kg)
1.488
587543682
587543700
87.5
92
CO0.15% HC40ppm (78050r/min)
Idle exhaust emission
CO0.15% HC40ppm(200050r/min) GB18285-2005
Fuel
unleaded gasoline
SG grade 10W/30 (year around in the south and spring, summer and autumn
Lubricating oil
in the north)
SG grade 5W/30 (winter in the north)
Coolant
Clutch
Ethylene glycol based coolant

Configuration
Dry-type, single-disk, diaphragm spring clutch, with constant pressure
Overall
Clutch driven disk assembly 2008.9mm (free state)
dimensions
(mm)
Clutch cover assembly 25540.4mm
Weight
4.314kg

Configuration
Synchromesh transmission, 5 forward gears, 1 reverse gear

1st gear
nd
2
Gear ratio
3.308
gear
1.826
rd
3 gear
1.207
th
0.939
th
5 gear
0.730
Reverse
3.231
4 gear
Gearbox
Final drive ratio
4.471
Overall
(LWH) 504382363mm
dimensions
(mm)
Lubricating oil
Gear oil for medium duty vehicle (GL-4 SAE 80W/90)
1.2 Technical Parameters for Maintenance

Cylinder Head
Part Name
Cylinder head
Camshaft
Measuring
Measured Item
Condition
Warping
Height
119.9120.1mm
Camshaft axial clearance
0.050.25mm
0.5mm
Camshaft-bracket oil film clearance
0.0450.084mm
0.1mm
Total runout
Maximum 0.03mm
0.04mm
Clearance (cold)
Tappet outer diameter
Tappet-guide clearance
Width
Valve seat
Tappet installation height
Valve spring
Free length
Inner diameter
Valve guide
Installation height
Rocker arm
Service limit
0.08mm
Cam lobe lift
Valve
Standard Value
Rocker
clearance
arm-rocker
arm
shaft
Intake
35.38mm
Exhaust
35.377mm
Intake
0.150.18mm
Exhaust
0.230.28mm
Intake
5.4705.485mm
5.45mm
Exhaust
5.4555.470mm
5.42mm
Intake
0.0250.060mm
0.08mm
Exhaust
0.040.075mm
0.11mm
Intake
0.851.15mm
1.60mm
Exhaust
1.251.55mm
2.00mm
Intake
46.146.5mm
46.8mm
Exhaust
46.246.6mm
46.9mm
Intake
50.5mm
Exhaust
57.2mm
Intake
5.515.53mm
5.55mm
Exhaust
5.515.53mm
5.55mm
Intake
15.8516.35mm
Exhaust
15.8516.35mm
Intake
0.020.054mm
0.08mm
Exhaust
0.020.054mm
0.08mm
Cylinder Block
Part Name
Measuring
Measured Item
Condition
Surface warping
Cylinder
block
0.10mm
73.07mm
Cylinder bore conicity
----
0.05mm
Cylinder reboring limit
----
0.25mm
72.95572.975mm
72.945mm
0.0350.054mm
0.06mm
Air-tight ring
1.021.04mm
1.07mm
Air-tight ring
1.211.23mm
1.25mm
Oil-control ring
2.012.03mm
2.05mm
Air-tight ring
0.030.07mm
0.15mm
Air-tight ring
0.020.06mm
0.13mm
Air-tight ring
0.150.3mm
0.6mm
Air-tight ring
0.350.5mm
0.65mm
Oil-control ring
0.20.7mm
0.8mm
Clearance to cylinder
Piston ring groove
Piston ring-groove clearance

Piston ring
Piston ring gap
Outer diameter
17.99618mm
Piston pin to piston-pin boss
0.0050.015mm
clearance
Pin-connecting rod small end
0.0150.037mm
bore clearance
Connecting
Connecting rod small end bore
rod
Connecting rod big end bore

End play
when installed to
crankshaft
17.96317.981mm
Normal
4343.015 mm
0.150.3mm
Main journal diameter
49.93749.955mm
Connecting rod journal diameter
39.94039.955mm
Connecting
Crankshaft
Maximum 0.07mm
_
the piston skirt bottom
Piston pin
Service limit
7373.019mm
Cylinder bore
Outer diameter at 13mm from
Piston
Standard Value
rod/main
journal
rod/main
journal
0.4mm
0.005mm
0.01mm
0.005mm
0.01mm
End play
0.10.35mm
0.45mm
Runout
Maximum 0.03mm
0.04mm
0.0280.049mm
0.055mm
0.0220.050mm
0.055mm
conicity
Connecting
out-of-roundness
Mainshaft bearing-journal oil film

Crankshaft
clearance
bearing
Connecting
clearance
rod
bearing
Engine Lubrication
Part Name
Measured Item
Measuring Condition
Standard Value
Engine overhaul
4.0L
Replace oil (including oil

Engine oil
Oil capacity
filter)
Replace oil (excluding oil
filter)
Inner
rotor-outer
rotor clearance
Service limit
3.3L
2.9L
0.075mm0.15mm
0.18mm
0.06mm0.136mm
0.18mm
0.028mm0.065mm
0.085mm
Pump
Oil pump
housing-outer rotor
clearance
Pump
housing-outer rotor
shaft clearance
Pressure
relief valve
Oil pressure under
Idle
80C
Engine
oil
temperature
Minimum 30KPa
speed
at
3000rpm/min
Minimum 300KPa
Engine Coolant
Part Name
Coolant
Radiator
Thermostat
Measuring
Measured Item
capacity
Condition
(including
Coolant
tank)
replacement
782
Fully open
90
Above 8mm
To ON
Switching temperature
6.8L
Starting to open
Valve stroke when fully open

Thermoswitch
Service limit
Engine overhaul
engine, heater, hose and water
Opening temperature (C)
Standard Value
To OFF
9195
3 8
lower
than
the
actual
temperature switching to ON
1.3 BYD473QA/QB Gasoline Engine Tightening Torque Table

Tightening torque:
SN
Part /Location To Tighten
Bolt Description
Cylinder head
Cylinder head bolt with washer
Main bearing cap
Connecting rod cover
Connecting rod bolt
9.8 plus 90 rotation
Flywheel
Flywheel bolt
95
Spark plug
M141.25
20
Breather cover plate
Bolt M612
12
Knock sensor
Bolt M830
25
Oil pressure alarm device
----
15
Cylinder head plug
Bolt M101.2512
30
10
Tensioner assembly
Tensioner pivot bolt
22
11
Camshaft sprocket
12
Guide assembly
Bolt M616
12
13
Tensioner seat
Bolt M630
12
14
Bolt M625
Oil pump assembly
10
Bolt M635
10
Bolt M635
12
Bolt M612
10
Bolt M6
10
Bolt M630
12
Bolt M835
25
Bolt M650
12
Oil filter
12
Corrugated pipe
74
15
Water pump
16
Oil collector
17
Oil pan
(N.m)
Main bearing cap bolt with

washer
Camshaft
sprocket
bolt
assembly
29 plus 130 rotation

25 plus 40 rotation
56
18
Oil filter
19
Dipstick tube welded assembly
Bolt M612
10
20
Water outlet pipe part
Bolt M612
10
21
Intake manifold
Bolt M835
25
Nut M8
25
22
Oil rail
Bolt M612
10
23
Air intake temperature/pressure sensor
24
Intake valve assembly
25
Accelerator cable bracket
26
Exhaust manifold
27
Exhaust manifold heat shield
28
Exhaust manifold bracket
Cross
recessed
screw
pan
head
Bolt M630
12
Bolt M635
12
Bolt M612
12
Bolt M101.2520
44
Nut M10
44
Bolt M612
10
Bolt M816
25
Nut M8
25

29
Front oxygen Sensor
----
45
30
Thermostat cover
Bolt M620
10
31
Camshaft phase sensor
Bolt M616
10
32
Water temperature sensor
33
Cylinder head cover
34
Ignition coil
Bolt M625
10
35
Carbon canister control valve bracket
Bolt M612
10
36
Crankshaft pulley
Pulley bolt with washer
37 plus 90 rotation
37
Water pump pulley
Bolt M612
14
38
Generator
Bolt M870
25
Bolt M825
25
39
Clutch cover assembly
40
41
42
Gearbox
Starter
Intake manifold bracket
20
Cylinder-head
cover
bolt
assembly
Hexagon socket head cap

screw
65
Bolt M121.2565
65
Bolt M121.2595
65
Bolt M101.2545
44
Bolt M101.2520
44
Bolt M616
12
Intake
manifold
bracket
Hexagon head bolt for reamed

hole
44
45
46
Timing cover
Clutch back plate

Cylinder identification signal (CID signal)
cover
Camshaft phase sensor signal plate
25
Bolt M121.2560
washer bolt M630
43
12
12
25
Bolt M850
25
Bolt M870
25
Bolt M630
10
Bolt M121.2512
20
Bolt M612
10
Bolt M620
10
Hexagon socket screw
34
1.4 BYD473Q Engine Special-purpose Part List

Model
Part No.
BYD473QA
BYD473QB
Cylinder block assembly
BYD473QA-1002100
BYD473QB-1002100
Main bearing cap assembly
BYD473QA-1002300
BYD473QB-1002300
Timing cover
BYD473QA-1002031
BYD473QB-1002031
Fractured connecting rods
N/A
BYD473QB-1004030
Machined connecting rod part
BYD473QA-1004030
N/A
Crankshaft
BYD473QA-1005021
BYD473QB-1005021
Exhaust manifold bracket
BYD473QA-1008032
BYD473QB-1008032
Guide assembly
BYD473QA-1021020
BYD473QB-1021020
Tensioner assembly
BYD473QA-1021030
BYD473QB-1021030
Silent timing chain assembly
BYD473QA-1021040
BYD473QB-1021040
Tensioner seat
BYD473QA-1021061
BYD473QB-1021061
Part Name
Section 2 Cylinder Head

2.1 Adjust Valve Clearance
Notice: valve can not be adjusted when the cylinder head temperature is over 38C.
1. Remove the cylinder head cover.
2. Rotate the crankshaft until the number one piston is at TDC. UP mark on the camshaft
sprocket shall be on the top, and TDC groove on the camshaft sprocket shall be aligned with
the cylinder heads upper edge.
UP mark
DTC groove
3. Choose a proper feeler gauge for the valve you will check.
Intake valve clearance: 0.15mm0.18mm
Exhaust valve clearance: 0.23mm0.28mm
4. Insert the feeler gauge between the regulating screw and valve stem end, and slide the gauge
back and forth; a slight resistance shall be felt.
5. If the resistance is too large or small, loosen the lock regulating screw, and rotate the regulating
screw with a screwdriver until you can fill appropriate resistance when sliding the feeler gauge.
Regulating screw
Lock nut
6. Tighten the lock regulating screw and recheck the valve clearance; repeat the process above
until the clearance is appropriate.
7. Rotate the crankshaft clockwise. Repeat the procedure for valve clearance adjustment to adjust
cylinder 3, 4, 2 in strict order.
8. Install the cylinder head cover.
2.2 Remove/Install Crankshaft Pulley

Removal Procedure
Remove the pulley bolt with a ratchet wrench, extension rod and 19mm sleeve.
Installation Procedure
1. Clean the crankshaft pulley A, crankshaft B, bolt C and washer D, and conduct lubrication
process as shown in the figure below:
Cleaning
Lubricating
2. Install the crankshaft pulley and pulley bolt, and tighten it to 37N.m with a torque wrench and
19mm sleeve. Do not use an impact wrench. For a new pulley bolt or new crankshaft, tighten
the bolt first to 177N.m, loosen it and then tighten it to 37N.m.
3. Tighten the pulley bolt for additional 90.
2.3 Remove/Install Silent Timing Chain

Notice: keep the silent timing chain away from any magnetic field.
Removal Procedure
1. Remove the belt.
2. Remove the mounting bolt 1 from the generator adjusting arm, and then loosen the generator
mounting bolt 2.
Mounting bolt 1
Mounting bolt 2
3. Remove the idler pulley assembly.
4. Rotate the crankshaft pulley until its TDC mark is aligned with the arrow.
Arrow
DTC mark
5. Remove the water pump pulley.

6. Remove the crankshaft pulley.

7. Remove the oil pan.
8. Place a jack and wooden block under the cylinder block to support the engine.
9. Keep the engine away from the timing cover and then remove the timing cover.
Timing cover
10. Apply engine oil to the support surface of the silent timing chain tensioner. Pry open the hole
on the support of the silent timing chain tensioner with a screwdriver, and then remove bolt 1
and loosen bolt 2.
Tensioner support
Bolt 1
Bolt 2
11. Remove the support of the silent timing chain tensioner.
12. Remove the tensioner assembly and guide assembly.
Tensioner assembly
Guide assembly
13. Remove the silent timing chain.
1. Set the crankshaft to the TDC position. Align the TDC mark on the crankshaft sprocket with the
arrow on the oil pump.
Arrow
TDC mark
2. Set the number one piston to the TDC position. UP mark on the camshaft sprocket shall be on
the top, and TDC groove on the camshaft sprocket shall be aligned with the cylinder heads
upper edge.
DTC groove
UP mark
3. Install the silent timing chain to the crankshaft sprocket, with the color mark aligned with the
TDC mark on the crankshaft sprocket.
DTC mark
Color mark
4. Install the silent timing chain to the camshaft sprocket, with the arrow aligned with the color
marks.
3 color marks
Arrow
5. As for 473QA engine, when installing the silent timing chain to the camshaft sprocket, the arrow
shall point to the center of the color marks.
2 color marks
Arrow
6. Apply engine oil to the threads of the tensioner pivot bolt, and then install the tensioner
assembly and guide assembly.
Tensioner assembly
Tensioner
pivot bolt
Guide assembly
7. Install the tensioner support and tighten the bolt slightly.
8. Apply engine oil to the sliding surface of the tensioner support.
Tensioner support
9. Rotate the tensioner support clockwise to press tight the tensioner assembly, and then install
the other bolts to fix it.
10. Check whether the crankshaft front oil seal on the timing cover is damaged. Replace the
crankshaft front oil seal if it is damaged.
11. Clear away the old sealant on the timing cover matching surface, bolt and bolt hole.
12. Clean the timing cover matching surface and dry it.
13. Evenly apply sealant to the matching surface between the timing cover and cylinder block and
on the female threads in the bolt holes.
Notice:
The sealant shall be 2-3mm wide along the dash line.
Apply 3-4mm wide sealant to the cylinder block upper surface of the timing cover.
The assembling shall be conducted within 4 minutes of applying the sealant. If not, the sealant
applied in the previous step shall be cleared away and new sealant shall be applied again.
Cylinder block upper

surface contact
Dash line
14. Install the timing cover.
Timing cover
15. Install the oil pan.

16. Install the crankshaft pulley with washer.
18. Install the water pump pulley.
19. Install the idler pulley assembly.
20. Install the mounting bolt for the generator adjusting arm.
21. Install and adjust the belt.
2.4 Install Crankshaft Front Oil Seal

The SST assembling tool for front crankshaft oil seal is required.
1. Use the SST to push in a new oil seal straightly into the timing cover at the specified installation
height.
2. Measure the distance between the timing cover surface (matching surface with the cylinder
block) and the oil seal.
Oil seal installation height: 34.5mm35.2mm
2.5 Remove Cylinder Head Cover

1. Remove the intake manifold.
2. Remove 4 coils of the ignition device.
2.6 Remove Cylinder Head

Notice:
Use a fender cover to prevent damage to the paint surface.
To prevent damage, hold the connector by the hard part and pull out the wire harness connector
carefully.
To prevent damage to the cylinder head, do not loosen the bolts until the engine coolant
temperature is lower than 38 (100).
Make proper marks on all cables and hoses to prevent wrong connection. Make sure the cables
and hoses are not contacting each other or interfering with other parts.
Keep the silent timing chain away from any magnetic field.
1. Drain the engine coolant.
2. Remove the air filter housing.
3. Remove the water inlet/outlet hose from the throttle body.
4. Remove the water inlet/outlet hose from the radiator.
5. Remove the hose from the fan heater.
6. Remove the belt.

7. Remove the intake manifold.
8. Remove the exhaust manifold.
9. Remove the engine wire harness connector and wire clip from the cylinder head.
4 fuel injector connectors
Engine coolant temperature sensor connector
Camshaft phase sensor connector
Oil pressure alarm device connector
Knock sensor
10. Remove the bolt for connecting wire harnesses and wiring harness bracket.
11. Remove the connecting pipe for the water outlet pipe, and positive crankcase ventilation (PCV)
hose.
Connecting pipe
PCV hose

13. Remove the generator bracket mounting bolts, and then loosen the generator mounting bolts.
14. Remove the idler pulley assembly.
15. Rotate the crankshaft pulley until its TDC mark is aligned with the arrow.
17. Remove the crankshaft pulley.
18. Place a 30030025mm wooden block and a jack under the oil pan to support the engine.
Notice: do not locate the jack in the middle of the oil pan to prevent damage to it.
19. Remove the grounding cable and then remove the front engine bracket.
20. Keep the engine away from the timing cover and then remove the timing cover.
21. Make a reference mark on the camshaft sprocket and silent timing chain.
Reference mark
22. Loosely install the crankshaft pulley.

23. Apply engine oil to the sliding surface of the silent timing chain tensioner support through the
oil return hole on the cylinder head.
24. Fix the crankshaft pulley, and fit the sleeve wrench to the camshaft sprocket bolt.
Socket wrench
Bolt hole
Tensioner assembly
Bolt
25. Rotate the camshaft clockwise to compress the silent timing chains tensioner assembly, insert
a 61.0mm bolt into the bolt hole on the cylinder block through the tensioner assembly, and
then tighten the bolt.
26. Hold the camshaft with an open-end wrench, and then remove the camshaft pulley.
27. Remove the bolt fixing the silent timing chains guide assembly.
28. Remove the cylinder head bolts. To prevent warping or deformation, loosen the bolts in an
alternating pattern, 1/3 round at a time, in the order shown in the figure below, and repeat this
process until all bolts are loosened completely.
Loosen the bolts in the order shown in this figure
29. Remove the cylinder head.
2.7 Remove/Install Camshaft Sprocket

Removal Procedure
2. Make a reference mark on the camshaft sprocket and silent timing chain.
Reference mark
3. Apply engine oil to the sliding surface of the silent timing chain tensioner support through the oil
return hole on the cylinder head.
4. Remove the sight port cover.
5. Remove the M121.2512 bolt and washer on the timing cover, hold the crankshaft pulley, and
then attach a sleeve wrench to the camshaft sprocket bolt.
Socket wrench
Bolt hole
Tensioner assembly
Bolt
6. Rotate the camshaft clockwise to compress the silent timing chains tensioner assembly, insert a
61.0mm bolt into the bolt hole on the cylinder block through the tensioner assembly, and then
tighten the bolt.
7. Hold the camshaft with an open-end wrench, and then remove the camshaft pulley.
Notice: hang the silent timing chain with an iron wire.
1. Install the timing chain onto the camshaft sprocket after aligning the reference mark, and then
install the camshaft sprocket onto the camshaft.
Reference mark
2. Hold the camshaft with an open-end wrench, and then tighten the bolt.
Specified torque: 56N.m
3. Apply engine oil to the sliding surface of the silent timing chain tensioner support through the oil
return hole on the cylinder head.
Socket wrench
Bolt M6X1.0
Washer
Bolt M10X1.25X12
5. Rotate the camshaft clockwise to compress tight the silent timing chain's tensioner assembly,
and then remove the 61.0mm bolt.
6. Install the M121.2512 bolt with a new washer.
7. Install a new sight port cover.
2.8 Replace Camshaft Phase Sensor Signal Plate

Removal Procedure
1. Remove the air filter.
2. Remove the bolt for the connecting wire harnesses and relevant wiring harnesses.
4. Remove the camshaft CID signal cover.
5. Hold the camshaft with an open-end wrench, and then loosen the hexagon socket screw.
6. Remove the camshaft phase sensor signal plate.
1. Install the camshaft phase sensor signal plate.
2. Hold the camshaft with an open-end wrench, and then tighten the bolt to 34N.m.
3. Install the camshaft CID signal cover with a new O-ring.
Camshaft CID signal cover

5. Install the wire harness bracket, wire harnesses and bolts.
6. Install the air filter.
2.9 Check Cylinder Head Warping

2. Check the camshaft.
3. Check whether the cylinder head has warping. Measure the length of each side and the
diagonal length of the cylinder head, as shown in the figures below.
If the warping is less than 0.08mm, repairing is not necessary;
If the warping is somewhere between 0.08mm and 0.2mm, the cylinder head shall be
repaired;
The maximum repairable warping is 0.2mm on the basis of 120mm height.
Cylinder head height
Standard: 119.9mm120.1mm
Precision ruler
2.10 Remove Rocker Arm Assembly

2. Loosen the regulating screws of the rocker arms.
Rocker arm regulating screw
Rocker arm regulating screw
3. Loosen the hollow bolts fixing the rocker arms in an alternating pattern, 2 rounds at a time, in the
order shown in the figure below, and repeat this process until all bolts are loosened completely.
4. Remove the hollow bolts, and then remove the rocker arm assemblies.
Notice: to disassemble a rocker arm, first remove the dowel pin, and then detach it from the rocker
arm shaft at the timing chain side.
2.11 Disassemble/Reassemble Rocker Arm and Rocker Arm Shaft

Notice:
Make marks on each part before disassembling so that you can reassemble them properly.
Disassembling/reassembling a rocker arm from the rocker arm shaft at the silent timing chain
side.
Check the rocker arm and rocker arm shaft.
Any reused rocker arm shall be installed at its original location.
Before reassembling, please clean all parts with solvent, dry them in air, and apply lubricating
oil at all contact points.
Washer
Rocker arm
Rocker arm shaft
2.12 Check Rocker Arm and Rocker Arm Shaft

1. Remove the rocker arm assemblies.
2. Measure the shaft diameter at the number one rocker arm.
3. Reset the dial bore gauge according to the shaft diameter.
Dial bore gauge
4. Measure the inner diameter of the rocker arm with a dial bore gauge and check its
out-of-roundness.
Rocker arm-rocker arm shaft clearance:
Service limit: 0.08mm
5. Repeat the process above for all rocker arms and shaft. If the clearance of any rocker arm is
beyond the allowable limit, replace it together with the rocker arm shaft.
2.13 Remove Camshaft

2. Remove the camshaft sprocket.
4. Remove the bolt for the connecting wire harnesses and relevant wiring harnesses.
5. Disconnect the camshaft phase sensor connector, and remove the camshaft phase sensor.
6. Remove the camshaft CID signal cover, and pull out the camshaft.
Camshaft
2.14 Check Camshaft

1. Remove the camshaft sprocket.
3. Set the rocker arm shaft to the cylinder head, and tighten the bolt to the specified torque.
Specified torque: 29 Nm
Apply engine oil to the threaded section and flange of the bolt.
4. Push the camshaft backwards toward the cylinder head until it stops.
5. Press a dial gauges push-rod on the camshaft end, and reset the dial gauge. Push the
camshaft back and forth and get the axial clearance reading. If the axial clearance is beyond
the service limit, replace the thrust cover and check again. If it is still beyond the service limit,
please replace the camshaft.
Camshaft axial clearance:
6. Support the camshaft with a V-shaped block, and check its total runout.
If the total runout is beyond the service limit, replace the camshaft, and check the oil film
clearance between the camshaft and its bore hole. If the oil film clearance is still beyond
the service limit, please replace the cylinder head.
Total camshaft runout
Standard: maximum 0.03mm
Repairable limit: 0.04mm
7. Measure the cam lobe lift.
Standard lobe lift (new part):
Intake: 35.38
Exhaust: 35.377
2.15 Remove Valve, Valve Spring and Valve Oil Seal

Make marks on the valve and springs before disassembling so that you can reassemble them to
their original locations.
2. Remove the camshaft.
3. Loosen the valve lock clamp by knocking the upper valve spring seat with a proper-size sleeve
and plastic hammer. Remove the valve lock clamp, valve spring, valve and valve oil seal.
Plastic hammer
Sleeve
2.16 Check Valve

Remove the valve and measure the dimensions at the locations shown in the figure below:
Intake valve dimensions:
A standard: 27.4mm27.6mm
B standard: 118.1mm118.7mm
C standard: 5.470mm5.485mm
C repairable limit: 5.44mm
Exhaust valve dimensions:
A standard: 22.9mm23.1mm
B standard: 117.3mm117.9mm
C standard: 5.455mm5.470mm
C repairable limit: 5.42mm
2.17 Check Valve Tappet-Valve Guide Clearance

1. Remove the valve.
2. Slide out the valve from the guide for some 10mm, shake the valve tappet from the normal
thrust direction (shaking method) and then measure the inner diameter of the guide with a dial
bore gauge, and the outer diameter of the tappet with a micrometer. The difference between the
two measured values is the valve tappet-valve guide clearance.
If the result is beyond the service limit, install a new valve and measure the clearance again.
If the new clearance is within the service limit, proceed with the reassembling process.
Go to step 3 if the new clearance is still beyond the service limit.
Intake valve tappet-valve guide clearance:
Exhaust valve tappet-valve guide clearance:
3. Measure the inner diameter of the valve guide and the outer diameter of the valve tappet at 3
different locations, using the devices mentioned in step 2, and then subtract the measured inner
diameters by the outer diameters. The difference between the maximum inner diameter and the
minimum outer diameter shall fall in the service limit.
Intake valve tappet-valve guide clearance:
Exhaust valve tappet-valve guide clearance:
2.18 Replace Valve Guide

The following SST tools are required:
Valve guide remover/installer
Valve guide reamer
1. Check valve tappet-valve guide clearance.
2. Use the pneumatic valve guide punch modified according to the valve guide diameter (available
in the market) as shown in the figure below. Normally you can also complete the same
operation using the SST and a hammer.
3. Choose proper substitute valve guides, and freeze them in a refrigerator for about 1 hour.
4. Heat up the cylinder head to 150 with a electric hot plate or oven. Monitor the temperature
with a thermometer. The temperature of the cylinder head shall be kept under 150.
Overheating may cause loose valve seat.
5. Use a punch and air hammer to push the valve guide to the combustion chamber for some 2mm
from the camshaft side. This process can get off some carbon to facilitate the removal. Keep
the air hammer parallel with the valve guide to prevent damage to the punch.
6. Go the opposite side and knock off the valve guide towards the camshaft side.
7. If the valve guide cannot move, drill an 8mm hole and knock again. Drilling is not recommended
because the cylinder may be damaged if the valve guide is broken during drilling.
8. Take out one valve guide from the refrigerator.
9. Apply thin oil film to the outer surface of the new valve guide. Install the valve guide from the
cylinder head camshaft side; use the SST to knock in the guide to specified installation height. If
all 16 valve guides shall be replaced, you need to heat up the cylinder head again.
Installation height of valve guide: 15.85mm16.35mm
10. Apply cutting oil to both the reamer and valve guide.
11. Rotate the reamer clockwise along the full length of the valve guide.
12. Rotate the reamer further until it gets through the valve guide.
13. Flush the valve guide with detergent and water to clear away all swarf.
14. Insert and slide a valve in the intake/exhaust valve guide to check the clearance, and make
sure there is no resistance.
2.19 Check Valve Seat

1. Check valve tappet-valve guide clearance. Any worn valve guide shall be replaced before
reaming the valve seat.
2. Repair the valve seat in a cylinder with a valve seat reamer.
3. Carefully cut a 45 edge on the seat to ensure that the valve seat is smooth and concentric.
4. Mill the upper angle and lower angle as shown in the figure below. Check the width of the valve
seat and adjust it if necessary.
Air inlet: 67.5

o
Air outlet: 60
5. Use a 45 reamer to reaming the seat again slightly to eliminate burrs resulting from the
previous process.
Valve seat width
Intake:
Exhaust:
6. Check the valve seat flatness upon completion of surface processing: apply Prussian blue
compound agent to the valve surface, insert the valve into its original location in the cylinder
head, and then pull up and press down the valve against the valve seat for several times.
7. The valve seat surface indicated by the blue agent in the figure above shall be aligned with the
center of the valve seat.
z If the valve seat is high (near to the tappet), use a 67.5 reamer (for the intake valve) or 60
reamer (for the exhaust valve) to cut it lower, and then use a 45 reamer again to restore the
valve seat width.
If the valve seat is low (near to the valve edge), use a 30 reamer to heighten it, and then use
a 45 reamer again to restore the valve seat width.
Notice: only 45 milling cutter shall be used for the final milling process.
8. Insert the intake valve and exhaust valve into the cylinder head, and measure the installation
height A of the valve tappet.
Installation height of the intake valve tappet:
Installation height of the exhaust valve tappet:
z
9. If the tappet height is beyond the service limit, replace the valve and check again. If it is beyond
the service limit, the cylinder head shall be replaced as the valve seat sinks deeply into the
cylinder head.
2.20 Install Valve, Valve Spring and Valve Oil Seal

The following SST tools are required:
Tappet oil seal remover/installer
Valve spring compressor
1. Apply engine oil to the tappet and install the valve into the valve guide.
2. Check whether the valve moves up and down smoothly.
3. Install the lower spring seat onto the cylinder head.
4. Apply grease on the valve guide, and install a new valve oil seal with the valve guide oil sealer
remover/installer.
Notice: the exhaust valve oil seal is indicated by EX, and the intake oil seal is indicated by IN.
They are not interchangeable.

Marked IN
Intake valve oil seal
Marked EX
Exhaust valve oil seal
Guide oil seal

remover/ installer
Valve oil seal
5. Install the valve spring. The valve spring end with more winding shall point to the cylinder head.
6. Install the upper spring seat.
7. Attach the valve spring compressor to compress the spring, and then install the valve lock
clamp.
8. Use a plastic hammer to slightly knock each valve tappet for 2 or 3 times so as to ensure that
the valves and valve lock clamps are installed correctly. Only knock the tappet in its axial
direction to prevent bending.
Plastic hammer
2.21 Install Camshaft

1. Install the camshaft onto the cylinder head, and install the camshaft CID signal cover with a new
O-ring.
Camshaft
O-ring
2. Install the camshaft phase sensor with a new O-ring, and then connect the camshaft phase
sensor connector.
3. Install the wire harness bracket and its mounting bolts.
4. Install the camshaft sprocket.
5. Install the rocker arm assemblies.
2.22 Install Rocker Arm Assembly

1. Install the rocker arm assemblies with a dowel pin.
Notice: reassembling the rocker arms to the rocker arm shaft at the silent timing chain side.
Dowel pin
Rocker arm assembly
2. Tighten all bolts fixing the rocker arms in an alternating pattern, 2 rounds at a time, in the order
as shown in the figure below, and repeat this process until all bolts are tightened properly.
Apply engine oil to the threaded section and flange of the bolts.
3. Adjust the valve clearance.

2.23 Install Cylinder Head

Install the cylinder head in the reverse sequence of removal.
1. Clean the junction surface between the cylinder head and cylinder block.
2. Install the cylinder head gasket and dowel pin onto the cylinder block. Only use a new cylinder
head gasket.
Cylinder head gasket
Dowel pin
3. Make sure the crankshaft keyslot is facing upwards.

4. Install the cylinder head onto the cylinder block.
5. Apply engine oil to the threaded section of all cylinder head bolts and the bottom side of all bolt
heads.
6. Tighten all cylinder head bolts to 29N.m in the order shown in the figure below. Use a flat beam
torque wrench. If you use a preset torque-wrench, do tighten the bolts slowly and within
specified torque. If any bolt makes noise during tightening, loosen it and repeat the tightening
process.
7. Tighten all cylinder head bolts for another 130.

8. Install the mounting bolt of silent timing chains guide assembly.
Mounting bolt
9. Install the timing chain onto the camshaft sprocket after aligning the reference mark, and then
install the camshaft sprocket onto the camshaft.
Reference mark
10. Hold the camshaft with an open-end wrench, and then tighten the bolt.
11. Loosely install the crankshaft pulley.

12. Apply engine oil to the sliding surface of the silent timing chain tensioner support through the
oil return hole on the cylinder head.
Socket wrench
Bolt
14. Rotate the camshaft clockwise to compress tight the silent timing chain's tensioner assembly,
and then remove the 61.0mm bolt.
15. Check whether the crankshaft front oil seal is damaged. If any damage, replace it with a new
one.
16. Clear away the old sealant on the timing cover matching surface, bolt and bolt hole.
17. Clean and dry the timing cover matching surface.
18. Evenly apply sealant to the matching surface between the timing cover and cylinder block and
on the female threads in the bolt holes.
Notice:
Apply 3-4mm wide sealant to the cylinder block upper surface of the timing cover.
Cylinder block upper

surface contact
Dash line
19. Evenly apply sealant to the matching surface between the timing cover and oil pan and on the
female threads in the bolt holes.
Notice:
Apply 5.0mm wide sealant to the shadow area as shown in the figure below.
The assembling shall be conducted within 4 minutes of applying the sealant. If not, the sealant
applied in the previous step shall be cleared away and new sealant shall be applied again.
Dash line
Shadow area
20. Align the timing cover edge against the oil pan cover, and then install the timing cover onto the
cylinder block.
Notice: when installing the timing cover, do not slide the bottom of the oil pan mounting surface;
otherwise the sealant may be scratched and lead to deteriorated sealing performance.
Timing cover
Cylinder block
Timing cover
Oil pan
21. Install wire harness bracket.

22. Install the crankshaft pulley.
24. Install the water pump pulley.
25. Install the idler pulley assembly.

26. Install the generator adjusting arm and its mounting bolts.
27. Install the belt and tighten it through adjusting the generator regulating screw.
28. Install the water outlet pipe using a new o-ring for water outlet.
O-ring
Water outlet part
PCV hose
29. Install the positive crankcase ventilation (PCV) hose.

30. Install the wire harness bracket and bolts.
31. Install the exhaust manifold.
32. Install the intake manifold.
33. Install the heater hose.
34. Install the water inlet/outlet hose to the radiator.

Upper radiator hose
Lower radiator hose
35. Install the water inlet/outlet hose to the throttle body.

37. Upon completion of assembling, check whether all pipes, hoses and connectors are connected
properly.
38. Check for fuel leakage. Turn the ignition switch to ON without running the starter, run the fuel
pump for 2 seconds and increase fuel line pressure. Repeat the process for 2 or 3 times and
check whether there is leakage in the fuel line.
39. Refill engine coolant into the radiator, and meanwhile discharge the air in the cooling system
with the heater valve remaining open.
40. Check idle speed.
41. Check the ignition timing.
2.24 Install Cylinder Head Cover

1. Thoroughly clean the cylinder head cover gasket and grooves.
2. Install the cylinder head cover gasket into the groove.
3. Make sure the matching surface is dry and clean.
4. Apply 3.0mm wide sealant within the timing cover matching surface.
Notice: The assembling shall be conducted within 4 minutes of applying the sealant. If not, the
sealant applied in the previous step shall be cleared away and new sealant shall be applied
again.
5. After installing the cylinder head cover on the cylinder head, slightly slide the cylinder head
cover back and forth so that the gasket can be fit in place.
6. Check the cylinder head cover gasket. Replace the gasket if it is damaged or aged.
7. Tighten bolts by 2 or 3 steps. The tightening torque is 12N.m in the order shown in the figure
below.
8. Install 4 ignition coils.

9. Install the intake manifold cover.
10. Check whether all pipes, hoses and connectors are connected properly.
11. Upon completion, wait for 30 minutes before filling in engine oil.
Section 3 Cylinder Block

Component Layout (a)
Main bearing cap axle
Main bearing cap
Crankshaft
Flywheel bolt
Flywheel
Main bearing bush
Thrust plate
Crankshaft oil seal
Component Layout (b)

Piston ring
Piston
Connecting rod body

Piston pin
Cylinder block
Connecting rod bearing shell
Connecting rod bolts
3.1 Check Connecting Rod-Crankshaft Axial Clearance

1. Remove the oil pump.
2. Measure the axial clearance between the connecting rod and crankshaft with a feeler gauge.
Connecting rod axial clearance:
Standard range: 0.15mm 0.30mm
3. If the axial clearance is beyond the allowance range, install a new connecting rod and check the
clearance again. If it is still out of the allowance range, replace the crankshaft.
4. Push the crankshaft as far away from the dial gauge as possible, reset the dial gauge while
pressing it against the crankshaft end, and then pull back the crankshaft to press against the
dial gauge tightly: the reading of the gauge shall be in the service limit.
Crankshaft axial clearance:
5. If the axial clearance is beyond the allowance range, replace the thrust plate and check the
clearance again. If it is still out of the allowance range, replace the crankshaft.
3.2 Replace Crankshaft Main Bearing Bush

Check main bearing bush clearance
1. When checking the oil film between the main bearing bush and journal, you shall remove the
main bearing cap and bush.
2. Clean the main journal and bush with a piece of clean service cloth.
3. Place plastic clearance gauges between main journals.
4. Reinstall the bearing bush and crankshaft main bearing cap, and tighten the bolt to 25N.m +40.
Notice: do not rotate the crankshaft during the check procedure.
5. Remove the crankshaft main bearing cap and bush again, and measure the plastic clearance
gauges at the widest location.
Main bearing bush-journal oil film clearance:
Standard range: 0.018mm0.036mm
6. If the clearance measured with the plastic clearance gauge is too large or small, remove the
crankshaft and the upper bearing bush. Install a new complete bearing bush with the same
grouping code, and check the clearance again. It is prohibited to adjust the clearance by filing,
filling or grinding the bearing bush or cover.
7. If the clearance indicated by the gauges is still beyond range, try to use a larger or smaller
bearing bush (the color above or below the current cell in the table below) correspondingly and
check again. If using of the appropriate bush still cannot get a proper clearance, replace the
crankshaft and repeat the check procedure.
Choose main bearing bush

Location of crankshaft hole grouping code
1. Grouping indicator representing 5 main journals are embossed on the end of the crankshaft.
Take notice of the crankshaft hole's grouping code. If the code is coved by dirty or dust, do not
use a wire brush or scraper. Only clean it with solvent or detergent.
1st gear journal

(pulley side)
5th gear journal

(gearbox side)
Location of Main Journal Grouping Code

2. Main journal grouping code is embossed on the crankshaft.
1st gear journal
2nd gear journal
1st gear journal
3rd gear journal
4th gear journal
5th gear journal
5th gear journal
3. Choose a proper bearing bush from the table below by reference to the grouping code of the
crankshaft hole and crankshaft journal.
Notice: the grouping code is located on the edge of the main bearing bush.
Assembling Relationship between Main Shaft Hole, Bush and Diameter
Main
shaft
hole
diameter increase
Shaft hole
Shaft
diameter
Bush
Shaft diameter
increase
Grouping
code
Bush
thickness
increase
3.3 Replace Connecting Rod Bearing Shell

Check connecting rod bearing clearance
1. Check the oil film clearance between the connecting rod bearing and journal. Remove the main
bearing cap.
2. Remove the connecting rod cover and connecting rod bearing shell.
3. Clean the crankshaft connecting rod journal and bearing shell with a piece of clean service
cloth.
4. Place a plastic clearance gauge on the connecting rod journal.
5. Reinstall the bearing shell and connecting rod cover and tighten the bolts.
Tightening torque: 9.8N.m+90
Notice: do not rotate the crankshaft during the check procedure.
6. Remove the connecting rod cover and bearing shell, and measure the plastic clearance gauge
at the widest location.
Connecting rod bearing shell-journal oil film clearance:
7. If the clearance measured with the plastic clearance gauge is too large or small, remove the
upper bearing shell. Install a new complete bearing shell with the same grouping color code,
and check the clearance again. It is prohibited to adjust the clearance by filing, filling or grinding
the bearing or cover.
8. If the clearance indicated by the gauges is still beyond range, try to use a larger or smaller
bearing bush (the color above or below the current cell in the table) correspondingly and check
again. If using of the appropriate bearing shell still cannot get a proper clearance, replace the
crankshaft and repeat the check procedure.
Choose connecting rod bearing shell

1. Check each connecting rod for crack and thermal damage.
Location of connecting rod big-end hole code
2. Depending on the size of the connecting rod big-end hole, the tolerance for each connecting rod
is 0 - 0.015mm, with an increment of 0.008mm. The code is embossed in numbers or bar codes.
You can find a variety combination of numbers and bar codes on the engine (half of them
printed on the bearing cap and another half on the connecting rod).
If the code is coved by dirty or dust, do not use a wire brush or scraper. Only clean it with solvent
or detergent.
Standard hole size: 43.0mm
Grouping code
Location of connecting rod journal grouping code

3. Connecting rod journal grouping code is embossed on the crankshaft.
Location of connecting rod journal grouping code
1st gear journal
2nd gear journal
1st gear connecting

rod journal
3rd gear journal
4th gear journal
4th gear connecting

rod journal
4. Depending on the big-end hole code and connecting rod journal code, choose an appropriate
substitute bearing shell from the table below.
Notice: the grouping code is located on the edge of the bearing shell.
Assembling Relationship between Bore, Connecting Rod Bearing
Shell and Connecting Rod Shaft Diameter
Bore increase
Shaft hole
Shaft
diameter
Bush
Shaft
diameter
increase
Grouping
code
Bush
thickness
increase
3.4 Remove Oil Pan

1. Completely drain engine oil in the engine.
2. Remove the dipstick tube.
Oil dipstick tube
3. Remove the clutch back plate and then remove 2 bolts (A) fixing the gearbox.
Clutch back plate
4. Remove the bolts fixing the oil pan.

5. Attached a slotted screwdriver as shown in the figure, and then detach the oil pan from the
cylinder block.
6. Remove the oil pan and place it carefully with the joint surface with the cylinder block facing
upwards.
3.5 Remove Crankshaft and Piston

1. Remove the engine.
2. Remove the gearbox.
5. Remove the oil collector and then remove the oil pump.
Oil collector
Oil pump
6. Remove the main bearing cap bolts. To prevent warping, loosen the bolts in alternating pattern,
1/3 round at a time, in the order shown in the figure below. Repeat the process until all bolts are
loosened.
7. Remove the main bearing cap.

8. Remove the connecting rod cover/bearing shell and place them carefully in good order.
9. Take out the crankshaft from the cylinder block with care, as impact with the cylinder block may
cause damage, especially to the journal.
10. Remove the upper shells from the connecting rod, and place them together with their
corresponding bearing shell.
11. Check the top inside of the cylinder liner for metal protruding or accumulated carbon and, if any,
remove them with a reamer following the manufacturers instructions. If the protruding matter is
not removed, the piston may be damaged when you pull it out.
12. Push out the piston with the hammers wooden handle. Hold the piston with another hand
during this process.
Wooden handle
Piston
13. Install the main bearing cap and bush onto the cylinder block again in proper order.
14. Remove the piston rings and connecting rod assemblies, and then install the connecting rod
bodies and covers again.
15. To prevent wrong installation, mark each piston/connecting rod assembly with its cylinder
number.
Notice: the existing mark on a connecting rod represents its connecting rod hole size, not its
position.
3.6 Check Crankshaft

Out-of-roundness and conicity
1. Remove the crankshaft from the cylinder block.
2. Clean the crankshaft oil way with a tuber cleaner or an appropriate brush.
3. Clean the keyslot and threads.
4. Measure the roundness at 2 positions where each connecting rod journal and main journal
center are perpendicular to each other, and the measured difference of each journal cannot
exceed the service limit.
Journal out-of-roundness:
Standard: maximum 0.005mm
Connecting rod journal
Main journal
5. Measure the conicity at the edge of each connecting rod and main journal, and the measured
difference of each journal cannot exceed the service limit.
Journal conicity:
Standard range: Maximum 0.005mm
Verticality
6. Place the cylinder block on the marking-off table.
7. Clean the bearing bush and install it on 1# and 5# journal of the cylinder block.
8. Lower the crankshaft and place it into the cylinder block.
9. Measure the runout on all main journals. Rotate the crankshaft for 2 rounds and then measure
the runout. The difference between all measured values shall be within the service limit.
Crankshaft total runout:
3.7 Check Cylinder Body and Piston

1. Remove the crankshaft and piston.
2. Check whether the piston is deformed or cracked.
3. Measure the piston diameter at the bottom of the piston skirt, at the location as shown in the
figure below.
Piston diameter:
Piston diameter
Measuring point
Oversized piston diameter:

0.25: 73.205mm73.225mm
4. Measure the wear and conicity of each cylinder in X and Y direction, at 3 locations with different
height, as shown in the figure below. If the measured value of any cylinder is beyond the service
limit of oversized cylinder bore, replace the cylinder block. If any cylinder block requires reboring,
go to step 7.
Cylinder bore:
Oversized dimension:
0.25: 73.25mm73.269mm
Reboring limit: maximum 0.25mm
Bore conicity:
Limit: 0.05mm (the difference between the first and third measured value)
First measurement
Second measurement
Third measurement
5. Cylinder with scratched damage shall be honed.
6. Check the top of the cylinder block for warping. Measure the edge and diagonal line of the
cylinder block as shown in the figure below.
Cylinder block warping:
Precision ruler
7. Measure the cylinder bore and piston diameter and calculate their difference. If the difference is
near or over the service limit, check for excessive wear on the piston and cylinder.
Piston-cylinder clearance:
Piston-cylinder clearance
Cylinder honing process

Honing is applicable only to the cylinder bores with scratch damage.
1. Measure cylinder bore
After honing a cylinder block, measure the cylinder bore again before reusing it.
2. Using honing oil and honing stone (400 grit) to hone the cylinder bore in a 60 cross hatch
pattern. Only honing stones with 400 or finer grit, such as those from Sunnen, Ammco or other
equivalents, shall be used. Do not use any worn or broken honing stone.
Cross hatch
3. Clear away all metal particles in the engine body after honing. Wash the cylinder bore with hot
water and soap. Dry it and apply engine oil immediately to prevent rusting. Do not use any
solvent in this step, as it may carry metal particles around the cylinder wall.
4. If the scratch still exists when honing to service limit, the cylinder block shall be rebored again.
But very slight vertical scratch is acceptable, provides that its length is less than the cylinder
bore and your finger is not retarded when moving across its deepest part.
3.8 Replace Piston, Piston Pin and Connecting Rod

Disassembling
1. Remove the piston from the cylinder block.
2. Remove the piston pin with a SST.
Inspection
1. Measure the diameter of the piston pin.
Piston pin diameter:
Standard value: 17.996mm18.000mm
2. Reset the dial bore gauge according to the piston pin diameter.
Replace piston, piston pin and connecting rod

3. Measure the piston pin-connecting rod small end bore clearance.
Piston pin-connecting rod small end bore clearance:
Standard value: -0.037mm-0.015mm
4. Check the difference between the piston pin diameter and piston bore diameter.
Piston pin to piston bore clearance
Reassembling
1. Install the piston and connecting rod, with the orientation arrow and connecting rod mark
pointing to the same direction.
Orientation arrow
2. Press the piston pin into the piston with a SST.

Replace Piston ring
1. Remove the piston from the cylinder block.
2. Remove the old piston ring with a piston ring expander.
Piston ring
Piston ring tensioner
3. Clean all the piston ring grooves using a split ring without cutting edge, or a ring groove cleaner
with a cutting edge matching with the piston groove.
Groove width of the first air-tight ring: 1.0mm.
Groove width of the second air-tight ring: 1.2mm.
Groove width of the oil ring: 2.8mm.
The cutting edge may be filed if necessary.
Do not use a wire brush to clean the ring groove, and prevent the cleaning tool from cutting the
ring groove deeper.
Notice: if you need to detach the piston from the connecting rod, do not install the new piston
ring at this time.
4. Push a new piston ring into the cylinder bore with the piston, until its distance to the cylinder
bottom is 15mm20mm.
Piston ring
Clearance
5. Measure the piston ring end clearance with a feeler gauge.

Standard clearance
Service limit
First air-tight ring
0.20mm0.35mm
0.79mm
Second air-tight ring
0.35mm0.50mm
0.75mm
oil control ring
0.200.70mm
0.80mm
If the measured value is over the biggest end clearance, replace the piston ring and measure
again.
If the measured value is still over the biggest end clearance, replace the cylinder block.
6. Install the first air-tight ring (A) and second air-tight ring (B) as shown in the figure below. When
installing the piston ring, make sure the side (C) with manufacturer mark is facing upwards.
Piston ring diameter
Air-tight ring 1 (standard)

A: 2.45 mm
B: 1.0 mm
Air-tight ring 2 (standard)
A: 3.0 mm
B: 1.2 mm
7. Check whether the piston rings rotate smoothly in the groove.
8. Set the end clearance of the piston rings as shown in the figure below:
Lower lid of oil scraper
ring gap
Bush ring gap
2nd air-tight ring gap
Assembling position arrow

facing engine free end
1st air-tight ring gap
Upper lid of oil scraper

ring gap
9. Measure the clearance between ring grooves after installing a set of new piston rings.
Air-tight ring 1 clearance:
Air-tight ring 2 clearance:
Install piston
If the crankshafts are installed:
1. Set the crankshaft in each cylinder to BDC in turn.
2. Remove the connecting rod cover, install the piston ring compressor and then make sure the
bearing bush is fixed in place firmly.
3. Place the orientation mark towards the engine silent timing chain (front end).
Orientation arrow
4. Place the piston into the cylinder, and knock it with the hammer's wooden handle (A) or similar
wooden objects. Keep downward pressure on the piston ring compressor (B) before installation
in the cylinder bore to prevent the piston ring opening.
5. After the compressor rebounds, check whether the connecting rod-crankshaft journal alignment
is correct before pushing the piston in place.
6. Check the clearance of the connecting rod bearing shell with a plastic clearance gauge.
7. Check the connecting rod bolts.
8. Apply engine oil to the bolt threads. Install the connecting rod cover with a bearing shell. Tighten
the bolt to 9.8 Nm+90.
If the crankshafts are not installed:
1. Remove the connecting rod cover, install the piston ring and make sure the bearing shell is fixed
in place.
2. Place the orientation mark towards the engine timing chain (front end).
3. Place the piston into the cylinder, and knock it with the hammer's wooden handle (A) or similar
wooden objects. Keep downward pressure on the piston ring compressor (B) before installation
in the cylinder bore to prevent the piston ring opening.
4. Set all pistons to TDC.
3.9 Check Connecting Rod Bolt

1. Measure the connecting rod bolt diameter at location A & B with a micrometer, as shown in the
figure below.
2. Calculate the difference of the diameter at A & B.

Diameter difference = diameter A diameter B
Diameter difference allowance: 00.05mm
3. If the difference is beyond the allowance, replace the connecting rod bolt.
3.10 Install Crankshaft

1. Check the clearance of the connecting rod bearing with a plastic clearance gauge.
2. Check the clearance of the main bearing with a plastic clearance gauge.
3. Check the connecting rod bolt.
4. Install bearing bush and shells on the cylinder block and connecting rod.
5. Apply engine oil to the main bearing bush and connecting rod bearing shell.
6. Hold the crankshaft to keep the number 2 and 3 journal pointing straightly upwards, and then
place the crankshaft into the cylinder block.
7. Install a thrust plate at the number 4 journal of the cylinder block.
Indicator A
Indicator B
8. Apply engine oil to the thread and flange of the connecting rod bolt.
9. Fit the connecting rod journal to number 1 and 4 connecting rod. Align the marks on the
connecting rod and cover, and then tighten the connecting rod cover and bolt manually.
10. Rotate the crankshaft clockwise, and fix the journal in number 2 and 3 connecting rods. Align
the marks on the connecting rod and cover, and then tighten the connecting rod cover and bolt
manually.
11. Tighten the connecting rod bolt to 9.8N.m.
12. Tighten the connecting rod bolt for additional 90.
13. Install the crankshaft rear oil seal assembly. Before installation to the crankshaft, apply
lubricating grease to the oil seal inner groove.
14. Measure the distance between the crankshaft and oil seal.
Oil seal installation height: 7mm8mm.
15. Install the integrated main bearing cap, and keep the orientation mark in proper direction.
16. Clear off the old sealant on the matching surface of the main bearing cap rear end (5# bearing
cap).
17. Clean and dry out the matching surface of the main bearing cap rear end (5# bearing cap).
18. Apply 3mm wide sealant along the dash line in the figure below.
sealant applied in the previous step shall be cleared away and new sealant shall be applied again.
Sealant application path
19. Place the main bearing cap on the cylinder block.
20. Apply engine oil to the threaded section and flange of the main bearing cap bolts.
21. Tighten the bolts to 25N.m in the order shown in the figure below.
22. Tighten the bolts for additional 40.

23. Clear off the needless sealant on the cylinder block.
24. Install the dowel pin (A) and a new O-ring (B) to the oil pump (C), align the inner rotor with the
crankshaft, and then install the oil pump.
25. Install the oil collector (D) with a new washer (E).
26. Install the cylinder head.
27. Install the silent timing chain.
28. Install the gearbox.
29. Install the engine.
Notice: after replacing the crankshaft or connecting rod bearing shell, keep the engine running idle
until it reaches the normal working temperature, and then let it run for additional 15 minutes.
3.11 Install Oil Pan

1. Clear off the old sealant on the matching surface of the oil pan, the bolt and bolt holes.
2. Clean and dry out the matching surface between the oil pan and cylinder block.
3. Install a new crescent sealing ring on the oil pan.
Crescent sealing ring
4. Evenly apply special-purpose sealant to the matching surface between the oil pan and cylinder
block and in the bolt holes.
Notice: apply 2mm3mm wide sealant along the dash line in the figure below.
Apply 5.0mm wide sealant to the shadow area B shown in the figure below.
sealant applied in the previous step shall be cleared away and new sealant shall be applied
again.
5. Install the oil pan A with a dowel pin B and a new O-ring C.
6. Tighten the bolts by 2 or 3 steps.

Tightening torque: (see indication below)
Indicated by A: 25Nm
Indicated by B: 12Nm
7. Install the clutch back plate, and then tighten the 2 bolts fixing the gearbox. The tightening
torque for the bolts is shown below:
Clutch back plate
8. Install the dipstick tube (A) with a new O-ring (B). The tightening torque is shown in the figure.
9. After completing the installation, wait for at least 30 min before filling engine oil into the engine.
Chapter 2 Lubricating System

Component Layout
Gasket
Oil drain plug
Oil pan
Oil filter
Oil filter thread pipe
Crescent sealing ring
O-ring
Oil collector
Oil collector
gasket
Oil dipstick pipe
Breather cover plate Oil pressure warner
Dowel pin
O-ring
Oil pump
1. Check Oil Pressure Warner

1. Disconnect the oil pressure warner connector (A) from the oil pressure waning device (B).
2. Check the conductivity between the positive terminal (C) and engine (grounded). The circuit
shall be turned on when the engine stops running and be turned off when the engine is running.
3. If the pressure warning device isnt work normally, check the oil level; if the oil level is normal,
check the oil pressure; if the oil pressure is normal, replace the oil pressure warner.
2. Inspect Oil Pressure

If oil pressure warning light shall remain on when the engine is running, check the oil level; if the oil
level is normal:
1. Remove the oil pressure warner, and connect an oil pressure gauge to its mounting hole with a
special-purpose adapter.
2. Start the engine and check the oil pressure gauge. If the reading indicates no oil pressure, shut
down the engine immediately. Solve this trouble before going to the next step.
3. When the engine reaches the running temperature (cooling fan started at least twice), the oil
pressure shall be:
Oil temperature: 80C
Oil pressure:
Idle running: minimum 30kPa
At 3000rpm/min: minimum 300kPa
4. If the oil pressure is beyond the specified range, check the following items:
Check whether the oil collector is blocked;
Check the oil pump.
3. Change Engine Oil

1. Pre-warm the engine.
2. Loosen the oil drain plug (A) to completely drain the oil in the engine.
39 N.m Do not tighten it excessively.
3. Install the oil drain plug again with a new washer (B).
4. Fill new engine oil in the engine.
When changing oil: 2.9L
When changing oil (including the oil filter): 3.3L
After engine overhaul: 4.0L
5. Keep the engine running for over 3 minutes and check for oil leakage.
4. Replace Engine Oil Filter

1. Remove the oil filter with the oil filter wrench SST.
2. Check the thread (A) and rubber sealing (B) of a new oil filter, clean the contact surface between
the oil pan and filter, and then apply a thin oil film on the oil filter rubber seal ring. Only use an oil
filter with internal bypass system.
3. Install the oil filter manually.

4. Fit the rubber seal ring in place, and lock the oil filter clockwise with the SST.
Tightening: rotate 3/4 to 1 round clockwise.
Tightening torque: 12N.m
5. After installation, fill engine oil to the specified oil level, start the engine and let it idle for 3
minutes, and then check the oil drain plug and oil filter for leakage.
5. Replace Oil Filter Thread Pipe

1. Remove the oil filter.
2. Install two 201.5mm nuts (A) on a new oil filter thread pipe. Hold the nut with a wrench, and
then tighten one nut.
3. Tighten the oil filter thread pipe on the oil pan to 74N.m, and then remove the nuts on the thread
pipe.
6. Overhaul Oil Pump

Exploded view
O-ring
Pump housing
Dowel pin
Oil pump cover

Outer rotor
Inner rotor
Pressure relief valve

The valve shall slide freely in the housing.
Replace the valve if any scratch.
Spring
Sealing bolt
20N.m
Removal Procedure
2. Remove the oil collector (A) and then the oil pump (B).
Inspection
1. Remove the pump cover.
2. Check the radial clearance between the inner rotor (A) and outer rotor (B). If the radial
clearance is beyond the service limit, replace the oil pump.
Inner rotor-outer rotor radial clearance:
Standard: 0.0750.15mm
3. Check the axial clearance between the rotor (A) and pump housing (B). If the axial clearance is
beyond the service limit, replace the oil pump.
Pump housing-rotor axial clearance:

4. Check the radial clearance between the outer rotor (A) and pump housing (B). If the radial
clearance is beyond the service limit, replace the oil pump.
Pump housing-outer rotor radial clearance:
5. Check the inner rotor, outer rotor and pump housing for scratch and other damages, and make
replacement if necessary.
6. Install the oil pump cover.
1. Install the dowel pin (A) and a new O-ring to the oil pump (C). Align the inner rotor with the
crankshaft, and install the oil pump.
2. Install the oil collector (D) with a new washer (E).
3. Install the silent timing chain.
7. Install Breather Cover Plate

1. Clean and dry out the matching surface, bolts and bolt holes of the breather cover plate.
2. Apply 2-3mm wide sealant along the dash line (A).
sealant applied in the previous step shall be cleared away and new sealant shall be applied again.
3. Install the breather cover plate.
8. Replace Oil Pressure Warner

1. Disconnect the oil pressure warner connector (A), and remove the oil pressure warner (B).
2. Apply sealant to the threaded section of the oil pressure warner, and then install it with a
tightening torque of 15N.m.
Chapter 3 Air Intake and Exhaust System

1. Standard Service Value
See Table 6-1 for standard values.
Table 6-1
Item
Standard Value
Service Limit
Deformation of intake manifold mounting surface (mm)
< 0.15
0.20
Deformation of exhaust manifold mounting surface (mm)
< 0.15
0.20
2. Air Intake System Parts Layout
Front air intake pipe

assembly
Crankcase
vent pipe
Crankcase vent
pipe
sleeve
Air
intake hose
Rear air intake
pipe
assembly
Air
filter assembly
3. Air Filter Assembly

Removal & installation:
Notice: when operating the filter element that consists of non-woven fabrics, and mixed material
made from waster paper and resin, pay attention to the following:
1. Avoid severe impact or large load on the filter element after disassembly and reassembly.
2. Ensure there is good fitting between the filter element and the lower filter case.
See Fig. 6-1 for the removal procedure:
.
.
Fig. 6-1
1- inlet pipe assembly, 2-outlet pipe assembly, 3-crankcase vent pipe, 4-air filter assembly, 5-upper filter case,
6-filter element, 7- lower filter case
4. Intake manifold
Works before removal and after installation
1. Drain and fill the coolant (refer to the relevant section);
2. Remove and install the air filter (refer to the section above on the air filter);
3. Remove and install the throttle body and injection driver. (refer to the relevant section for
removal procedure)
Tips on removal of intake manifold
Disconnect the intake manifold resonator and remove the intake manifold.
Tips on installation of engine hood:
(1) Pretighten the mounting bolts to the extent that you can move the engine hood manually.
(2) Tighten the mounting bolts with the specified torque.
5. Intake Pipe and Muffler

5.1 Removal and installation (see Fig. 6-2)
1
2
1
6
8
50N.m
6
5
4
7
6
9
45 5N.m
9
45 5N.m
Fig. 6-2
1-sealing ring, 2- front exhaust pipe assembly, 3-rear oxygen sensor, 4-middle welded exhaust
pipe assembly 5- rear exhaust pipe assembly, 6-rubber hanger I, 7-rubber hanger III, 8-connecting
bolt I (shank length 43mm, spring length 40mm), 9-connecting bolt II (shank length 39mm, spring
length 43mm) 10. -connecting bolt III (shank length 39mm, spring length 43mm)
Notice: connecting bolt II and III are interchangeable.
5.2 Remove/Install Front Exhaust Pipe Assembly
1. Removal:
(1) Firstly remove the rear oxygen sensor on the front exhaust pipe assembly with an oxygen
sensor wrench;
(2) Remove 2 connecting bolts II and spherical sealing ring;
(3) Remove 2 connecting bolts I and spherical sealing ring;
(4) Remove the front exhaust pipe assembly.
2. Installation
(1) Install spherical sealing rings;
(2) Tighten two connecting bolts I with a tightening torque of 455N.m;
(3) Tighten two connecting bolts II with a tightening torque of 455N.m;
(4) Install the rear oxygen sensor onto the front exhaust pipe assembly with an oxygen sensor
wrench;
5.3 Remove/Install Middle Welded Exhaust Pipe Assembly

1. Removal
(2) Remove 4 rubber hangers.
2. Installation
(1) Install 4 rubber hangers and spherical sealing ring;
(2) Tighten two connecting bolts II with a tightening torque of 455N.m;
5.4 Remove/Install Main Muffler Assembly
1. Removal
(2) Remove 2 rubber hangers (F3F and F3V);
(3) Remove 2 rubber hangers (IB5 and IB6).
2 Installation
(1) Install the rubber hangers and spherical sealing ring;
(2) Tighten two connecting bolts III with a tightening torque of 50N.m;
6. Inspection
Check the parts and assemblies for damage and defect (such as broken welding and crack), and
make replacement if necessary.
7. Remove/Install intake manifold

Removal Procedure
1. Remove the intake manifold cover.
3. Remove the breather pipe (A), power brake vacuum hose (B) and positive crankcase ventilation
(PCV) hose (C).
4. Remove the throttle cable.

5. Remove the wire harness bracket and bolt.
6. Remove the canister control valve connecting hose.
7. To replace the intake manifold, remove the throttle body.
8. After the engine coolant is drained completely, remove the water inlet/outlet hose from the
throttle body.
9. Remove the engine wire harness connector and wire clip on the intake manifold.
10. Remove the intake manifold bracket and then the intake manifold.
1. Install the intake manifold with a new sealing washer, and then tighten the bolts and nuts by 2-3
steps in alternating pattern, starting from the innermost bolt, with a tightening torque of 25N.m.
2. Install the intake manifold bracket.
3. If the water inlet/outlet hose have been removed on the throttle body, install them properly.
4. If the throttle body is removed, install it with a new sealing washer for throttle body.
5. Install the canister control valve connecting hose.
6. Install the wire harness bracket and bolt.
7. Install the throttle cable and adjust it.
8. Install the breather pipe, power brake vacuum hose and positive crankcase ventilation (PCV)
hose.
10. Install the intake manifold cover.
11. Upon completion of assembling, check whether all pipes, hoses and connectors are connected
properly.
12. If the engine coolant is drained completely, fill the coolant into the radiator again while leaving
the heater valve open to discharge the air in the cooling system.
8. Remove/Install Exhaust Manifold

1. Remove the insulation cover and bracket for the exhaust manifold, and then remove the
exhaust manifold.
2. Install the exhaust manifold and then tighten the bolts and nuts by 2-3 steps in alternating
pattern, starting from the innermost bolt.
3. Install the other parts in the reverse sequence of removal.
Chapter 4 Engine Cooling System

Component Layout
Coolant temperature sensor
Water pump
Thermostat
Radiator fan
Radiator
1. Information on Maintenance Standard

See Table 7-1 for maintenance standard values.
Table 7-1
Item
Standard Value
Service Limit
Thermostat opening temperature (C)
821.5
Thermostat full opening temperature (C)
95
Thermostat full opening lift (mm)
above 8.5
Item
Brand
Capacity (L)
Coolant capacity (including coolant tank)
Shell Freeze Guard
7.0
2. Coolant
See Table 7-2 for coolant capacity.
Table 7-2
3. Sealant
See Table 7-3 for information on sealant.
Table 7-3
Application location
Brand
Water pump
Thermostat housing assembly
Sealant: LT5699 (150g)
Cylinder block drain valve
4. On-board Maintenance
1. Check Radiator Cap Valve Opening Pressure
Standard: 74103kPa
Limit: 64 kPa
2. Check Coolant
(1) Check whether the coolant level in the tank is located between F and L.
(2) Check whether there is engine oil in the coolant.
3. Change Coolant
(1) Remove the radiator water drain plug and radiator cap. Drain the coolant in the radiator, air
heater and the engine.
Fig 7-1
(2) Remove the water drain valve from the cylinder block and drain the coolant in the water jacket
(see Fig. 7-1).
(3) Remove the coolant tank and drain the coolant.
(4) After draining the coolant, fill water from the radiator cap to clean the coolant pipeline.
(5) Tighten the cylinder block water drain valve by the specified torque. Tightening torque:
405Nm
(6) Make sure the radiator water drain plug is tightened.
(7) Install the coolant tank;
(8) Fill the coolant into the radiator until it reaches the opening, and into the coolant tank until it
reaches the F line.
Coolant: Shell Freeze Guard
Coolant capacity: 7.0L
(9) Install the radiator cap;
(10) Start and warm up the engine until the thermostat opens.
(11) Start the engine at high idle speed and stop it for several times and then stop the engine.
(12) When the engine is cold, remove the radiator cap, and fill the coolant into the radiator until it
reaches the opening, and into the coolant tank until it reaches the F line
5. Thermostat
1. Install and Check Thermostat
Fig. 7-2
1-connector for radiator water outlet pipe;

2-connector for water inlet pipe;
3-thermostat
Install thermostat
(1) Install the sealing ring onto the thermostat and prevent distortion and damage. The thermostat
air bleeder shall be on the top (see Fig. 7-3).
(2) Connect the radiator water outlet pipe.
Insert the radiator water outlet pipe into the protruding part of the water inlet connector.
Align the alignment marks on the radiator water outlet pipe and pipe clamp and install them.
Notice: prevent the thermostat sealing ring from oil stain, and replace a thermostat if the sealing
ring is damaged.
Air bleeder
Sealing ring
Fig. 7-3
Check thermostat
(1) Submerge the thermostat into the container filled with water; stir the water to heat up it and
then check whether the thermostat opening temperature confirms to the standard value (see
Fig. 7-4). Standard value: 821.5C
(2) Heat up the water to the thermostat full opening temperature, and check whether the valve lift
confirms to the standard value (see Fig. 7-5). Standard: lift over 8.5mm at 95 C
Tips: measure the valve height when the thermostat is fully closed and when it is fully open, and
then calculate the valve lift.
Valve lift
Fig. 7-4
Fig. 7-5
Notice:
Prevent the O-ring from stains such as grease and engine oil.
6. Water Pump
1. Works before removal and after installation:
Drain and fill the coolant (refer to relevant
sections in this chapter).
Remove and install the timing belt cover (refer
to relevant sections in this manual).
See Fig. 7-6 for the removal procedure.
(1) Clear off the attachments on the liner with

a liner scraper or wire brush.
(2) Evenly apply the specified LT5699 sealant
to the location indicated in Fig. 7-6, and
do not get any other place stained.
(3) Install the water pump when the sealant is
still wet (within 15 minutes).
Bolt size and installation position
Thread diameter X length (mm)

Fig. 7-6
Tips on installation:
1-alternator support arm; 2-water pump
2. Install water pump
7. Water Inlet/Outlet Hose

Works before removal and after installation
Drain and fill the coolant (refer to relevant sections in this chapter)
Remove and install the engine hood (refer to relevant sections in this manual)
Remove and install the lower cover
Remove and install the battery and battery bracket. See Fig. 7-7 for the removal procedure.
Tips on removal
(1) Disconnect the radiator water inlet/outlet pipe, and make alignment marks on the pipes and
clamps before removal.
(2) To remove the water inlet pipe, remove the bolts for pressure stabilizing box resonator and
move the resonator out of the operation range.
(see Fig. 7-8)
Remove the water inlet pipe (see Fig. 7-8)
Tips on installation
(1) Install O-ring
(1) Soak the periphery and inside of the O-ring with water and then insert it in place (see Fig. 7-9).
(2) Install the thermostat housing assembly
a. Clear off the attachments on the liner with a liner scraper or wire brush.
b. Evenly apply the specified sealant on the mounting surface for sealing, and do not get any
other place stained.
c. Install the thermostat when the sealant is still wet (within 15 minutes).
(3) Connect radiator water inlet/outlet pipe
a. Insert the water inlet/outlet pipe into the protruding part of the connectors.
b. Align the alignment marks on the radiator water inlet pipe and pipe clamp and install them.
Fig. 7-7
1-radiator water inlet pipe connector; 2-radiator water outlet pipe connector;
3-water temperature sensor connector; 4-heater hose connector;
5-water temperature gauge assembly connector; 6-water supply hoses;
7-thermostat housing assembly; 8-water inlet pipe connector;
9-water outlet pipe connector; 10-heater hose connector;
11-intake manifold bracket; 12-water supply hose;
13-water inlet pipe; 14-O-ring; 15-water supply hose;
16-water supply hose
Intake manifold
Cylinder block
O-ring
Pressure stabilizing
box resonator
Water pump inlet pipe
Fig. 7-8
Fig. 7-9
8. Radiator
Remove/install radiator
1. Works before removal
Drain the coolant.
(1) Remove the radiator water drain plug and radiator cap. Drain the coolant in the radiator, air
heater and the engine;
(2) Remove the water drain valve from the cylinder block and drain the coolant in the water jacket
(see Fig. 7-10);
Fig. 7-10
(3) Remove the coolant tank and drain the coolant;

(4) After draining the coolant, fill water from the radiator cap to clean the coolant pipeline;
(5) Remove the lower cover;
(6) Remove the air filter;
(7) Remove the battery and battery bracket.
2. Works after removal:
(1) Apply the designated sealant on the thread of cylinder block water drain valve, and then tighten
it by the specified torque (see Fig. 7-11);
Sealant: LT5699
Clear off the old sealant before applying the new sealant.
Tightening torque: 405Nm
(2) Make sure the radiator cover water drain plug is tightened.
(3) Install the coolant tank;
(4) Fill the coolant into the radiator until it reaches the radiator opening, and into the coolant tank
until it reaches the F line.
Coolant: Shell Freeze Guard
Coolant capacity: 7L
Fig. 7-11
(5) Install the radiator cap;

(6) Start and warm up the engine until the thermostat opens.
(7) Start the engine at high idle speed and stop it for several times.
(8) When the engine is cold, remove the radiator cap, and fill the coolant into the radiator until it
reaches the opening, and into the coolant tank until it reaches the F line
(9) Replenish ATF and check it;
(10) Install the lower cover;
(11) Install the battery and battery bracket;
(12) Install the air filter.
3. See Fig. 7-12 for the removal procedure.
Remove/install electronic fan assembly
See Fig. 7-12 for the removal procedure of the electronic fan assembly:
3-coolant tank hose; 5-radiator water inlet pipe; 7-upper bracket assembly; 10- electronic fan
assembly; 11-fan; 12-fan motor and controller; 13-shield
Tips on removal
Remove the radiator water inlet/outlet pipe
Make alignment marks on the pipes and clamps before removal.
Install the radiator water inlet/outlet pipe
Insert the hoses into the protruding part on the radiator and engine while aligning the marks on the
pipe clamps.
Fig. 7-12
1-radiator; 2-radiator upper mount bracket; 3-radiator upper mount liner; 4- hexagon head bolt; 5-radiator lower
mount liner; 6-radiator water inlet hose; 7- radiator water outlet hose; 8-overflow reservoir inlet hose; 9-overflow
reservoir breather pipe; 10-overflow reservoir; 11-electronic fan assembly; 12-hexagon flange bolts; 13-worm ring
clamp
9. Check Thermostat
Replace the thermostat if it opens under the room temperature.
Test the thermostat when it is in closed position.
1. Hang the thermostat (A) in a container filled with water, and keep the thermometer (B) away
from the bottom and wall of the container.
2. Fill in water, and measure the water temperature for thermostat opening and thermostat full
opening.
3. Measure the lift with the thermostat full opening.
Standard thermostat:
Lift: over 8.0mm
Opening temperature: 76C80C
Full opening temperature: 90C
10. Check Water Pump

1. Remove the belt.
3. Rotate the water pump pulley anti-clockwise to check whether the pump can rotate freely.
4. Check whether seal leakage occurs. It is normal that there is a little water seepage at the drain
hole (A).
11. Replace Water Pump

1. Remove the belt.
4. Remove the 5 bolts fixing the water pump and then remove the water pump.
5. Check and clean the O-ring groove and the matching surface with the cylinder body.
6. Install the water pump with a new O-ring in the reverse sequence of removal.
7. Clear off the overflowing engine coolant.
12. Replace Thermostat

Removal Procedure
1. Remove the thermostat cover (A) and then remove the thermostat (B).
2. Clear off the old sealant on the matching surface of the thermostat cover, the bolts and bolt
holes.
3. Apply 2-3mm wide sealant along the dash line (A).
4. Install the thermostat sealing ring (A) on the thermostat (B), and then install the thermostat with
the pin (C) facing upwards.
5. Install the thermostat cover (D).

Notice: after assembling, wait for at least 30 minutes and then fill coolant into the engine.
13. Replace Water Temperature Sensor

2. Disconnect the water temperature sensor connector and then remove the sensor.
3. Apply the sealant on the thread on the water temperature sensor and then install the sensor.
4. Clear off the overflowing engine coolant.
Chapter 5 Fuel and Exhaust System

1. Fuel Tank
1. Removal & installation
Works before removal
Pump out the fuel.
Prevent the fuel from splashing on the
ground.
Remove the secondary muffler
Works after installation

Fill fuel into the tank
Make sure there is no fuel leakage
Install the secondary muffler
1. See Fig. 8-1 for the removal procedure.
Fig. 8-1
1-fuel tank assembly; 2-fuel tank band; 3-fuel tank mounting bolt; 4-fuel tank filler cap assembly; 5-filler cap shield;
6-wire retaining ring ; 7-fuel filler pipe jacket; 8-fuel filler pipe assembly; 9-fuel filler pipe bracket; 10-bracket I bolt;
11-two hole pipe clamp; 12-bracket II bolt; 13-oil filling pipe bracket II; 14-air outlet pipe bracket I; 15-air outlet pipe
bracket II; 16-worm ring clamp; 17-air outlet hose; 18-oil filling hose ring clamp; 19-oil filling hose; 20-fuel pump
assembly; 21-pump circlip; 22-oil return hose; 23-pipe clamp; 24-oil inlet hose; 25-fuel filter bracket; 26-fuel filter
assembly; 27-three hole pipe clamp; 28-anti-tilt valve assembly; 29-elastic ring clamp; 30-evaporative emission
hose
2 Precautions on removal of fuel tank

(1) Lift up the vehicle with a lift and support it properly. When lifting/supporting the fuel tank with a
jack, apply auxiliary support to prevent the fuel tank from toppling.
(2) The rubber pipe shall be replaced as a whole; do not repair any pipe segment.
(3) To service the fuel system, cover the attachment and plug the hold to prevent dirt and other
contaminants from entering the system from open pipeline or other passages.
(4) Keep the fuel system parts clean and in good order.
Notice:
Reinstall the 4 M10 bolts fixing the fuel tank, and tighten them with 20N.m tightening torque.
Tighten the ring clamps and make replacement if necessary.
Check and make sure the hoses are not damaged or twisted during removal and installation.
Keep the ignition switch at ON for 2 seconds, turn it to OFF and remains for 10 seconds, then
turn it to On again, and finally check for fuel leakage.
2. Power Fuel Pump

1. Replace the power fuel pump (see Fig. 8-2).
(1) Remove the wire harness connector and fuel pipe.
(2) Remove the fuel tank.
(3) Remove the fuel pump circlip and then the power fuel pump.
(4) Install a new power fuel pump and the circlip.
(5) Install the fuel tank.
(6) Connect the fuel pipe (hose) and wire harness connector.
Oil return pipe
Notch
High pressure
oil pipe
Wire harness
socket
Power
pump
fuel
Fig. 8-2
Notice:The notch of the power fuel pump shall be aligned to the notch on the fuel tank.
2. Replace the fuel filter.
Remove the fuel filter.
(1) Discharge the pressure in the fuel system.
(2) Collect the fuel in a proper container.
(3) Take out the fuel filter from the bracket.
The disassembled fuel filter is shown in Fig. 8-3.
Fig. 8-3
3. Install the fuel filter.

(1) Remove the protection cover of a new fuel filter.
(2) Slowly insert the fuel filter into the bracket, and tighten the bracket bolts.
(3) Connect the fuel hoses on both ends of the fuel filter in the fuel circuit.
(4) Tighten the fuel filler cap of the fuel tank.
(5) Reconnect the battery negative cable.
(6) Keep the ignition switch at ON for 2 seconds, turn it to OFF and remains for 10 seconds, then
turn it to On again, and finally check for fuel leakage.
Notice:After install the high pressure pipe, pull it slightly to the opposite direction to make sure it is
installed firmly; and make sure there is 3mm clearance.
Arrange vacuum hose
Carbon
canister
interface assembly
Carbon canister control valve
Carbon canister control

valve connecting hose
PGM-FI system
(1) Install the high pressure pipe and fuel supply pipe
Programmed fuel injection (PGM-FI) system is a multi-point sequential fuel injection system.
Crankshaft position (CKP) sensor
CKP sensor detects the engine speed and determines the ignition timing and fuel injection timing
of each cylinder.
O-ring
Magnet
Camshaft phase (CMP) sensor

CMP sensor detects the position of the number 1 cylinder, which is used as reference for
sequential fuel injection.
O-ring
Magnet
Engine coolant temperature (ECT) sensor

ECT sensor is a resistor whose resistance varies significantly with temperature (thermistor). Its
resistance reduces with the increase of the coolant temperature.
Thermistor
Idle stepper motor

Idle stepper motor (IMA) is a resistance device controlling the idle mixture concentration.
Idle stepper motor
Knock sensor
Knock control system can reduce the knock to minimum by regulating the ignition timing.
Piezoelectric ceramics
element
Throttle position (TP) sensor

TP sensor is a potentiometer connecting to the throttle shaft. The sensor sends variable voltage
signal to ECM/PCM according to the change in throttle openness. TP sensor shall be replaced
together with the throttle body.
Element
Brush holder
Brush
System description
Throttle body
TP sensor
IAC valve
Positive crankcase ventilation (PCV) system

PCV valve sucks the gas leaked from the piston into the intake manifold, preventing it from
entering the atmosphere.
Vent pipe
Intake manifold
PCV valve
hose
PCV valve
Vapor leakage
Fresh air
Idle control system diagram

The engine idle speed is control by the idle stepper motor.
z When the engine starts, the solenoid valve is turned on for some time. The air intake is
increased so as to improve the idle speed.
z When the engine coolant temperature is low, the solenoid valve is turned on to get a higher
idle speed. The bypass air volume is controlled according to the coolant temperature.
Throttle body
Intake guide
Air filter element
Intake manifold
Engine
coolant
IAC valve
From PGM-FI main relay
Different sensors
Air intake system

The system provides air supply to the engine. When the air is sucked in, the resonance chamber
in the intake pipe can further reduce the noise level.
Throttle body
Intake guide
Intake manifold
Engine
coolant
Air filter element
IAC valve
From PGM-FI main relay
Resonance chamber (to air

filter )
Different sensors
PCV system
1. Check the PCV valve (A) and hose (B) and the connections for leakage or block.
2. At idle speed, slightly press the PCV valve and intake manifold with a finger or pliers to check
whether the PCV valve is giving click sounds.
If no click sound, check the PCV valve retainer for crack or damage. If the retainer is normal,
replace the PCV valve and check again.

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Page 1, Total pages 119

Section 2 Cylinder Head .................................................................................. 9

Section 3 Cylinder Block ................................................................................ 54

Page 2, Total pages 119

3.7 Check Cylinder Body and Piston ..............................................................................69

Chapter 2 Lubricating System ............................................................86

Chapter 3 Air Intake and Exhaust System ..........................................95

Chapter 4 Engine Cooling System....................................................100

Chapter 5 Fuel and Exhaust System ................................................ 112

Page 3, Total pages 119

Chapter 1 Gasoline Engine

1.1 Major Technical Parameters

In-line, water-cooled, SOHC, EFI, 4-stroke engine

Cylinder bore (mm)

Piston stroke (mm)

Maximum torque (N.m)

120 (4700 r/min)

Declared speed (r/min)

Declared power (kw)

Oil pressure (kPa)

Minimum stable idle speed (r/min)

Total displacement (L)

Oil/fuel consumption ratio (%)

CO0.15% HC40ppm (78050r/min)

Idle exhaust emission

CO0.15% HC40ppm(200050r/min) GB18285-2005

Ethylene glycol based coolant

Dry-type, single-disk, diaphragm spring clutch, with constant pressure

Clutch driven disk assembly 2008.9mm (free state)

Clutch cover assembly 25540.4mm

Page 4, Total pages 119

Synchromesh transmission, 5 forward gears, 1 reverse gear

Final drive ratio

Gear oil for medium duty vehicle (GL-4 SAE 80W/90)

1.2 Technical Parameters for Maintenance

Camshaft axial clearance

Camshaft-bracket oil film clearance

Cam lobe lift

Page 5, Total pages 119

Cylinder bore conicity

Cylinder reboring limit

Piston ring-groove clearance

Piston pin to piston-pin boss

Connecting rod small end bore

Connecting rod big end bore

Main journal diameter

Connecting rod journal diameter

the piston skirt bottom

Outer diameter at 13mm from

Mainshaft bearing-journal oil film

Page 6, Total pages 119

Replace oil (including oil

Oil pressure under

Valve stroke when fully open

engine, heater, hose and water

Opening temperature (C)

Page 7, Total pages 119

1.3 BYD473QA/QB Gasoline Engine Tightening Torque Table

Part /Location To Tighten

Cylinder head bolt with washer