5 2.8L Diesel Engine

Refine MPV Workshop Manual Engine General
Chapter II Diesel Engine Mechanic System [2.5TCI]
Section I General
I. Engine exterior view
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II. Technical data, size and parameters

Type Standard value Limit value
TCI Diesel engine
Number of cylinders 4-cylinder inline
Valve mechanism Top arranged
Total displacement 2.467cc
Bore X stroke 91.1×95 mm
Compression ratio 21
Compression pressure 27kg/250-400rpm
Valve timing
Air intake valve
Open (BTDC) 20°
Close (ABDC) 48°
Exhaust valve
Open (BTDC) 54°
Close (ABDC) 22°
Ignition sequence 1-3-4-2
Cylinder head
Cylinder gasket surface planeness 0.05 mm 0.2mm
Mounting surface planeness 0.15 mm 0.3mm
Total height 94.0-94.1 mm
Size enlargement for repair of valve guide
pipe hole (intake and exhaust)
0.05 13.050-13.068mm
0.25 13.250-13.268mm
0.50 13.500-13.518mm
Size enlargement for repair of air intake
valve seat ring hole
0.30 43.300-43.325mm
0.60 43.600-43.625mm
Size enlargement for repair of exhaust valve
seat ring hole 37.300-37.325mm
0.30 37.600-37.625mm
0.60
Camshaft
Cam height
Intake and exhaust 37.05 mm 36.55mm
Journal diameter 29.94-29.95 mm
Clearance 0.05-0.08 mm 0.13 mm
End play 0.1-0.2 mm 0.4 mm
Rocker arm
ID 18.910-18.928mm 0.08 mm
Clearance between rocker arm and rocker 0.012-0.050 mm
shaft
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Rocker shaft
OD 18.878-18.898mm
Valve
Total length
Air intake and exhaust 136.5 mm
Valve stem diameter
Air intake 7.96-7.975 mm
Exhaust 7.93-7.950 mm
Surface taper 45º-45º30’
Valve head thickness (critical)
Air intake and exhaust 2.0 mm 1.0 mm
Clearance between valve stem & guide pipe
Air intake 0.03-0.06 mm 0.10 mm
Exhaust 0.05-0.09 mm 0.15 mm
Valve spring
Free height 49.1 mm 48.1mm
Loading/installation 276 N/40.4 mm
Nonperpendicularity Max 2º 4º
Valve guide pipe
Total length
Air intake 71 mm
Exhaust 74 mm
ID 8.0 -9.02 mm
OD 13.06-13.07 mm
Valve seat
Seat angle 45º
Valve contact width 0.9-1.3 mm
Depression 0.2 mm
Balance shaft
Journal diameter
Right
Front 18.300-18.467mm
Rear 42.975-42.991mm
Balance shaft
Left
Front 18.959-18.980mm
Rear 42.975-42.991mm
Clearance
Front 0.02-0.06 mm
Rear 0.05-0.09 mm
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Piston
OD 79.0-79.2 mm
Clearance between piston and cylinder 0.04-0.08 mm
Ring groove width
No.1 ring 2.601-2.603 mm
No.2 ring 2.100-2.102 mm
Oil ring 4.010-4.035 mm
Maintenance dimensions 0.25, 0.50 0.75, 1.00
Piston ring
End play
No.1 ring 0.35-0.50 mm 0.8 mm
No.2 ring 0.25-0.40 mm 0.8 mm
Oil ring 0.25-0.45 mm 0.8 mm
Clearance between ring and ring groove
No.1 ring 0,056-0.076 mm 0.15 mm
No.2 ring 0.046-0.066 mm 0.15 mm
Oil ring 0.02-0.065 mm 0.1 mm
Maintenance dimensions 0.25,0.50,0.75,1.00
Piston pin
OD 28.994-29.000mm
Connecting rod
Length from large head center to small head 157.95-158.05mm
center
Camber Max.0.05 mm
Twist Max. 0.1 mm
Large head side play 0.10-0.25 mm
Crankshaft
End play 0.05-0.18 mm 0.25 mm
Journal OD 66 mm
Pin OD 53 mm
Out of roundness and taper of journal & pin 0.05mm
Journal clearance 0.02-0.05 mm 0.1 mm
Pin clearance 0.02-0.05 mm) 0.1 mm
Journal
0.25 U.S. 65.735-65.750mm
0.50 U.S. 65.485-65.500mm
0.75 U.S. 65.235-65.250mm
Pin
0.25 U.S. 52.735-52.750mm
0.50 U.S. 52.485-52.500mm
0.75 U.S. 52.235-52.250mm
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Engine body
ID 91.10-91.13 mm
Gasket surface planeness 0.05 mm 0.1 mm
Total height 318.45-318.55mm
Flywheel
Planeness 0.13 mm 0.1 mm
Engine oil pump
Gear tip clearance
Inner gear 0.22-0.35 mm
Outer gear 0.12-0.22 mm
Gear backlash
Inner gear, outer gear 0.04-0.10 mm 0.5 mm
Pump body clearance 0.4 mm
Outer gear 0.12-0.22 mm
Inner gear 0.03-0.09 mm 0.15 mm
Engine oil pressure during engine idling 80 KPa (0.8 kg/cm²) and above
Standard value Limit value
Forced water cooling circulation
Cooling system
system
Driving belt V type
Type of water pump Centrifugal impeller type
Duel metal plate temperature
Fan clutch type
difference type
Type of thermostat Wax bypass valve type
Type of coolant temperature meter Thermistor type (2 elements)
element
Thermostat
Valve open temperature (℃) 82
Fully open temperature (℃) 95
Coolant temperature meter element
Resistance
Coolant temp. meter element (Ώ/℃) 90.5-117.5/70,21.3-26.3/115
Heating control element (Ώ/℃) 22.3-27.3/-20,2.92-3.58/20
Air filter Paper filter type
Silencer Expansion resonance type
Note:
·OD: outer diameter
·ID: inner diameter
·US: undersized
·OS: oversized
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III. Torque parameters

Nm
Crankshaft belt bolts 170-190
Camshaft sprocket bolts 65-75
Timing belt tensioner bolts 22-30
Fuel injection pump sprocket nuts 80-90
Balance shaft sprocket nuts 34-40
Timing belt tensioner “B”nut 22-30
Rocker cap bolts 5-7
Rocker shaft bolts 35-40
Camshaft bearing cover bolts 19-21
Cylinder head bolts
Cold engine 105-115
Hot engine 115-125
Oil tray bolts 6-8
Oil tray drain plug 35-45
Front cover bolts (upper, lower) 12-15
Balance shaft driven gear bolts 34-40
Balance shaft plug cover 30-45
Balance shaft gear cover bolts 15-18
Connecting rod cap nuts 45-48
Flywheel bolts 130-140
Crankshaft bearing cap bolts 75-85
Engine oil safety valve plug 30-45
Engine oil pump hood screws 9-14
Engine oil pressure switch 8-12
Engine oil filter holder 12-15
Engine oil nozzle inspection valve 30-35
Engine oil cooler bypass valve 50-60
Cooling fan connecting bolts 10-12
Fan clutch connecting bolts 10-12
Water outlet matching part connecting bolts 10-12
Water pump connecting bolts 12-15
Coolant temperature meter element 30-40
Intake/exhaust manifold nuts and bolts 15-20
Exhaust manifold to thermal protector 12-15
Exhaust pipe to exhaust manifold stud bolts and nuts 30-40
Exhaust pipe to silencer 30-40
IV. Common troubleshooting

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Phenomenon Possible causes Repair
Low Cracked cylinder gasket Install new cylinder gasket
compression Worn or damaged piston ring Grind bore and install new piston ring
pressure Bent or depressed valve Install new valve
Excessive radial runout of valve seat Restore new valve seat and valve
on valve contact surface
Incorrect valve clearance Adjust to specified value
Valve noise Worn valve guide pipe Install new valve and/or new valve guide pipe of
enlarged dimensions
Excessive radial runout of valve seat Restore valve seat and valve
on valve contact surface
Excessive camshaft end play Correct end play
Connecting Insufficient supply of engine oil Check engine oil height
rod noise Low engine oil pressure Check engine oil height, safety valve and spring
Thin engine oil Replace engine oil to achieve correct viscosity
Excessive bearing clearance Measure bearing and correct clearance
Rod journal not round Replace crankshaft and re-grind journal
Connecting rod not straight Replace bent connecting rod
Crankshaft Insufficient supply of engine oil Check engine oil height
bearing noise Low engine oil pressure Check engine oil height, safety valve and spring
Thin engine oil Replace engine oil to achieve normal viscosity
Excessive bearing clearance Check bearing and correct clearance
Excessive end play Check No.3 main bearing flange for wear, replace
crankshaft or re-grind journal
Worn crankshaft journal (not round) Correct wear of crankshaft journal
Loose flywheel Tighten to correct torque
Piston noise Worn cylinder, excessive clearance Replace piston
Worn piston or piston pin Replace piston
Burnt piston Replace piston
Damaged piston ring Replace with new piston ring
Engine oil Loose oil tray drain plug Tighten to correct torque
leakage Loose oil tray installation bolts Tighten to correct torque
Damaged oil tray gasket Install new gasket
Defective crankshaft front oil seal Install new oil seal
Defective crankshaft rear oil seal Install new oil seal
Damaged rocker cap gasket Install new gasket
Loose engine oil filter Tighten to correct torque
Damaged engine filer gasket Install new gasket

Excessive Worn, scratched or broken ring Grind bore and install new ring
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engine oil Accumulated carbon in oil ring groove Install new ring
consumption Oil ring installed too tight in groove Remove oil ring, check ring groove; if groove
width is not correct, replace piston
Worn valve guide pipe Install new valve and/or new valve guide pipe of
enlarged dimensions
Faulty valve stem seal Install new valve stem seal
Drop of engine Low engine oil level Check engine oil height
oil pressure Low idling speed Set idling speed to specified value
Drop of engine Faulty engine oil pressure switch Install new switch
oil pressure Clogged engine oil filter Install new engine oil filter
Worn engine oil pump parts Replace worn part or pump
Thin engine oil Replace engine oil to achieve correct viscosity
Excessive bearing clearance Detect bearing and correct clearance
Clogged engine oil safety valve Remove valve, check, clean and install again
Bent or cracked engine oil pump hood Install new engine oil pump
Loose or clogged engine oil strainer Clean and replace engine oil strainer
Hole on engine oil pipe Replace and repair oil pipe
Cracked, hole on or clogged oil pipe Repair or replace the body
Oil channel plug lost or not installed Install new oil channel plug
Engine overheat Insufficient amount of coolant Fill coolant
Coolant concentration too high Correct
Driving belt loose or damaged Correct or replace
Fan clutch not operating Replace
Radiator fins damaged or clogged (insufficient Correct
ventilation)
Water leakage
Radiator core connector damaged Replace
Hose corroded or cracked (radiator hose, heater Replace
hose)
Loose water outlet matching part (thermostat) Repair or replace
bolts or defective gasket
Faulty radiator cap valve or spring fastener Repair
Loose cylinder head bolts Tighten to specified torque
Damaged cylinder head gasket Replace
Cracked body Replace
Cracked cylinder head Replace
Fault in thermostat operation Replace
Fault in water pump operation Replace
Stickum/rust/foreign matter clogging waterway Clean
No temperature Repair or replace
rise; faulty
thermostat
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Power failure Air intake system
a. Clogged air filter a. Clean or replace filter core
b. Air leakage in air intake system b. Repair
Exhaust system
a. Deformed or accumulated carbon in a. Repair or replace
silencer and exhaust pipe
b. Gas leakage in system b. Tighten connector
Repair or replace damaged exhaust pipe or
silencer
Abnormal noise Air intake system
and vibration a. Loose clamping bolts and nuts in air a. Tighten to specified torque
intake system
Exhaust system
b. Loose clamping bolts and nuts in b. Tighten to specified torque
exhaust system
c. Damaged silencer and exhaust pipe c. Replace
Damaged rubber lifting lug Replace
Interference of piping or silencer with Correct
vehicle body
V. Special tools
Tool (No. and name) Graphic Purpose
Balance shaft bearing extractor Removal of balance shaft rear
(09212-43100) bearing
Balance shaft bearing installation Installation of balance shaft rear

device (09212-43200) bearing
Bearing installation device spacer Removal of right balance rear

(09212-43300) bearing
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Crankshaft front oil seal installation Installation of crankshaft front oil
device (09214-32000) seal
Crankshaft front oil seal guide part Guiding during crankshaft front oil
(09214-32100) seal installation
Connecting rod small head liner Replacement of connecting rod

replacement tool (09214-43000) small head liner
Camshaft oil seal installation device Installation of camshaft oil seal

(09221-21000)
Cylinder head bolt wrench Loosening and tightening of

(09221-32000) cylinder head bolts
Valve seat tool pilot Correction of valve seat

(09221-43200)
Valve seat 45°reamer Correction of valve seat

(09221-43300)

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(09221-43400)

(09221-43500)
Valve spring compressor Compression of valve spring

(09222-21000)
Valve stem sealing installation Installation of valve stem seal

device (09222-32100)
Valve guide pipe installation device Removal and installation of valve

(09222-32200) guide pipe
Balance shaft driving gear oil seal Installation of balance shaft oil seal
guide
(09222-43200)

Crankshaft rear oil seal installation Installation of crankshaft rear oil
device seal
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(09231-32000)
Engine oil pressure switch wrench Removal and installation of engine

(09260-32000) oil pressure switch
Fuel injection pump sprocket Removal of fuel injection pump

extractor sprocket
(09314-43000)
Section II Engine maintenance
I. Maintenance of lubrication system
Inspection of engine oil

1. Park the vehicle on a horizontal plane.
2. Turn off engine.
Caution:
If the vehicle has not been used for a long time,
rotate the engine for several minutes, turn off
the engine and wait for at least 5min. Later,
check engine oil height.
3. Check if engine oil is in the range of height
indicated by oil rule. If it is found that oil level has
fallen to low limit (mark “L”), fill oil again to
bring it to mark “F”.
Caution:
For refilling of oil, use engine oil of correct grade.
4. Check if engine oil is dirty, or mixed with coolant or gasoline. Also check for suitable viscosity.
Selection of engine oil

Recommended API classification: CD or higher; CE or higher
Recommended SAE viscosity class:
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Caution:
In order that all types of operations can obtain best performance and maximum protection, it is necessary to
select lubricating oil meeting the following requirements:
1. Requirements by API classification are well satisfied.
2. Suitable SAE classification No. is available for anticipated air temperature range.
Do not use lubricants on the container of which SAE class No. and API service classification are not marked.
Replacement of engine oil

1. Run the engine till normal operating temperature is reached; check for oil leakage.
2. Turn off engine.
3. Remove engine oil cap and drain plug; drain engine oil.
4. Tighten oil drain plug to specified torque.
Tightening torque
Oil tray drain plug:
35-45 Nm
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Caution:
Always use new drain plug gasket for tightening.
5. Fill new engine oil by means of open engine oil cover.
Capacity:
Oil drain and filling
4,3L
Caution:
Do not fill too full; otherwise engine oil bubbling will occur as well as loss of engine oil pressure.
6. Fit engine oil cover.

7. Start and run engine for a few minutes and check for oil leakage.
8. Turn off engine and then check engine oil level; fill if required.
Replacement of engine oil filter

All engines of Hyundri Automobile Co. are
equipped with high quality engine oil filter that can
be used freely. This type of filter is recommended
as replacement engine oil filter for all vehicles.
Normally, quality of replacement engine oil filters
provided by aftersales service varies greatly.
High quality replacement engine oil filters shall be
used to ensure most efficient service. Before
installing an engine oil filter, ensure that all rubber
washers of oil filter have been taken away from
engine contact surface.
Engine oil filter replacement procedure
1. Use engine oil filer wrench to remove the filter.
2. Before installing new engine oil filter on engine,
apply engine oil on clean rubber gasket.
3. Tighten engine oil filter to specified torque.
Engine oil filter: 12-16Nm
4. Start and run engine, and check for leakage of engine oil.
5. After turning off the engine, check engine oil height. Add engine oil if required.
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II. Maintenance of cooling system

Check for leakage of coolant
1. Loosen radiator cover;
2. Confirm coolant height reaching neck of
filling port;
3. Install a radiator cover tester at radiator filling
port and apply 150KPa pressure. Keep this state
for 2min and then check for leakage at radiator,
hose or connector.
Caution:
1. Coolant temperature in radiator may be very high. Do not directly open radiator cover. To service this system,
wait for cooling of the vehicle so as to prevent injury due to spouting of high temperature coolant.
2. When removing the tester, take care not to splash coolant.
3. Confirm that all surplus things are removed from the area.
4. When installing and removing tester for testing, do not deform radiator filling port neck.
5. In case of leakage, repair or replace suitable parts.
Radiator cover pressure test
1. Use a connector to fit the cover on the tester.
2. Increase pressure till the gauge stops moving.
Main valve opening pressure:

107.9KPa±14.7KPa
Main valve closing pressure:
83.4Kpa
3. Check that the pressure is maintained at set limit value or above.

4. If reading is not maintained at limit value or above, replace radiator cover.
Caution:
Before testing, confirm that the cover is clean; this is because rust or other foreign matter on cover seals will
result in inaccurate reading.
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Testing of specific weight
1. Use a hydrometer to measure coolant specific

weight;
2. Measure coolant temperature and calculate
concentration according to relation between
specific weight and temperature and by referencing
the following table.
Relation between coolant concentration and specific weight

Coolant temperature (℃) and specific weight Safe
Freezing Coolant
operating
temperature concentration
10 20 30 40 50 temperature
℃ (specific volume)
℃
1.054 1.050 1.046 1.042 1.036 -16 -11 30%
1.063 1.058 1.054 1.049 1.044 -20 -15 35%
1.071 1.067 1.062 1.057 1.052 -25 -20 40%
1.079 1.074 1.069 1.064 1.058 -30 -25 45%
1.087 1.082 1.076 1.070 1.064 -36 -31 50%
1.095 1.090 1.084 1.077 1.070 -42 -37 55%
1.103 1.098 1.092 1.084 1.076 -50 -45 60%
Example:
When coolant temperature is 20℃ and measured specific weight is 1.058, safe operating temperature is -15℃.
Caution:
◆ If coolant concentration is lower than 30%, anticorrosion performance will be adversely affected.
◆ If the concentration is above 60%, anti-freezing and engine cooling performance will weaken, adversely
affecting engine. Therefore, change of concentration shall be maintained in specified range.
◆ Do not mix different anti-freezing fluids.
Recommended anti-freezing fluid
Anti-freezing fluid
Mixing proportion of anti-freezing fluid in coolant
Glycol base (Al water tank)

50% [except for tropic areas]
40% [for tropic areas]
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III. Maintenance of valve system

Inspection of engine compression pressure
1. Confirm that engine oil, starting motor and
batteries are in normal state.
2. Start engine and allow engine coolant
temperature reaching 80-95℃.
3. Loosen nozzle side oil pipe nut and disconnect
pipeline from nozzle seat.
Caution:
It is necessary to use cover to prevent foreign matter from entering nozzle.
4. Remove preheating plug baffle and 4 preheating plugs.
5. Fix engine tachometer at its position.
6. Place pressure connector and pressure gauge in preheating plug hole.
7. Run engine with throttle fully open; measure pressure when the press indicates stable reading.
Standard value (at 250rpm):
1920kpa
Difference among cylinders:
300kpa
8. After measurement, if pressure is lower than limit, add small amount of engine oil using preheating plug hole.
Again measure pressure to determine cause of fault.
9. If after adding engine oil, the pressure rises, cause of fault is worn or damaged piston ring or cylinder inner
surface. If the pressure is not higher after adding engine oil, the fault may be damage of valve or gasket.
Inspection and adjustment of valve clearance

1. Start engine and warm engine till coolant Timing mark (on the
Timing mark (on the
temperature reaches 80-95℃. camshaft sprocket) front upper cover)
2. Check engine timing and idling speed; adjust if

required.
3. Remove upper timing belt hood.
4. Remove rocker cap.
5. Rotate crankshaft clockwise and align marks on
camshaft sprocket and top of front upper cover.
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6. Check if valve clearance shown in Fig. A is
within standard value.
Standard value
Hot engine Exhaust Intake, Exhaust Intake, Exhaust Intake, Exhaust Intake
Air intake: 0.25mm
Exhaust: 0.25mm
Cold engine
Air intake: 0.15mm
Exhaust: 0.15mm
7. If the clearance is not within standard value,

loosen adjusting screw lock nut. When rotating
adjusting screw, use feeler gauge to adjust valve
clearance to specified value.
8. Hold adjusting screw with a screw driver so that

it does not move; tighten lock nut to specified
torque.
Tightening torque: 12-18 Nm
9. Rotate crankshaft clockwise for one round (360 Exhaust Intake, Exhaust Intake, Exhaust Intake, Exhaust Intake
degrees).
10. Check if valve clearance shown in Fig.[B] is
Standard values
Hot engine Air intake: 0.25 mm
Exhaust: 0.25 mm
Cold engine Air intake: 0.15 mm
Exhaust: 0.15 mm
11. If not within standard value, repeat steps 7-8 to
adjust clearances of remaining valves.
12. When installing rocker cap assembly on Applying sealant
cylinder head, apply a layer of specified sealant on
upper surface of half-round gasket and cylinder
head. Then tighten to specified torque.
Specified sealant: 3M ART Part No.8660 or Engine body
equivalent. Semicircular
Caution:
Over tightening may cause rocker cap deform
or leakage of engine oil.
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IV. Inspection and adjustment of belt

Timing mark
Adjustment of timing belt tension
1. Remove timing belt upper hood. Place piston of
No.1 cylinder on top dead center of compression
stroke. Check for alignment of timing marks on
sprocket.
No.1 cylinder piston on the
top dead center
Back for 1-2 circles

Tensioning direction
2. Loosen timing belt tightener pulley mounting
bolts.
Caution:
Do not loosen the belt too much; otherwise the
belt may fall into lower hood.
Back for 1 circle
3. Rotate crankshaft in normal direction

Camshaft sprocket
(clockwise) by 2 camshaft sprocket gears and hold. 2 gears
4. Tighten mounting bolts of tightener pulley.
Caution:
First tighten upper bolts and then lower bolts.
5. Rotate crankshaft in reverse direction to align

timing marks. Use forefinger to press middle part
of belt down to check if belt tension is within
standard value range.
Standard value: 4-5 mm
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6. Install timing belt upper hood.
Tension adjustment for timing belt “B” Timing

mark
1. Remove timing belt upper hood and place
No.1 cylinder piston at top dead center of
compression stroke. Check alignment of timing
marks of each sprocket.
On the top dead

center
2. Remove access cover.
3. Loosen timing belt “B” tightener pulley

mounting bolts and nuts.
Caution:
Do not loosen (upper) bolts too much; otherwise
it is very likely that they may fall into lower
hood.
4. Tighten tightener pulley mounting nuts and bolts.

Caution:
First tighten (lower) nuts and then (upper) bolts.
1. Install access cover.

2. Install timing belt upper hood.
Inspection and adjustment of driving belt deflection
1. Check belt for damage or wear and confirm correct placing of driving belt in belt sheave groove.
Caution:
If belt screeches or slips, check belt for wear, damage or cracking; also check sheave contact surface for
damage.
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Water pump pulley

2. Apply 100N downward force at middle points
between sheaves as shown to measure belt Power steering wheel
A/C pulley
deflection.
Standard value A/C compressor
AC compressor: 7-10 mm belt
Generator: 10-13 mm
Generator
V-belt
Caution:
Measure belt deflection between specified
driving sheaves.
Generator Crankshaft A/C compressor

pulley pulley
pulley
V. Adjustment of fuel injection timing
Cut
Caution:
Timing display
Fuel injection timing shall be adjusted along
with matching of engine.
1. Rotate crankshaft so that No.1 cylinder is at
top dead center of compression stroke.
Crankshaft pulley
2. Loosen (but not remove) fuel injection pipe

Valve seat
assembly nuts (total 4 nuts) at side of injection
pump. When loosening these nuts, use wrench to Nut
clamp fuel supply valve seat to prevent it from
moving with nuts.
3. Loosen the two nuts and two bolts that lock
fuel injection pump, but do not remove them.
4. Remove timing check plug from fuel injection

pump head.
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5. Before installation of special tool, confirm

that push rod has 10mm protruding part (can be
adjusted by internal nut).
6. Connect special tool (09310-43000) and dial

gauge.
About 300 Set to zero

7. Rotate crankshaft so that sheave notch is at
about 30ºangle from top dead center of No.1
cylinder piston compression stroke. Then set dial
gauge to zero. Slightly rotate crankshaft clockwise
and counterclockwise, and confirm that dial gauge
pointer has no deviation at zero position. If there is
deviation, re-adjust sheave position so that sheave
notch is at 30ºbefore top dead center.
8. Rotate crankshaft in normal direction so that

crankshaft notch is at 9ºATDC (top dead center)
(using fuel injection timing as reference). Confirm
that reading indicated by pointer is within standard
value.
Standard value: 1 ±0.03 mm
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9. If reading indicated by pointer is not within

specified value, tilt fuel injection pump body left
and right till the reading is within standard value.
Then tighten injection pump mounting bolts and
nuts to specified torque.
10. Repeat steps 7-8 and check that adjustment is
correct.
11. Remove special tool and dial gauge.

12. Install new copper gasket and timing check
plug, and then tighten the plug to specified torque.
13. Tighten fuel injection pipe nut to specified
torque. When tightening the nut, use wrench to
clamp fuel supply valve seat to prevent it from
rotating with the nut.
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Section III Engine machinery
I. Cylinder head assembly
Lock blade
Spring seat
Cylinder cover bolt
Spring Valve spring
base
Valve tappet sealing member
Intake valve
pipe
Exhaust valve pipe
Cylinder head
Cylinder head gasket

Exhaust valve seat ring
Intake valve
seat ring
Exhaust valve
After removing, replace with a new gasket.

Torque
Removal
Cylinder head
1. Removal fuel injection pipe assembly. When loosening injection pipe nut, use wrench to clamp injection
nozzle seat and fuel supply valve seat to prevent them from rotating with nut.
Caution:
After removal of injection pipe, place a cover on nozzle seat and fuel supply valve seat to prevent foreign
matter from falling into them.
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2. Remove timing belt upper hood.
3. Loosen camshaft sprocket bolts till they can
be loosened by hand.
4. Place No.1 cylinder piston at top dead center
of compression stroke and align timing marks on
camshaft sprocket and upper cover.
5. Use hand to remove camshaft sprocket bolts.
6. With timing belt engaged, remove sprocket
from camshaft and place the assembly in timing
belt lower hood.
Caution:
Once sprocket is removed, do not rotate
crankshaft any more to maintain timing belt
tension.
7. Remove rocker cap, rocker shaft assembly
and camshaft.
8. Use special tool cylinder head bolt wrench
(09221-32000) to loosen and remove 18 cylinder
cover bolts. Loosen these bolts in 2 or 3 steps
according to the sequence shown in the figure.
9. Remove cylinder cover.
10. Remove cylinder head gasket, clean cylinder
head and body gasket surface.
Valve and valve spring
1. Remove cylinder head assembly.
2. Remove parts shown in the figure and store
them according to each cylinder. Use valve spring
compressor (09222-21000) to remove valve spring
gasket.
3. Place removed parts according to cylinder No.

and intake/exhaust.
Inspection
Air intake valve, exhaust valve
1. If valve tappet is worn (taper wear) or
damaged, replace it. If stem end face (in contact
with rocker adjusting screw) is bent, replace it.
- 286 -
2. Check contact of valve face. If contact is not
correct, repair with valve face repair device.
Contact with valve seat shall be at center of valve
face and even.
Contacting area
3. If the margin (valve head thickness) exceeds (must be the center
of the valve)
the limit, replacement shall be made.
Threshold
Standard value
Intake/exhaust valve: 2.0 mm
Limit
Intake/exhaust valve: 1.0 mm
Valve spring
1. Spring free height is as follows. If the limit is
exceeded, carry out replacement.
Standard value: 49.4 mm
Limit: 48.1 mm
2. Measure spring perpendicularity. If the limit Free height
value is exceeded, carry out replacement.
Standard value: ≤2º
Limit value L: 4º
Valve guide pipe

Measure clearance between valve guide pipe and
stem; if limit value is exceeded, replace valve
guide pipe or valve, or both.
Standard value
Intake: 0.03-0.06 mm
Guide pipe outside diameter
Exhaust: 0.05-0.09 mm
Guide pipe inside diameter
Limit value
Intake: 0.10 mm
Exhaust: 0.15 mm
Cylinder head
1. Before cleaning cylinder head, check for
water leakage, oil leakage, damage or cracking.
2. Thoroughly remove oil, debris, sealant and
accumulated carbon. After cleaning of oil path, use
compressed air to ensure no channel clogging.
3. If air leaks from cylinder head gasket surface,
measure surface planeness. If deform exceeds limit,
replace cylinder head.
- 287 -
Limit: 0.2 mm
4. Carry out visual inspection of internal surface
of camshaft bearing to check for damage or
sticking. If a defect is found, replace the bearing.
Repair valve seat

Check valve seat for ablation or incorrect contact with valve face. If needed, repair or replace valve seat. Before
repair of valve seat, check valve guide pipe for wear. If valve guide pipe is worn, replace it and then repair it. Use
valve seat repair device and reamer to repair the valve seat. Valve seat contact width shall be in specified range and
at center of the valve face. After repair, use abrasive paste to lightly grind valve and valve seat.
Angle Tool No.

45º 09221-43300
65º 09221-43400
30 09221-43500
Valve guide replacement procedure

1. Use push rod and press of valve guide
installation device (09222-32200) to remove valve
guide toward engine body.
Repeat boring of valve guide hole to new enlarged
valve guide OD.
2. Use valve guide installation device
(09222-32200) to press fit valve guide from
cylinder head upper surface.
- 288 -
Caution:
To replace valve guide, check valve contact. If
required, repair valve seat.
3. After installation of valve guide, insert new

valve to check sliding.
Valve guide hole diameter:
0.05 O.S.: 13.050-13.068 mm
0.25 O.S.: 13.250-13.268 mm
0.50 O.S.: 13.500-13.518 mm
Installation
Valve stem seal
Use valve stem seal installation device
(09222-32100), fit valve seal into valve guide.
Caution:
a． Used valve stem seal must not be used again.
b． It is necessary to use special tool to install valve stem seal. Incorrect installation will cause oil leak
through valve guide.
Valve spring
Spring seat
Apply identification color on the end of valve Identified
spring facing rocker arm. color
Guide sealing
member
Spring seat
Valve spring retainer clamp
Use valve spring compressor (09222-21000) to

compressor spring and fix the retainer clamp on its
position.
Caution:
If valve spring is pressed too much, it will
contact seat bottom end, damaging tappet seal.
- 289 -
Cylinder head
Remove cylinder gasket on cylinder head
assembly.
Caution:
Do let foreign matter fall into coolant path.
1. Use special tool to tighten in 2 or 3 steps
according to sequence shown in the figure.
Specified torque
Cold engine: 105-115 Nm
Hot engine: 115-125 Nm
Rocker arm
Breath hose
Fuel filler cap
Rocker arm cap
Rocker arm cap gasket 35-40
Rocker arm shaft

Rocker arm (intake)
Rocker arm shaft spring
Rocker arm (exhaust)

Gear shaft bearing cap
18-21
Camshaft
Sealing member
Gear shaft oil seal

Torque:
- 290 -
Inspection
Rocker shaft
1. Check oil hole for clogging; clean if there is
clogging.
2. If rocker installation surface has damage or
sticking, replace rocker shaft.
Rocker arm
1. Check slider surface (in contact with cam); if
there is damage or sticking, replace rocker
arm.
2. Check bore for damage or sticking; replace
defective part.
3. Check clearance; if limit value is exceeded,
carry out replacement.
Standard value: 0.01-0.04 mm
Limit value: 0.08 mm
Inspection and adjustment of valve clearance.
Installation
Rotate crankshaft so that No.1 cylinder piston is at
top dead center of compression stroke.
Rocker shaft
1. Face oil hole down;
2. Install rocker shaft with the side with oil hole
facing forward.
Rocker arm (exhaust and intake)

Install at correct position and confirm
identification mark.
Half-round seal
Apply sealant on the part shown.
Specified sealant: 3M part No.8660 or equivalent.
- 291 -
II. Engine timing
Timing belt upper cover Camshaft sprocket 1.2-2.0
05-75
Injecting sprocket
Timing belt
lower cover
Flange
Timing belt
Crankshaft sprocket
Crankshaft pulley
170-180
Torque:
Removal
Timing belt
1. Remove cooling fan, water pump, crank

pulley and timing belt hood.
2. Rotate crankshaft so that No.1 cylinder piston
is at TDC of compression stroke.
3. Use chalk to mark an arrow on backside of
timing belt and timing belt B to indicate
rotation direction. This allows installation of
belt in the same position in the future.
- 292 -
4. When timing marks on the 3 positions shown

in the figure are aligned, No.1 cylinder piston Timing mark
will be at TDC of its compression stroke.
No.1 cylinder piston on

the top dead center
5. Lightly loosen two bolts fixing tightener

pulley and then slide this pulley toward water
pump. Temporarily tighten bolts to fix Sliding along with the direction of the water pump
tightener pulley.
6. Remove timing belt.
Camshaft sprocket
1. Loosen bolts fixing camshaft sprocket and
remove camshaft sprocket.
2. Loosen sprocket nuts.
Caution:
Do not hit fuel injection pump shaft; otherwise
the injection pump will be damaged. Use
injection pump sprocket pull-out device
(09314-43000) or other suitable tool to remove
sprocket from injection pump.
3. Remove tightener and tightener spring.
- 293 -
Inspections:
Timing belt
Oil Water
1. Check belt for oily dirt or fouling; replace
according to situations. Small amount of dirt
can be wiped clean with dry cloth or paper.
2. To service the engine or adjust belt tension,
carefully check belt. In case of the following,
replace with new belt.
Description Defects
1. Hardened rubber back Rubber back is smooth and very hard, and has no
2. Rubber back cracked elasticity, so that no mark will be generated when
3. Canvas cracked or separated pressing down with finger.
4. Teeth seriously worn (preliminary stage) On stress surface, canvas exposes from teeth side
5. Belt teeth seriously worn (later stage) (canvas ground rough and white; texture not clear)
6. Cracked root of tooth
7. Broken teeth
8. Belt edge seriously worn
9. Belt edge cracked
Crankshaft
Inspections
Crankshaft sprocket Front

1. Install crankshaft sprocket on crankshaft. Oil pump gear drive shaft
Note directions of sprocket and flange. Sprocket
2. Install camshaft sprocket and tighten flange
nut to specified torque. Flange
Sliding along with the direction

Timing belt tightener pulley of the water pump
Install tightener pulley, tension spring and
tightener pulley gasket, so that the tightener pulley
moves toward water pump. Temporarily tighten
bolt A. Do not fully tighten bolt B; just tighten
with hand.
- 294 -
Timing belt
1. Correctly align timing marks on 3 sprockets.
2. When it is confirmed that timing belt tension
side is not slack, fit belt on crankshaft sprocket,
injection pump sprocket, tightener pulley and
camshaft sprocket in correct sequence.
Caution:
When installing belt on injection pump sprocket,
keep this sprocket at its position; as it would
automatically rotate at timing mark aligned
position. If the belt is being used a second time,
ensure that the arrow made during removal
faces correct direction upon re-installation. Bolt A
3. Check that all timing marks are correctly

aligned. Bolt B
4. Retreat tightener pulley bolt A tightened at water
pump side by one or two rounds, so that the belt is
tensioned by tightener pulley spring force.
Camshaft sprocket 2 gears
5. Confirm that timing belt is correctly engaged

with the 3 sprockets.
6. Rotate crankshaft clockwise to pass 2 teeth of
camshaft sprocket and maintain it at this position.
Caution:
Do not rotate crankshaft counterclockwise.
7. Tighten bolt A. Bolt A

8. Tighten bolt B.
If bolt B is tightened first, tightener pulley will
rotate along with, causing excessive tension in
timing belt. Bolt B
- 295 -
9. Rotate crankshaft toward rear direction to align

timing marks. At this time, ensure deflection with
forefinger pressing middle part of belt.
Standard value: 4-5 mm
Flange
Note that bolt holes on flange do not coincide with Timing Sprocket
(lower than) bolt holes on injection pump sprocket adjusting cut
at the same positions. For assembling, fix flange Offsetting
and sprocket as shown.
Flange
Timing belt
Tension pulley B of the timing belt

Tension
Spacer pulley
spacer
Balancer axis sprocket (right) Washer
Balancer axis sprocket (left) Tension pulley spring
Timing belt B
Crankshaft sprocket B
Flange
Torque:
- 296 -
Removal
Timing belt “B”
1. Remove timing belt.

2. Use chalk or similar to mark an arrow on
backside of timing belt “B” to indicate
driving direction.
3. Lightly loosen bolts and nuts used to tighten

tightener pulley. Then, slide tightener pulley
toward water pump and tighten nuts to
temporarily fix this pulley at the position.
4. Remove timing belt “B”.
5. Remove crankshaft sprocket “B”.
6. Remove two balance shaft sprockets.
7. When loosening bolts and nuts of the two
balance shaft sprockets, note to lock balance
shaft as shown.
Wrench extension rod or
Caution: Screw drive rod with the similar size
1. Water, oil or grease on belt will apparently

Left balance
shorten belt service life. Pay special attention shaft
to ensure that removed timing belt, sprockets Right balance
and tightener pulley are free of oil and grease. shaft
2. Also note that these parts can only be cleaned

by dry cloth and must not be washed. Replace Right hand
them if pollution is serious.
3. If there is oily trace at parking position, check
cover and camshaft mounting oil seal for oil
leakage.
Insert a detent plug and a screwdriver.

Insert a cover and a rod.
Left hand
- 297 -
Installation Crankshaft
Crankshaft sprocket “B”
1. Install crankshaft sprocket “B”on crankshaft. Front

Note direction of sprocket “B”. Oil pump gear drive shaft
Sprocket
Flange Sprocket “B”
2. To install the spacer, face the end with

chamfer toward balance shaft. If installation
direction is wrong, oil seal will be damaged.
Spacer Balancing axis
Cone angle
Timing belt “B”tightener pulley

Install tightener pulley spring and spacer so that
this pulley moves toward water pump. Tighten nut
and use hand to put on bolt; do not fully tighten.
Water pump
Tension pulley “B”
Bolt
Nut
Spacer
Gasket
Front lower cover
Spring Tension pulley
- 298 -
Timing belt “B”

Timing mark
1. Align timing marks on crankshaft sprocket
Tension pulley
“B”and left and right balance shafts.
Timing mark
2. To install timing belt “B”, ensure its tension
Timing belt
(no slack). “B”
Caution: Sprocket B
If belt has been used, during re-installation,
ensure that the arrow made during removal is
in correct direction.
3. Use finger to press slack side (shown in the

figure by A) to confirm tensioning of timing Timing mark
belt B tension side. Ensure that timing marks Tension pulley
are aligned with one another. Timing mark
Tension force
value
Timing belt B
4. Loosen the nut used to fix water pump side

tightener pulley B by 1 to 2 rounds. Increase
belt tension using tightener pulley spring.
5. Tighten tightener pulley B connecting nut.
6. Tighten tightener pulley B connecting bolt.
Timing mark
Tension pulley
Caution: Timing mark
If bolt is tightened first, the tightener pulley will Tension force
value
rotate, reducing timing belt tension.
Timing belt B
7. Ensure that when forefinger is used to press

Balancer axis
the belt as shown by the arrow in the figure, sprocket
there is suitable belt deflection.
Belt deflection
Belt deflection: 4-5 mm
Crankshaft
sprocket
- 299 -
III. Engine cylinder block
Cylinder liner
50-60
Cylinder liner
Cover
Engine body 50-60
Torque: Nm
Inspections
Caution:
1. Before inspection and repair, clean parts to remove dirt,
oil, accumulated carbon and debris.
2. Before cleaning cylinder block, make sure to check for
leakage of water or damage.
3. Use compressed air to remove dirt in oil hole; confirm no
clogging of oil hole at the same time.
- 300 -
Cylinder block
1. Check for scratch, rust and corrosion. You can
also use flaw detector. If there is a defect,
repair or replace.
2. Use ruler and feeler gauge to check cylinder
block upper surface planeness. Place ruler at
longitudinal and diagonal positions (A,
B… … as shown). If planeness is not in the
limit range, replace cylinder block. For
measurement, ensure that there is no
shimming material on cylinder block upper
surface.
Limit value: 0.1mm
3. Check cylinder walls for scratch or sticking
glue. If there is a defect, correct (to enlarged
size) or replace.
4. Use cylinder gauge to measure bore. If worn
excessively, bore the cylinder to enlarged size
and replace piston and piston ring.
Measurement point is as shown:
Boring of cylinder
1. Use maximum cylinder bore as datum to
determine enlarged size piston to be used.
2. 4 types of enlarged size pistons can be used:
0.25 mm, 0.50 mm, 0.75 mm, 1.00 mm.
According to piston OD, bore cylinder to
obtain specified clearance.
3. Based on measured piston OD, calculate Piston outer diameter
Pushing direction
boring dimension.
Boring dimension =piston OD + 0.04~0.08 mm
Clearance between piston and cylinder: 0.02mm
(margin)
4. Bore cylinder to obtain calculated boring
dimension.
- 301 -
Caution:
1. Prevent thermal distortion due to high
temperature during boring. Bore cylinder
according to cylinder No. sequence 2413.
2. Grind cylinder to trimming dimensions.
3. Check clearance between piston and
cylinder.
Clearance between piston and cylinder:
0.04-0.08 mm
Caution:
1. To bore a cylinder, 4 cylinders shall be
trimmed to the same enlarged dimension.
2. Do not bore only one cylinder to enlarged
dimension.
- 302 -
IV. Engine support
Front engine bracket

18-28
Front spacer of the engine bracket
Engine bracket
35-55
35-55
Torque: Nm
Inspection
1. Check separator for damage, crack or deform
2. Check separator baffle for damage, crack or deform.
Caution:
Do not pollute separator by engine oil.
- 303 -
V. Engine front cover
Bearing
Balance shaft (right)
Driven gear
34-40
Gear cover
20-27
Driving
Balance shaft
gear
(left)
Front lower
cover
Front oil seal
Oil strainer
12-15
Washer Oil drain plug

35-45
12-15
Front upper cover
Oil plug washer
Oil pan
Torque: Nm
Removal
Balance shaft
1. Remove oil tray.
2. Remove engine oil strainer.
3. Remove baffle from left balance shaft front
end.
4. Remove front upper cover.
5. Remove balance shaft.
6. Remove plug cap from right balance shaft
driving gear top.
- 304 -
7. Lightly loosen flange bolts at front end of
right balance shaft. When loosening the bolts,
remove plug at right side of engine while
inserting a screw driver to prevent rotation.
Balance
shaft
8. Remove front lower case and balance shaft as (right)
one assembly.
9. Remove left balance shaft from front lower
case.
Engine oil pump
1. Remove engine oil pump hood from front
lower case.
2. Remove the gear at engine oil pump. Make
matching marks on outer gear to ensure
correct re-installation.
3. Remove balance shaft driving gear cover, and
then driving gear and driven gear.
Camshaft
1. Rotate crankshaft so that No.1 cylinder piston
is at TDC of compression stroke (when dowel
pin is at upper most position, cylinder piston
is at TDC of compression stroke).
2. Remove timing belt upper cover. Do not
remove timing belt. Remove camshaft
sprocket and place it on timing belt lower
cover.
3. Remove rocker shaft assembly.
4. Remove camshaft bearing cover and take out
camshaft.
Inspection
Balance shaft
1. Engine oil hole must not be plugged.
2. Check journal for sticking, damage and
contact with bearing. If there is a defect,
replace balance shaft, bearing or front cover
assembly.
3. Check balance shaft clearance. If worn
excessively, replace balance shaft bearing,
balance shaft or front cover assembly.
Standard clearance
Front: 0.02-0.06 mm
Rear: 0.05-0.09 mm
- 305 -
Camshaft
1. Check camshaft journal surface. In case of
damage or sticking, replace camshaft. If
camshaft journal is stuck, check cylinder head
for damage. Also check if cylinder head oil
hole is clogged.
2. Check cam surface for abnormal wear and

damage. In case of an apparent defect, replace
camshaft. Measure height of protruding tip; if
limit value is exceeded, replace camshaft.
Standard value
Intake and exhaust: 37.05 mm
Limit value
Intake and exhaust: 36.55 mm
Replacement
Balance shaft
Caution:
Use bearing installation limit stop especially
designed for removal and re-installation of right
bearing (special tool).
1. Use bearing installation limit stop and balance

shaft bearing extractor (09212-43300,
09212-43100) to remove 2 rear bearings from
the body.
- 306 -
2. Use bearing installation limit stop and balance

shaft bearing installation device
(09212-43300, 09212-43100) to press fit
bearing into the body.
Installation
Back of the balance shaft gear
Matching mark
Pressure
reducing pillar
plug
Driven gear
Pressure reducing
spring
Washer Gear cover
30-45
Driving
gear
Oil pump
cover
Oil Pump outer rotor
Oil pump inner rotor
Torque: Nm
- 307 -
Oil seal
When installing oil seal from rear side, avoid oil
seal lip being clamped at shaft step.
Caution:
Apply engine oil on outer surface of oil seal guide
tube.
Balance shaft driving gear

When installing driving gear from rear side, since
driving oil seal is press fit on front lower case,
before insertion, first fit oil seal guide tube
(09222-43200) on driving gear shaft.
Caution:
Apply engine oil on oil seal guide tube outer
surface.
Front lower case

Tighten 7 flange bolts to specified torque.
Flange bolts
Balance
When tighten these bolts, confirm that balance
shaft (right)
shaft is at its correct position.
- 308 -
Front
Crankshaft front oil seal Oil seal lower
Use oil seal installation device and guide device Crankshaft cover
(09214-32100, 09214-32100) top install crankshaft
front oil seal. Oil pump
drive
Caution: shaft
Before installing oil seal, engine oil pump drive
shaft must be installed.
Applying oil on the external surface
Camshaft
1. To obtain end play, measure A and B. If limit
value is exceeded, replace the part.
End play=B-A
Limit value: 0.4 mm
2. Install camshaft in cylinder head so that

dowel pin is at highest position.
Camshaft oil seal

1. Apply engine oil on oil seal lip.
2. Use camshaft oil seal installation device
(09221-21000) to press fit new camshaft oil
seal in front bearing cover.
Caution:
When installing oil seal after installation of
camshaft bearing cover, apply engine oil on oil
seal lip.
- 309 -
VI. Main movement mechanism
Crankshaft
130-140
Rear oil seal Flywheel
Washer
Oil separator
Manual transmission
Connecting
Rear oil seal plate
cover
Automatic
transmission
Upper bearing bush
Crankshaft Driving connecting fitting
Crankshaft connecting fitting
Lower bearing bush
Crankshaft bearing cap
75-85
Torque: Nm
Crankshaft clearance
1. This clearance shall be determined from journal
OD and difference between pin OD and ID of each 75-85 Nm
bearing installed in the crankshaft. Measure
bearing ID in directions A and B at front and rear
(1 and 2) positions.
Standard value
Journal clearance: 0.02-0.05 mm
- 310 -
Pin clearance: 0.02-0.05 mm
Limit value: 0.1 mm
2. If a new bearing is used and the clearance is still
larger than standard value, grind crankshaft to
reduce its dimensions and use bearing of
relatively reduced size.
3. When grinding crankshaft to reduced
dimensions, ensure that corner radius of
journal and pin are correct.
Crankshaft clearance (using plastic clearance

gauge)
A plastic clearance gauge can be used to measure
clearance in a simple way. Execute the following
procedure to measure clearance (for journal).
1. Wipe clean crankshaft outer diameter and
bearing inner diameter to eliminate engine oil.
2. Install crankshaft.
3. Place a plastic clearance gauge into journal
center in longitudinal direction.
4. Carefully install main bearing cover and
tighten bolts to specified torque.
5. Remove bolts and carefully remove main
bearing cover.
6. Use scale at back of plastic clearance gauge to
measure width of pressed and extended part
of the gauge (widest point).
Inspection of crankshaft front/rear oil seals
1. Wear and damage of oil seal lip
2. Aged or hardened rubber.
3. Cracked or damaged oil seal cover.
Flywheel ring gear (manual transmission drive)
1. If flywheel ring gear teeth are worn, damaged
or broken, replace flywheel ring gear. If the
gear is damaged or broken, check starting
motor pinion. To remove ring gear for
replacement, lightly tap its outer tooth ring.
This part adopts cold contraction matching in
flywheel and heating will not allow you to
remove it. To install the ring gear on flywheel,
heat to 260-280℃.
2. Check rotation of guiding ball bearing and for
its abnormal noise. Confirm that applied
grease does not overflow.
- 311 -
Flywheel
1. Carry out visual inspection of flywheel clutch
compressing disc surface.
Without oil With oil
2. If disc ridge is worn, cracked or sticking, hole
hole
replace the disc.
3. If clutch compressing disc surface radial Upper
Lower bearing bush
runout exceeds a limit, replace the disc. bearing bush
Without oil
Limit value: 0.13 mm hole
(center)
Installation Upper & lower
Crankshaft bushings bearing bush
Upper main bushing has oil hole while lower
bushing has not. Upper bushing and lower bushing
Direction of the
(with crimp) of middle bearing have no difference. main bearing cap
Arrow (means front

Bering cover Front side of of the engine)
1. Install main bushing in the body. Ensure the engine
correct bearing cover No. and direction shown Cap no.
by arrow.
2. Check to ensure stable operation of crankshaft

and sufficient end play.
Oil seal cover

Use special tool to press fit new crankshaft rear oil
seal into oil seal cover.
- 312 -
Engine oil separator

1. Push engine oil separator into oil seal cap.
2. Confirm that oil hole in separator is at bottom
(as shown by the arrow in the figure).
Piston
No.1 piston ring

No.2 piston ring
Oil ring
Piston pin Piston
Piston and connecting rod

Snap ring assembly
Lining Upper bearing bush
Connecting rod
Engine body
Lower bearing bush
Connecting rod cover

Torque: Nm
45-48
- 313 -
Inspection
Piston
1. Check each piston for damage, scratch, wear
and other defects;
2. Check matching of piston pin in pin hole.
Piston pin must be smoothly pressed into pin
hole with hand (under room temperature).
3. Piston shall be replaced in complete set.
Piston ring
1. Check each piston ring for breaking, damage
and abnormal wear.
2. To replace piston, also replace its ring.
3. Measure side play between piston
Standard value: clearance between ring and

ring groove
No.1 ring: 0,056-0.076 mm
No.2 ring: 0.046-0.066 mm
Oil ring: 0.02-0.065 mm
Piston ring End clearance
[Limit value]:
No.1 ring: 0.15 mm
No.2 ring: 0.15 mm
Oil ring: 0.1 mm
4. Place a piston ring in cylinder and lightly press
piston down to place it at a position perpendicular
to cylinder arm.
5. Use feeler gauge to measure end play.
Standard value: end play
No.1: 0.35-0.50 mm
No.2: 0.25-0.40 mm
Oil ring: 0.25-0.45 mm
Connecting rod bearing
1. Check bearing surface for uneven contact
print, scratch and sticking. If this surface is
seriously scratched and worn, also check
crankshaft. If crankshaft is also damaged,
replace crankshaft or grind it to reduced
dimensions for reuse.
2. Measure connecting rod bearing ID and
crankshaft pin OD. If clearance (oil gap)
exceeds a limit, replace bearing. If required,
replace crankshaft or grind it to reduce
dimensions. Also replace bearing with one of
reduced size.
- 314 -
Installation:
Connecting rod, piston pin and piston
1. Match piston to connecting rod.
2. Align front mark and place piston pin inside.
You must use hand to smoothly press piston
pin into piston. If clearance is too large,
replace piston pin.
Piston ring
1. Fit oil ring expander and oil ring into piston.
Then, first fit No.2 piston ring and then fit
No.1 piston ring. Make sure to face the side Oil
with manufacturer and size markings toward
top of piston.
2. For positions of piston end, oil (doctor bar,

lining reed), refer to the figure. Upper blade
Piston pin
Lower blade
3. Place in piston and connecting rod assembly

from top of cylinder. Ensure that front mark
on top of this assembly faces engine front
(crank pulley side).
4. Use endless belt to clamp piston ring and fit
piston assembly into cylinder. Do not tap
piston hard; otherwise piston ring or crank p
in may be damaged.
- 315 -
5. Ensure that connecting rod large end side play

is in specified range.
Limit value: 0.4 mm
VII. Engine lubrication system

Engine oil filter
Connector
Oil filter
30-48
12-18
Oil filter bracket
Oil cooler bypass valve
Oil pressure switch
Washer Oil injection nozzle
Return valve 30-60

Torque: Nm
- 316 -
1. Engine oil filter mounting surface must not be damaged.

2. Check for cracking and oil leakage.
3. Ensure smooth sliding of decompression
plunger and no damage of decompression
spring.
Oil pressure switch

1. Connect a tester (ohmmeter) between terminal
and switch body to test connectivity. If yes,
the switch is normal. If not (tested resistance
is infinity), replace switch.
2. Insert a thin rod in switch oil hole and push it
lightly. If connectivity is not detected (tested
resistance is infinity), the switch is normal;
otherwise replace the switch.
3. Apply 0.5kg/cm² pressure at oil hole. If

connectivity is not detected, the switch is
normal. Oil
Also check for leakage of air. If air leakage is
detected, possible cause is damaged membrane. If
there is leakage, replace the switch.
Engine oil nozzle, check valve Oil injection nozzle

1. Check for clogging of engine oil nozzle and Check valve assembly
check valve.
2. Check engine oil nozzle for damage and
deform.
Engine oil cooling bypass valve

1. Ensure smooth valve movement.
2. Ensure that dimension L measured under
normal temperature and humidity is standard
value.
Dimension L: 34.5 mm
3. Dip valve in 100℃ engine oil; measured L
must be standard value.
- 317 -
Dimension L: 40 mm or higher
Cylinder Cylinder
Installation
Oil injection
Engine oil nozzle nozzle Oil injection
Install two types of engine oil nozzles: one for (with No.1.3) nozzle
(with No.2.4)
No.1 and No.3, the other for No.2 and No.4.
Ensure that each nozzle is installed correctly and in
correct direction as shown.
Cylinder
block
Locating pin
Oil injection nozzle
Oil pressure switch
Before installation, apply sealant on switch thread.
Caution:
Do not apply sealant on thread upper surface.
Note that torque must not be too large.
Engine oil filter

Clean mounting surface of engine oil filter holder
and then apply a thin layer of engine oil on O-ring
of the filter. Later, tighten the filter with hand.
Caution:
Never tighten engine oil filter by wrench.
- 318 -
Engine oil pump
Parts
Pressure reducing pillar plug

Pressure reducing spring
Washer
Plug
30-46 Oil pump internal
gear
Oil pump external Oil pump cover

gear
Torque: Nm

Oil pump cover
Removal
Internal gear
Engine oil pump
Before removing engine oil pump inner and outer Mark
gears, make marking on outer gear to ensure
re-installation in correct direction. External
gear
Inspection
Engine oil pump
1. Fit outer gear and inner gear on front cover
and ensure their smooth rotation and suitable
clearance.
2. Check side play (front cover and engine oil
pump cover surface).
- 319 -
3. Check pump body clearances
[Standard]
Driving gear: 0.03-0.09 mm
Driven gear: 0.12-0.22 mm
Internal gear
[Limit]
Driving gear: 0.5 mm Mark
Driven gear: 0.4 mm
Installation External gear

Engine oil pump
Install outer gear according to marking made
during removal to ensure positioning in correct
direction.
Caution:
To install gear, apply engine oil on the surface.
VIII. Engine cooling system
Engine cooling water pump
Power steering pump

Power steering
pump bracket
Thermostat
cover O ring
Thermostat
Gasket
Radiator lower hose Gasket
Water pump
Water inlet
part
After removing, replace with a new
gasket and O ring.
- 320 -
Inspection
Thermostat
1. Check if valve is tightly closed under room
temperature.
2. Check for defect or damage.
3. Check valve for rust; remove any rust.
4. Dip thermostat in water container. Increase
water temperature and measure if thermostat
valve-open temperature and valve-fully open
temperature [valve rise exceeding 8.5 mm]
are within standard values.
Standard values:
Valve-open temperature: 82℃
Valve-fully open temperature: 95℃
Caution:
When the valve is fully closed, measure valve
height. When the valve is fully open, measure
height to calculate valve rising.
Belt
1. Check water pump belt surface for damage,
peeling or cracking
2. Check water pump belt surface for oil and
grease.
3. Check for wear and hardening of rubber.
Water pump
1. Check each part for crack, damage or wear;
replace water pump assembly if required.
2. Check bearing for damage, abnormal noise,
and inertia rotation. Replace water pump
assembly if required.
3. Check seals for leakage. Replace water pump
assembly if required.
4. Check for water leakage. If water leaks from
hole of “A” seal, replace the seal as an
assembly.
Installation
Water pipe O-ring
Fit water pipe O-ring in the groove at end of water
pipe. Wet area around the O-ring and insert water
pipe.
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Caution:
1. Do not apply engine oil or grease on water
pipe O-ring.
2. Keep water pipe connector free of sand or
dust etc.
3. Insert water pipe till bottom of its end.
Water pump
Water pump mounting bolt size is different. Ensure
normal installation.
No. Hardness category (pressure head mark) d ×1 mm Torque (Nm)

1 4T 8×5 mm
12-15
2 4T 8×0 mm
3 7T 8×0 mm 20-27
- 322 -
Radiator
Radiator upper hose Radiator lower hose Protective case
Lower isolating
bracket
Overflow pipe
Minor water tank
Removal
Radiator
1. Loosen radiator drain plug to drain coolant.
2. Disconnect radiator hose from the following
parts: disconnect lower hose from
radiator… … disconnect lower hose from
engine.
3. Disconnect overflow pipe from radiator.
4. Remove radiator guard bolts from radiator.
Caution:
The guard is suspended on cooling fan. This
guard cannot be removed if radiator is not
taken out.
- 323 -
5. Remove radiator mounting bolts.
6. Incline the radiator and slowly take it out

upward.
Caution:
When removing radiator, ensure that radiator
core is not bent or damaged by being hit by
other part.
7. Remove radiator guard.
Repair of radiator fin

Bent or damaged part shall be repaired using the
method shown in the figure.
- 324 -
Radiator fan
Driving belt
Cooling fan clutch
Cooling fan
Inspection
Cooling fan
1. Check fan blades for damage or cracking.
2. Check for crack or damage around fan hub
bolt hole.
3. In case any part of fan is damaged or cracks,
replace the fan.
Fan clutch
1. Check to ensure no leakage of liquid at
connector and seal of fan clutch. Such leakage
would reduce amount of coolant, decelerate
fan and cause engine overhead.
- 325 -
2. When the fan is connected to engine, some
resistance shall be felt during rotation. If fan
rotation is easy, there is a fault.
3. Check bimetal piece for thermostatic control
type.
Check fan driving belt

If belt has the following defect, replace it:
1. Surface damage, peeling or cracking;
2. Engine oil or lubricating grease on surface;
3. Worn belt resulting in contact with pulley
V-shaped bottom;
4. Rubber worn or hardened.
Water temperature gauge element, thermal switch
Heating switch
Water temperature meter

element
- 326 -
Inspection
Water temperature gauge element

1. Place sensor in water, increase water
temperature and measure its resistance.
2. If measured value exceeds specified range,

replace sensor. Measure resistance between
terminal (A) and water temperature meter
element, and resistance between terminal (B)
and preheat control element.
0.4Ώ/70℃
Terminal (A)
23.8 Ώ/115℃
24.8 Ώ/-20℃
Terminal (B)
23.5 Ώ/20℃
- 327 -
IX. Intake and exhaust system

Air filter
Vent hose
Air filter cover

Buckle clamp
Filter core
Resonator
Air filter body
Removal
1. Remove air intake hose and air pipeline
connecting air filter.
2. Remove 3 connecting bolts on air filter
mounting support.
3. Remove air filter.
Inspection
1. Check intake hose and air filter cap for
damage.
2. Check air pipeline for damage.
3. Check air filter element for clogging, dirt or
damage. In case of slight clogging of air filer,
connect compressed air to filter element to
remove dust and debris. If the element can no
longer be cleaned, replace with a new one.
- 328 -
Air intake manifold
Intake manifold
Exhaust gas
recirculation device
Exhaust gas actuator
Heat shield
Front exhaust pipe
Exhaust
manifold and
turbocharger
Heat shield Gasket
After removing, replace with

Torque: Nm
a new gasket.
Turbocharger
Gasket
assembly
Exhaust connection
Exhaust manifold
Gasket
Torque: Nm
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Inspection
Check the following parts and replace faulty parts.
Intake/exhaust manifold
1. Check parts for crack or damage.
2. Check vacuum port, water path and air path
for clogging.
3. Use ruler and feeler gauge to measure deform
of cylinder head mounting surface.
Standard value: 0.15 mm max.
Limit value: 0.3 mm
Exhaust manifold gasket

If gasket surface is free of peeling or damage, the
gasket can be used again.
Silencer
Lifting Catalytic converter

Gasket lug
Front
exhaust pipe
Lifting lug
Central
exhaust pipe
检查
1．检查消声器和管路有无腐蚀和损坏。
Main muffler
2．检查橡皮耳是否老化和开裂。
Gasket
30-40
Torque: Nm
- 330 -
Turbo-supercharger
Air intake outlet Piston ring
Bearing
Oil inlet
Air intake
Exhaust outlet
inlet
Piston ring Oil inlet
Exhaust inlet
O ring
Snap ring
Turbine cover
Compressor cover
Turbine core assembly
Shaft coupling
- 331 -
Inspection
1. Check inner cover in contact with turbo for
crack, inclination or other damage due to
overheat.
2. Ensure that waste gas valve stem can be
pushed freely by hand.
3. Ensure no damage on inner cover surface
connected to compressor.
4. In case of crack or break on turbo blades, the Oil Way Turbine

turbo and shaft assembly can no longer be
used. Blades cannot be used again if there is
slight bend.
Compressor pulley
5. Check for clogging by foreign matter in oil

pipe of turbo core assembly.
Inspection of waste gas valve
Check operation of waste gas valve stem under the
following pressure:
Normal value: 77.5KPa
- 332 -
Intercooler
Buckle clamp
Intercooler cover
Air temperature switch
Fan motor switch
Intercooler bracket
Fan motor assembly
Torque: Nm
Removal
1. Remove condenser hood;
2. Remove fan motor and temperature switch connector;
3. Remove air hose;
4. Remove condenser assembly;
5. Remove fan motor assembly;
6. Remove condenser support.
Inspection
Air temperature control switch
1. Place sensing part in water;
2. Heat water to check for connection.
- 333 -
Temperature Normal condition

50℃ or lower Disconnected
60℃ or lower Connected
Condenser fan motor

Check fan operation at vehicle speed ≤60 km/h and air intake temperature ≥ 50℃.
Notes:
Things in the world have contradiction. Increase of air pressure means increase of air density. Increase of air
density will inevitably increase air temperature, too. This is similar to heating of pump when pumping a tire. Air
outlet temperature of engine turbo-supercharger will increase with increased pressure, and increase of temperature
will limit increase of air density. To further increase air density, temperature of supercharged air shall be lowered.
Experiments show that under the same air/fuel ratio, for every 10℃ drop of supercharged air temperature, diesel
engine power can be increased by 3%-5%; in addition, NOx emission will be lowered, improving engine low
speed performance. Therefore, intercooling technology has been introduced.
There are two types of diesel engine intercooling technology: one using diesel engine circulating cooling water,
and the other using radiator (i.e. ambient air) for cooling of intercooler. If cooling water is used, an auxiliary
system of independent circulating water is required to achieve good cooling effect; this will be costly and have
complicated mechanism. Therefore, most automobile diesel engines adopt air cooling of intercooler.
Air-cooled intercooler uses pipeline to lead compressed air to a radiator, where forced cooling is carried out using
cooling air from a fan. Air-cooled intercooler can be installed in front of or beside engine water tank, or at another
independent position. Its corrugated Al radiating fins and piping are similar to structure of engine water tank and
have high heat conduction efficiency, hence can cool supercharged air to 50 to 60℃.
Intercooling technology is not simple. If supercharged air is too hot, there is no effect and energy will be wasted;
if too cold, condensate may be generated in intake pipe, resulting in problem. Therefore, accurate matching of
intercooler and turbo-supercharger shall be achieved so that required cooled temperature of compressed air can be
obtained.
- 334 -
Refine MPV Workshop Manual Fuel System (diesel)
Section II Diesel engine fuel supply system

I. General
1. Brief introduction
Diesel engines use diesel as fuel. Indices for evaluation are:
1. Ignition quality: evaluation of diesel spontaneous ignition capability (indicated by cetane value).
2. Evaporation
3. Viscosity: measurement of fuel fluidity.
4. Condensation point: temperature at which diesel starts to loss its fluidity.
- 335 -
Diesel engine and gasoline engine basically have the same structure. Both consist of cylinder block, cylinder head,
piston, valve, crank, crankshaft, camshaft, and flywheel etc. However, the former uses compression-ignited diesel
to do work, while the latter uses ignited gasoline to do work. The essential difference is between “compression
ignition”and “lighted ignition”.
Gasoline engine fuel is mixed with air in air intake stroke and then enters cylinder, where it is ignited by spark
plug to do work. Diesel engine fuel is directly injected into cylinder near end of compression stroke, where it is
ignited by compression in compressed air. Due to this difference, diesel engine has its characteristics in structure
of fuel supply system. Fuel injection system of diesel engine consists of fuel injection pump, fuel injector, high
pressure fuel pipe and some auxiliaries.
Simple process of diesel engine fuel transmission: the fuel transfer pump delivers diesel to the filter. After
filtering, the diesel will enter fuel injection pump (to ensure sufficient fuel and maintain certain pressure, it is
required that fuel supply by fuel transfer pump is much higher than demand by injection pump, surplus diesel will
return to fuel tank via low pressure pipe and other part will be compressed to high pressure by injection pump),
pass HP fuel pipe, and then enter injector for direct injection into cylinder combustion chamber for compression
ignition.
To allow stable operation of diesel engine at idling speed and limit engine overspeed, fuel injection pump is
provided with governor. Fuel injection pump is the most precise part of diesel engine fuel supply system and its
function is to adjust amount of diesel according to change of diesel engine operating conditions, increase diesel
pressure, and supply diesel to injector according to set time and rule.
2. Size and parameters

Fuel injection pump
Injection pump
Type Distributed type
Rotation direction Clockwise as seen from drive end
Fuel injection sequence 1-3-4-2
Type of governor Centrifugal
Type of timer Hydraulic type
Type of fuel transfer pump Blade type
Control device
Fast idling speed mechanism Manual
Nozzle and seat
Type Rotary tightening type
Nozzle
Type Throttling type
Engine control system Pedal-controlled pull wire type
Fuel tank
Volume (L) 65
- 336 -
3. Maintenance size and parameters

Standard value Limit value
Fuel injection
Injection timing (when plunger is lifted by 1mm) 4ºafter TDC
Cam lift mm 2.2
Plunger diameter mm 10
Fuel supply valve opening pressure kPa (… ) 2.150
Fuel cutoff EM valve Rated voltage: 12V
Resistance: 8Ω
Fuel injection nozzle

Injection hole (number-dia.) mm 1-1.02
Fuel injection pressure kPa (… ) 12,000-13,000 11,000
Idling speed rpm 750±30
Engine control system
Pull wire length
Acceleration control wire mm L:2725-2735
A+B:125-129
Throttle pull wire mm L:642-648
C:60-62
Throttle button stroke 25 or larger
4. Torque parameters
Nm
Fuel injection pipe clamp bolt 4-6
Fuel injection pipe connector and nut 23-37
Bolt between pump support and body 18-25
Bolt between injection pump and pump support 20-27
Injection pump mounting nut 15-22
Fuel return pipe nut 30-40
Injection nozzle 50-60
Positioning nut and nozzle 35-40
Pump sprocket nut 80-90
Fuel tank mounting bolts 15-22
- 337 -
5. Special tool
Tool (No. and name) Picture Purpose
09310-43000 Fuel injection timing adjustment
Pre-travel measurement connector
09314-43000 Removal of injection pump sprocket

Injection pump sprocket puller
6. Fuel supply system

Distributed type fuel injection pump is installed on front upper tank and driven by timing belt. Fuel is pumped
from fuel tank by a pump in fuel injection pump and sent to the fuel injection pump via a small filter complete
with oil-water separator. The fuel is then pressed into pump chamber. Fuel is sent from pump chamber to the HP
room above plunger via distributor head pipeline and plunger sleeve. The plunger pumps fuel so that HP fuel is
injected from nozzles according to injection sequence. Surplus fuel in pump chamber will return to fuel tank via
overflow valve and pipeline. Injection pump relies on fuel circulation cooling and lubrication. Surplus fuel in
nozzle holder returns to fuel tank via overflow pipe and injection pump connector. Since injection pump is
lubricated by fuel, water in fuel will greatly reduce pump service life. Therefore, special attention shall be paid to
prevent oil and dust from entering the system.
Overflow pipe Oil supply pump (air outlet)

Nozzle
Fuel Water level

filter warning light
Injection
pump
Fuel injection
pump
Fuel tank
- 338 -
切断阀
Stop valve
喷油嘴
Fuel
VE 喷射泵 injection
VE inject valve nozzle
回油管
油箱
柴油格
7. Common troubleshooting
Fault Possible causes Repair
Engine Starting speed too low Repair starting system or charge/replace batteries so that engine
cannot can start at minimum 150rpm
start No voltage at fuel cutoff solenoid Check voltage with testing lamp; replace fuse/faulty line if
valve in fuel injection pump required
Loose or faulty fuel cutoff solenoid Tighten solenoid valve. Check valve noise when switch
valve in fuel injection pump operates (open or close). Replace faulty solenoid valve.
No voltage at preheat plug bus With switch “On”, if testing lamp shows no voltage at bus, test
relay and circuit.
Faulty preheat plug Perform test; replace preheat plug if required
Air in fuel system Vent air from fuel system
Oil return pipe
Injection pump not supplying fuel If no fuel comes out from soft injection pipe during starting,
check timing belt and fuel supply from filter
Wrong connection of injection pipe Connect fuel pipe at correct position
Fuel tank
Incorrect
Diesel filter
fuel injection timing Adjust fuel injection timing
Faulty injection nozzle Check and repair/replace nozzle as required
Aforesaid engine mechanism fault Test cylinder compression pressure; repair engine if required
Faulty injection pump Try to start engine with a new pump; replace old pump if
required
- 339 -

Incorrect Idling speed incorrectly adjusted Check and adjust idling speed if required
or poor Poor throttle control Check that accelerator rod on pump is not loose;
idling then adjust throttle pull wire
speed Loose fuel hose between filter & injection pump Replace or clamp hose; vent air from the system
Air in fuel system Vent air from fuel system
Insufficient fuel supply due to clogged fuel Check and replace line, hose or fuel filter if
filter, leakage in fuel loop and injector pipe, dirt required
accumulation, winding or connector squeezing
Faulty nozzle Check and repair or replace nozzle if required
Incorrect fuel injection timing Adjust fuel injection timing
Aforesaid engine mechanism fault Test compression pressure; repair engine if
required
Faulty fuel injection pump Use new pump to test engine at idling speed;
permanently replace pump if required
Excessive engine loading Observe for correct shifting speed
Smoking Engine not reaching correct operating Check and replace cooling system thermostat if
exhaust temperature required
(black, Incorrect highest rotation speed Check and replace injection pump if required
blue or Incorrect fuel injection timing Adjust fuel injection timing
white) Clogged exhaust system Check this system for depression and clogging
Aforesaid engine mechanism fault Measure cylinder compression pressure and
replace engine if required
Faulty fuel injection pump Install new pump and observe exhaust; replace
pump permanently if required
Low power Injection pump acceleration rod loose or not Tighten the rod, check for jamming of pedal
output and reaching max. rotation speed adjusting screw stroke and then adjust throttle pull wire
slow Incorrect max. rotation speed Check and replace injection pump if required
acceleratio Dirty air filter Clean or replace filter element
n Insufficient fuel supply due to clogged fuel Check and replace line, hose and fuel filter if
(speedomet filter, leaking fuel loop and injection pipe, dust required
er is accumulation, winding, and connector
accurate squeezing
and clutch Air in fuel system Vent air from fuel system
is not Ice or solidified wax in fuel pipeline (in winter) Move vehicle to warm garage till ice or wax
slipping) melts. Vent vapor from fuel system.
Faulty injection nozzle Check and repair/replace nozzle if required
Aforesaid engine mechanism fault Test cylinder compression pressure; repair
engine if required.
- 340 -
Faulty injection pump Use new pump to check acceleration and speed.
Replace pump permanently if required

Excessive fuel Dirty air filter Clean or replace air filter element
consumption Leakage of fuel Check and replace or tighten all pipelines, hoses
and connectors if required.
Fuel return pipeline and hose clogged Check fuel return pipeline for winding and
depression. Replace faulty line. If line is clogged,
blow with compressed air and then vent air from
system.
Idling speed or max. rotation speed too Check and adjust idling speed or replace injection
high pump if required
Faulty injection nozzle Check and repair or replace injection nozzle if
required
Aforesaid engine mechanism fault Test compression pressure and repair engine if
required
Faulty injection pump Fit new pump to check fuel consumption; replace
pump permanently if required
Throttle pedal Pedal arm rusted Clean or lubricate
requiring too Incorrect path Ensure bending radius greater than or equal to
large stepping 150mm and correct excessive bending
force (incl. Pull wire rusted Replace
pedal cannot Throttle pull wire displaced Lubricate connecting rod and shaft
fully retreat)
Broken throttle Jammed pull wire end Remove rust and burr on pull wire end
control pull Incorrect pull wire end fixing point Correct end at shifting lever side
wire perpendicularity
Incorrect perpendicularity between pull Correct or replace parts
wire end and pull wire
Engine cannot Fault in starting switch operation Repair or replace parts
be stopped Broken harness between starting switch Replace harness
and fuel cutoff solenoid valve
II. Inspection and adjustment

Throttle pull wire Adjusting
1. Preheat engine till stabilized at idling speed; nut
2. Confirm idling speed at specified value;
3. Stop engine;
4. Confirm no apparent bend of inner pull wire
5. Check inner pull wire and correct its slack
- 341 -
Locknut
6. If too loose, adjust as follows:
1） Loosen adjusting nut to fully approach

accelerator rod;
2） Tighten adjusting nut till accelerator rod just
starts to move;
Rotate in reverse direction for one round and lock
with lock nut. Adjust accelerator pull wire gap to
standard value.
Standard value: about 1 mm

3) Adjust so that when accelerator rod is fully open,
throttle pedal stopper is in contact with pedal arm.
4) After adjustment, confirm that by means of
pedal, accelerator rod can be fully open and closed.
Adjustment
Venting of air from fuel pipeline
After the following maintenance, vent air:
●draining ad refilling of fuel during maintenance;
●replacement of fuel filter;
●removal of main fuel pipeline.
1. Remove air plug of fuel filter
2. Place cleaning cloth around air plug and
repeatedly operate hand pump till no bubble
comes out of the hole; tighten air plug.
3. Repeat these operations till it is difficult to
operate the hand pump.
Adjustment
Draining of water from fuel filter
If fuel filter indicator lights up, there is water in
the filter. Use the following steps to drain water:
1. Loosen drain plug;
2. Use hand pump to drain water; tighten the plug
by hand.
- 342 -
Inspection and adjustment
Nozzle
Pressure of start of injection
1. Fix nozzle on nozzle tester and check the
following.
2. Move nozzle tester handle at about one stroke
per second.
3. When fuel is injected, pressure gauge pointer
slowly rises and sways. Take the reading at
the position where the pointer starts to sway.
Check if pressure of start of injection is
Standard value: 12,000-13,000 kPa
Limit value: 11,000 kPa or less
4. If nozzle is faulty, remove it and adjust

injection pressure to standard value by
changing shimming thickness. For every
0.1mm increase of shimming thickness, fuel
injection pressure will increase by about 1000
kPa.
Caution:
When removing nozzle, keep dirt and water off.
5. If pressure of start of injection can not be
adjusted by changing shimming thickness,
replace nozzle assembly.
Fuel injection status
1. Move nozzle tester at about one stroke per
second.
[Needle valve vibration]
When operating the handle, if special intermittent
noise is heard, fuel injection is normal. Needle
valve vibration shall be felt at handle.
[Fuel beam]
During testing, check if fuel beam is ideal. As
shown in the figure, fuel beam may be of spiral
shape with atomizing process. This is normal in
such test and nozzle function is normal.
2. Move nozzle tester handle at 4 to 6 strokes
per second.
3. Confirm that fuel beam has about 15ºtaper;
this indicates good injection status.
- 343 -
1. If injection is not good, remove nozzle and

replace nozzle or the whole assembly.
2. After confirmation of injection, there shall be
no dripping of fuel.
3. In case of dripping, remove nozzle and replace
nozzle or the whole assembly.
Nozzle oil seal

1. Use nozzle tester to maintain nozzle internal
pressure (indicated by pressure gauge) at
10000-11000 kPa. In this state, check for fuel
leakage from nozzle.
2. In case of leakage, remove nozzle and replace
nozzle or the whole assembly.
- 344 -
III. Fuel distribution injection pump (rotor type injection pump)
1. Injection pipe No.1

5. Injection pump sprocket
6. Injection pump support
7. Injection pump harness assembly
8. Fuel injection pump
9. Fuel pipeline
10. Fuel return pipe nut
11. Fuel return pipe
12. Gasket
13. Nozzle
14. Seat gasket
15. Nozzle gasket
Caution:
Installation sequence is the reverse of removal.
- 345 -
Rotor distributed type fuel injection pump

Rotor distribution type fuel injection pump (VE type) is rotary single plunger axial compression type fuel
injection pump. Its basic principle is the same as that of gasoline engine ignition distributor. HP fuel outlet pipe is
installed on distributing head fuel outlet valve seat to distribute HP fuel to each cylinder.
This pump consists of driving mechanism, 2-stage blade type fuel transfer pump, distributor, fuel supply advance
angle auto adjustment device, and governor. Structure schematic is as follows:
1-drive shaft; 2-2-stage blade type fuel transfer pump; 3-gear; 4-roller; 5-roller support; 6-fuel supply advance angle auto
adjustment device (90° deployed); 7-disc cam; 8-fuel supply auto regulating lever; 9-distributing rotor spring; 10-fuel
amount control sleeve; 11-fuel relief hole; 12-distributing groove; 13-fuel outlet valve; 14-fuel inlet groove; 15-distributing
sleeve; 16-distributing rotor; 17-fuel cutoff solenoid valve; 18-starting spring; 19-full load regulating screw; 20-calibration
rod; 21-fuel return port; 22-pull rod; 23-governor spring; 24-fly block; 25-control level; 26-regulating valve
1. Driving mechanism
Drive shaft 1 is supported on Al alloy die cast pump casing and rotates at half the rotation speed of engine. This
shaft drives disc cam 7 via a driving disc. This disc cam has the same number of heaved faces as number of engine
cylinders. As driven by the drive shaft, this disc cam relies on roller 4 fixed on roller support 5 for reciprocal
movement according to specified convex surface lift. Rotor knock pin and distributing rotor spring 9 connected on
disc cam perform reciprocal movement with rotation of the disc cam. On 4-cylinder engine, since 4 rollers are
installed on the roller support, and the disc cam has 4 heaving faces, the plunger will perform 4 reciprocal
movements in each round.
2. 2-stage blade type fuel transfer pump
The 2-stage blade type fuel transfer pump is driven by the drive shaft to suck fuel from fuel tank. Then, this fuel
passes oil-water separator and fuel filter to enter the distributor; this section is LP fuel path. Regulating valve 26 is
used to adjust fuel transfer pump output pressure so that it suits rotation speed. Fuel is supplied to fuel injection
pump head at about 250kpa pressure at idling speed, or at 800kpa pressure at 4500rpm.
3. Distributor
- 346 -
The distributor consists of distributing sleeve 15 that performs fuel metering, compression, distribution and output,
distributing rotor 16 (plunger), fuel amount control sleeve 10 and fuel cutoff solenoid valve 17.
The distributing plunger is press fit in the distributor and includes 1 fuel inlet hole and 4 evenly arranged fuel
outlet holes.
On the distributing rotor, 4 evenly arranged fuel inlet grooves 14, 1 distributing groove 12 and 1 fuel relief hole 11
are provided.
Fuel intake stroke: When the distributing rotor moves left under the action by its return spring, fuel relief holes on
this rotor will be closed by fuel amount control sleeve and the fuel will enter and fill pump cavity from fuel cutoff
solenoid valve and fuel inlet groove; refer to the following figure.
Fuel compression stroke: including decompression zone stroke and effective stroke. When rotor moves right under
the action by roller and disc cam, fuel relief holes on rotor are still closed by fuel amount control sleeve. With
rotor rotation, and obstructed fuel inlet groove and fuel inlet hole, fuel pressure in pump cavity rises quickly.
When this pressure is enough to overcome action of fuel outlet valve spring, this valve will open to supply fuel to
fuel injectors. This section is high pressure fuel path.
Fuel return stroke: During rightward movement of distributing rotor, when fuel relief hole exposes from fuel
amount control sleeve, i.e. facing pump casing, fuel inside distributing rotor will flow toward pump casing. At this
point, fuel compression stroke ends and remaining stroke is fuel return stroke.
During one round rotation of drive shaft, distributing rotor (plunger) performs 4 reciprocal movements and rotates
by 360°. Each of the 4 fuel inlet grooves connects to fuel inlet hole once, the distributing groove is connected to
each of 4 fuel outlet holes once, and each of the 4 fuel outlet valves opens once, i.e. supplying fuel to each of the 4
fuel injectors once.
- 347 -
Amount of fuel supply is regulated by left and right sliding of fuel amount control sleeve, changing effective
stroke of distributing rotor before fuel relief hole exposes from fuel amount control sleeve, i.e. when this sleeve
moves left, effective stroke is shortened, reducing fuel supply; when the sleeve moves right, effective stroke is
lengthened, increasing fuel supply. Driver controls governor by acceleration pedal so as to change position of this
sleeve, realizing acceleration and deceleration.
The fuel cutoff solenoid valve controls LP fuel path. When ignition switch is at ON position, the solenoid valve is
energized, sucks up to open LP fuel path; when this switch is at OFF position, the solenoid valve is de-energized,
dropping down to close LP fuel path, and stopping the engine.
4. Fuel supply advance angle auto regulating device
As shown in the figure, This device is installed transversely at lower part of distribution pump and consists of
adjusting piston 4, adjusting spring 1, roller support 6 and roller 7 etc. There are 4 rollers 7 on the roller support.
The roller support is connected to adjusting piston via drive pin 2 and connecting pin 3. Piston cylinder left cavity
is connected to fuel inlet via fuel path and its right cavity is connected to pump cavity.
When engine rotation speed rises, drive shaft rotation speed also rises, as well as pressure of fuel transfer pump.
This acts on adjusting piston. When this force exceeds force of adjusting spring, adjusting piston will move in a
direction perpendicular to drive shaft. Therefore, via the drive pin, movement of adjusting piston drives roller
support to rotate in the reverse direction as drive shaft rotation (roller support is not affected by drive shaft
rotation direction), thereby accelerating disc cam lift time and advancing fuel supply.
5. Governor
Rotor distributed type fuel injection pump adopts omnirange mechanic governor (RSV type governor). In this
governor, a set of centrifugal element (fly block), spring and lever mechanism is used to control position of fuel
amount control sleeve, so that the engine can automatically adjust amount of fuel supply under various rotation
speeds.
- 348 -
6. Supercharging compensator
Since the engine is fitted with turbo-supercharger, a supercharging compensator is installed on top of pump body.
This device is used to limit amount of fuel injection, so as to satisfy strict emission standard.
Supercharging
Air intake
IV. Fuel injection system inspection, removal and installation

Inspection
Fuel injection pump and nozzle on vehicle
In case of defect found, replace injection pump as an assembly.
Caution: Injection pump adjustment is limited to idling speed adjustment.
Description Inspection procedure Standard
Idling operation Measure rotation speed
Exhaust gas color At no-load condition, accelerate engine fast and check color Excessive black smoke not
of exhaust gas (measure smokeness) permitted (smokeness
reference value: within 50%)
Distributor Control accelerator rod to keep engine at about 1500rpm; Change of engine noise
under this condition, manually operate throttle switch button
to observe change of engine rotation speed.
Fuel cutoff valve Turn ignition switch on and off Driving noise (“kata”) heard
- 349 -
Removal
Fuel injection pipe
When loosening connector nut, use wrench to
clamp injection pump head fuel supply valve seat
or fuel return pipe hex nut to avoid their rotation
along with connector nut.
Caution:
VE type fuel injection pipe is different from
DPC type fuel injection pipe. During
installation, pay attention to this (outer side of
VE type injection pipe is yellow).
Injection pump sprocket

Use special tool to remove injection pump
sprocket.
Caution:
Shaking and vibration of sprocket may cause
fault of injection pump.
Fuel injection pump

When removing fuel loop nut, use wrench to
clamp fuel return pipe by the hex nut.
Caution:
If fuel return pipe is not clamped when
removing hex nut, the pipe may be damaged.
Hence you must clamp fuel return pipe nut
when removing hex nut.
Fuel return pipe nut

When removing fuel return pipe nut, use wrench to
clamp hex nut to prevent moving of fuel return
pipe.
Caution:
If fuel return pipe nut is not clamped when
removing hex nut, the pipe may be damaged.
Hence you must clamp fuel return pipe nut
when removing hex nut.
- 350 -
Nozzle
Use deep socket wrench to loosen nozzle and
remove it.
Caution:
Mark cylinder No. on removed nozzle. Cover
open parts with suitable cover to prevent dust,
water and foreign matter from entering fuel
pipeline or combustion chamber.
Inspection
Nozzle
Check the following items. If a defect is found,
correct or replace.
Inspection of fuel injection pressure

1. Fit nozzle on nozzle tester and operate tester
handle to vent air from the nozzle.
2. Operate tester handle at about 1 stroke per
second and read value on pressure gauge.
If the reading is lower than maintenance limit,
remove nozzle and replace internal gasket to adjust
so that pressure reading is within standard value
range.
Standard value: 12,000-13,000 kPa
Maintenance limit: 11,000 kPa
Caution:
1) Add 0.1mm shims to increase pressure to
1000kPa;
2) Use 20 shims of thickness 1.00-1.95mm.
- 351 -
Inspection of fuel beam characteristics

1. Operate tester handle at about 1 stroke per
second. When moving tester handle, injecting
nozzle will generate special intermittent noise
and vibration of needle valve can be felt at the
handle.
Caution:
During fuel injection, some fuel may remain on
spray head. This can be seen when inspecting
nozzle and does not mean fault of nozzle.
2. Fuel beam status
In the figure, only one fuel beam status is good and
all others are not good. The fuel beam shall be
rod-shaped with thick fuel particle. After injection,
fuel vapor exists at spray head. This can be seen
during inspection but does not mean abnormal
state of nozzle.
3. Operate tester handle at 4 to 6 strokes per
second. Fuel beam shape is a cone of about 30
degrees.
Sealing of injection nozzle

Operate nozzle tester to maintain nozzle internal
pressure at 10000-11000kPa (pressure gauge
reading) and check nozzle for fuel leakage.
Installation
Nozzle gasket and nozzle holder gasket
1. Clean cylinder head nozzle holder mounting
plate.
2. Place new nozzle gasket and holder gasket
into cylinder head nozzle holder hole.
- 352 -
Nozzle
Use deep socket wrench to fit nozzle on cylinder
head and tighten to specified torque.
Fuel return pipe nut

Use wrench to clamp fuel return pipe by the hex
nut; tighten fuel return pipe nut to specified torque.
Fuel injection pipe

When tightening fuel injection pipe nut, use
wrench to clamp fuel supply valve seat or fuel
return pipe by the hex nut to prevent their rotation
with nut.
Adjustment of fuel injection timing

Caution: Cut Timing
Adjust fuel injection timing along with display
matching of engine.
Rotate crankshaft so that No.1 cylinder is at top
dead center of compression stroke.
Crankshaft
pulley
- 353 -
2. Loosen (but not remove) fuel injection pipe

assembly nuts (total 4 nuts) at injection pump side.
When loosening these nuts, use wrench to clamp
fuel supply valve seat to prevent its rotation with
nut rotation.
3. Loosen the 2 nuts and 2 bolts locking injection
pump, but do not remove them.
4. Remove timing check plug from injection pump

head.
5. Before installing special tool, confirm 10mm

protrusion of push rod. The protrusion part can be
adjusted by an internal nut.
6. Connector special tool (09310-43000) and dial

gauge.
- 354 -
7. Rotate crankshaft so that notch on sheave is at

about 30º position from No.1 cylinder piston About 300 Set to zero
compression stroke; then set dial gauge to zero.
Lightly rotate crankshaft clockwise and
counterclockwise to confirm dial gauge pointer at
zero position without deviation. If no deviation,
re-adjust sheave position so that the notch is at 30º
before TDC.
8. Rotate crankshaft in normal direction so that its 10.03mm

notch is at 9ºATDC (top dead center) (with fuel
injection timing as reference). Confirm that pointer
reading is within standard value.
Standard value: 1 ±0.03 mm
9. If pointer reading is not within specified value,

tilt injection pump body left and right till the
reading is within standard value. Then, tighten
injection pump mounting nuts and bolts to
specified torque.
10. Repeat steps 7-8 and check that adjustment is
correct.
11. Remove special tool and dial gauge.
12. Install new copper gasket and timing check
plug. Then tighten plug to specified torque.
13. Tighten fuel injection pipe nut to specified
torque. When tightening, use wrench to clamp fuel
supply valve seat to prevent its rotation along with
nut.
- 355 -
Injection nozzle holder
1． Positioning nut
2． Fuel injector nozzle head
3． Washer
4． Locating pin
5． Pressure spring
6． Gasket A:35-40Nm
Note:
Install in the reverse order of removal.
Removal
Set nut
1. Use elastic support to lightly clamp set nut;
2. Use socket wrench to clamp set nut and a
deep socket wrench to loosen nozzle holder.
- 356 -
Inspection
1. Check nozzle tip for accumulated carbon. Use
wood knife to remove accumulated carbon on
each part. Later, dip the parts in diesel. Pay
special attention to protect nozzle tip needle
valve.
2. While dipping nozzle tip in diesel, check the
needle valve for smooth sliding. If not,
replace nozzle tip. Before using a new nozzle
head, use clean diesel to completely remove
anticorrosion oil on the head.
3. Check plunger head “A” for deform and
breaking. If “A” is damaged or broken,
replace it.
Spacer
Check the surface in contact with nozzle holder.
Pressure spring
Check this spring for softening or breaking.
Re-installation
Set nut
1. Hand tighten nozzle holder.
2. Use gasket to lightly clamp set nut in jaw
vice.
3. Use socket wrench to clamp set nut and use
deep socket wrench to tighten nozzle holder
to specified torque.
Inspection and adjustment

Idling speed
1. Before inspection and adjustment, set vehicle to the
following status:
●Engine cooling temperature: 80-90℃
●Lights and other accessories: Off
●Transmission position: neutral
2. Check if valve clearance is in standard range.
3. Check if fuel injection timing is in standard range.
- 357 -
4. Check if idling speed is within standard value.

Standard value: 750±50 rpm
5. If idling speed exceeds standard value, loosen
lock nut of idle adjusting screw and adjust
idling speed to within standard value.
6. After adjustment, fully tighten lock nut.
V. Fuel tank
1． Fuel hose (main) 7. Oil level sensor

2． Oil level sensor connector 8. Oil return hose (main)
3． Fuel filter 9. Fuel hose (connecting)
4． Oil drain plug 10. Oil return hose (main)
5． Fuel filter sleeve 11. Main fuel pipe
6． Fuel filter pump 12. Oil return pipe
- 358 -
Removal
Fuel filter case
Clamp fuel filter in a jaw vice and use fuel filter
wrench to remove fuel filter case.
Water surface height transducer

Clamp water surface height transducer in a jaw
vice and use hands to rotate and remove fuel filter
case.
Inspection
1. General inspections
1） Check hose and pipeline for cracking, damage,
scratch and clogging.
2） Check fuel filter for clogging and damage.
2. Operation of water surface height transducer
Connect circuit tester to the transducer; when the
float moves up or down, if the circuit is not
conducting or conducting, the transducer is good.
Replacement
Fuel filter
1. Reduce fuel tank pressure by taking down
fuel filter cover.
2. Disconnect water surface height transducer
connector.
3. Use hand to remove fuel filter element from
fuel filter pump body.
4. Disconnect fuel hose (main) from fuel filter
pump.
5. Remove fuel filter pump.
6. Replace fuel filter element.
- 359 -
Removal of fuel tank
1. Fuel gauge element

2. Breathing hose
3. Fuel tank
4. Oil drain plug
5. Filling/breathing hose assembly
6. Filling hose
7. Breathing hose A:15-22Nm
8. Filling port
9. Filling port cover
- 360 -
Removal
1. Remove fuel drain plug and drain fuel.
2. Disconnect fuel supply hose and fuel return hose.
3. Disconnect fuel gauge element connector.
4. Disconnect breathing hose and filling hose.
- 361 -
5. Remove fuel tank; remove fuel gauge element if required.
6. Remove fuel filling port and filling pipe according to the

following procedure.
1）Disconnect filling pipe and breathing hose from filling port
and breathing pipeline.
2）Pull out filling port cover and remove filling port
3）Remove filling pipe and breathing pipe assembly
Installation
When connecting hose to pipeline, note that
overlap length shall be in specified range. Tighten
hose clamp at the position shown in the figure to
- 362 -
prevent interference of hose with other parts.
VI. Engine control
Accelerator pedal
1. Accelerator pedal assembly

2. Support assembly
3. Return spring
4. Circlip
5. Flat washer
Caution:
The numbers indicate removal sequence. Installation sequence is the reverse.
- 363 -
Throttle control
Re-installation
Accelerator pedal
Apply lubricating grease on accelerator pedal sliding
contact surface.
Return spring
Apply lubricating grease on inner surfaces.
Cable installation and adjustment
Throttle cable
Fully rotate throttle button in the reverse direction
to the arrow marked on button. With inner cable
fully extended, install accelerator pedal or
accelerator rod. Confirm that draw-in bar at fully
extended position when engine speed is lowest.
Caution:
1） Sort each cable so that it is not in contact with metal plate.
- 364 -
2） Path radius of each cable shall be ≥ 150mm.
Throttle control cable

Rotate throttle button in reverse direction to the
arrow marked on the button and confirm that
accelerator pedal cannot move. Install throttle
control cable on adjusting lever and fix cable at
one side of engine through tightening nut.
Caution:
To install throttle control cable, do not move
engine side adjusting lever.
Accelerator pedal stopper

Adjust so that when engine side adjusting lever
touches fuel stopper, clearance between accelerator
pedal and adjusting bolt is A.
Dimension A: 0-5 mm
- 365 -
VII. Circuit diagram
With current at the ON or START shift
Fuse block
Fuse 15
Detailed diagraph for

the fuses in the
passenger compartment
Throttle
position
sensor Solenoid Solenoid
valve valve
(duty (on/off)
ratio) Fuel cut-off
solenoid
valve
Signal Grounding Solenoid valve Solenoid valve Stored power Preheating

control (duty control (on/off) control
ratio) Line L of the module
starting signal Generator
Grounding
See the See the detailed
indicator diagraph for the
data connection
See the
grounding
distribution
Fuel
K line ON/START cut-off
shift
See the See the Input signal solenoid
starting charging valve
system system Grounding control
(with the
stopping
device)
Water temperature
sensor
- 366 -
Power on at the ON/STAR shift Keep power on
Fuse block Wiring

Fuse 13 Preheater
fuse
Detailed diagraph for the fuses

in the passenger compartment
Instrument
Preheating cluster Preheater relay
light
Speed
controller
Preheating
plug
supply indicator Preheater relay control

control
Grounding
Sensor power Sensor is grounded
Idle speed Speed controller

acceleratio sensor
n control
module
- 367 -
Refine MPV Workshop Manual Electrical System (Diesel)
Section III Electrical system of diesel vehicles (2.5TCI)
I. General
1. Size and parameters
Starter motor
Diesel
Model Speed reduction driving
Voltage 12V
Power 2.0kw
No-load characteristics
Terminal voltage 11V
Current intensity 90 or lower
Rotation speed 2,800rpm
Number of gear teeth 13
Gear clearance 0.5-2.0mm
Generator
Diesel
Model Battery voltage induction
Rated power 12V/75A
Type of voltage regulator Built-in electronic type
Regulator set voltage 14.4±0.3V
Temperature compensation -10±3Mv/℃
Batteries
All engines
Model MF 68 AH, MF 90 AH
Ampere hours
5HR 55AH or higher
Cold start [-17.8℃] 540AH or higher
Inversing capability 122min
Specified weight [25℃] 1.280±0.01
Caution:
Cold start current intensity refers to the current that can be supplied by batteries under specified
temperature for 30 seconds to maintain 7.2V or higher terminal voltage. Rated value of reversing capability
refers to the time period during which batteries can supply 25A at 26.7℃ and maintain minimum terminal
voltage of 10.5V.
- 368 -
2. Tightening torque
Item Ｎm
Generator terminal (B+) 5-7
Starter motor terminal (B+) 10-12
Battery terminal 4-6
Spark plug 20-30
3. Common troubleshooting
Charging system
Fault phenomena Fault causes Repair
With ignition switch “On” Melt fuse Check and replace fuse
and engine not rotating, Burnt light Replace light
charging alarm indicator Loose pull wire connector Tighten loose connector
does not light up Fault of electronic voltage regulator Replace voltage regulator
During engine operation, Belt loose or worn Adjust tension or replace drive belt
batteries frequently Loose, corroded or worn battery wires Repair or replace wire
request recharging and Melt fuse Replace fuse
charging alarm indicator Melt fuse wire Replace fuse wire
remains on Fault of electronic voltage regulator or Test generator
generator
Line fault Repair line
Slow or failed engine Drive belt loose or worn Adjust tension or replace drive belt
acceleration; excessive Loose line connector or open circuit Tighten loose connector or repair line
charging Melt fuse Replace fuse
Poor grounding Check
Faulty electronic voltage regulator or Detect generator; repair or replace in
generator case of fault found
Old batteries Replace batteries
Fault of electronic voltage regulator Replace voltage regulator
Fault of voltage induction line Repair line
- 369 -
Starting system
Engine not Low batteries Charge or replace batteries
rotating Loose, corroded or worn battery wire Repair, replace wire
Driving axle shifting switch faulty (only for vehicles with Adjust or replace switch
auto transmission)
Melt fuse Replace fuse
Fault of starter motor Repair starter motor
Fault of ignition switch Replace ignition switch
Fault of ignition lock switch fault Replace ignition lock switch
Engine rotating Low batteries Replace ignition lock switch
slowly Loose, corroded or won battery wire Repair or replace wire
Fault of starter motor Repair starter motor
Starter always Fault of starter motor Repair starter motor
rotating Replace ignition switch Ignition switch faulty
Starter rotating, Short or missing ignition pull wire Repair pull wire
but engine not Broken drive gear or damaged starter motor Repair starter motor
rotating Broken ring gear teeth Replace flywheel ring gear or
torque converter
Preheat control system

No starting of engine Loose line connector or damaged line Repair of replace line
at lower than 50℃ Engine coolant temperature sensor (ECT) faulty Replace ECT sensor
temperature Preheat plug fault Repair or replace preheat plug
Preheat control element damaged Replace preheat control element
At lower than 50℃ Loose line connection or damaged wire Repair or replace line
temperature, after Preheat plug fault Check preheat plug resistance
first ignition, engine Preheat plug relay faulty Check relay
stops or idles poorly. Preheat control element damaged Check control element
Yellow preheat Bulb damaged Replace bulb
indicator no lit Loose line connection or damaged line Repair or replace line
Short circuit Repair or replace line
Preheat plug control element damaged Replace control element
- 370 -
II. Ignition switch
1. Disconnect battery negative pole terminal.
2. Remove air bag module.
Warning:
SRS is so design that even after disconnection of
batteries, sufficient power can still be provided
to pop out air bag within about 30s. Therefore,
if SRS system maintenance is carried out
immediately after disconnection of battery
wires, air bag may suddenly pop out to seriously
hurt personnel.
3. Loosen taper screw, lift and remove tapered
gasket.
4. Loosen lock nut and gasket.
5. Pull out damper in forward direction, lift and
remove it.
6. Install special tool (09562-11001) and remove

steering wheel.
Caution:
Do not hit with hammer when removing steering
wheel.
7. Remove upper and lower sheath of steering

column.
- 371 -
8. Remove lower cover.
9. Disconnect connector and remove

multifunction switch.
10. Remove mounting bolts and separate ignition

switch from steering column.
Inspection
1. Separate the connector under steering column.
2. Check conduction between switch terminals.
3. If conduction does not meet specification,
replace switch.
Terminal Door alarm switch &
Ignition switch Lock
key illumination
Position Key 1 2 3 4 5 6 1 2 3 4 RO RE
Pull out ○ ○ L L
Lock
L F
Accessory ○ ○ F F
Insert
On ○ ○ ○ ○ F F
Start ○ ○ ○ F F
- 372 -
Notes:
○— ○indicates conduction between terminals
RO: rotation locking bar
RE: return locking bar
L: lock Ignition
switch
F: free
Prompt:
If engine cannot rotate, confirm driving axle gear
shifting switch at “Parking”or “Neutral”.
Door warning switch
If the phenomenon of “engine not rotating”only
occurs at one gear position and not any other
position, the fault most probably lies in driving
axle gear shifting switch.
Ignition switch Door warning switch
III. Batteries
Visual inspection
1. Ensure ignition switch and all accessories at
Off position.
2. Disconnect battery wires (negative pole line
shall be disconnected first).
3. Remove batteries from vehicle.
Caution:
With battery cover cracked or leaking, avoid electrolyte hurting your skin. Wear thick rubber gloves when
removing batteries.
4. Check battery holder for damage due to electrolyte leakage. In case of acid corrosion, use clean hot water and
dry soda water to clean areas around. Use steel wire brush and wet cloth dipped in soda water for cleaning.
5. Clean top of batteries with the same solvents as in step (4).
6. Check battery cover and box fro crack; if yes, replace batteries.
7. Use suitable tool to clean battery posts.
8. Use suitable battery cleaning tool to clean inner surfaces of terminal clamps. Replace damaged/worn wire
and damaged terminal clamps.
9. Install batteries on vehicle.
10. Connect wire terminals to battery posts. Ensure terminal head flush with top of post.
11. Tighten terminal nuts.
12. After tightening, apply mineral oil on all connectors.
- 373 -
Caution:
After charging of batteries several times, inflammable gas may exist under cover of each cell. Avoid open
flame near batteries. No smoking near batteries being charged or recently changed. Do not disconnect post
circuit of batteries being charged, as breaking of circuit may generate sparks.
Battery tests
1. Check current
Check if there is any loss or damage obviously

caused by the electrolyte on the cover or hood, for No good
example crack of break. Identify the cause for such Battery is normal.
damage and repair as the specific situation. Clean 更换蓄电池
the corrosive parts with soda water solution.
The height difference of the

good
electrolyte is above 10mm.
Check the height检查电解液的高度
of the electrolyte. Battery is normal.
更换蓄电池
The electrolyte is not

enough Battery is normal.
good 更换蓄电池
Battery testing Below 11.0V Battery is normal.

更换蓄电池
good Above 12.5V Battery is normal.

更换蓄电池
Below 11.0V Battery is normal.

Loading test (use the battery tester) 更换蓄电池
good
Battery is normal.
- 374 -
2. Inspection table
Item Fault Causes Repair Responsibility
User Manufacturer
Visual *Battery terminal damaged *Carelessness
inspection *Battery wire Replace ○
over-tightened
Cracked cover *Carelessness Replace ○
*Electrolyte leakage
Cracked cover *Carelessness Replace ○
Leaking cover *Poor cover sealing Replace ○
Electrolyte *Electrolyte height *Cell short circuit Replace
○
height between poles of a cell *Evaporation due to too Replace
○
inspection exceeds 10mm high temperature Replace
○
*Low electrolyte *Overcharging causing
loss of electrolyte
Voltage 1. Battery voltage >13.2V 1. Over-charging Replace ○
inspection 2. 12.5V<battery voltage 2. Normal Check electric
<12.9V system
3. 12.0V<battery voltage 1. Insufficient charging Battery load test ○
<12.4V (pure discharge) 2. Internal fault (reference load
4. 11.0V<battery voltage test below) ○
<12.0V (over-charging)
5. Battery voltage: 11.0V 1. Charging condition Replace
or less fault ○
2. Long-term discharging ○
of batteries ○
3. Internal circuit open
3. Load test
1) Under half current of cold start power (CCP), after 15s battery discharge, battery voltage shall be as shown in
the table below.
Table of regulated voltage
Ambient temperature Regulated voltage
20℃以上 9.6V
～18℃ 9.5V
～10℃ 9.4V
～4℃ 9.3V
～-1℃ 9.1V
～-7℃ 8.9V
～-12℃ 8.7V
- 375 -
2) When the voltage is not within specified value, repeat load test and charge batteries.
3) If after placing re-charged batteries for 2 hours, battery output exceeds 12.5V and voltage after load test
exceeds standard value, these batteries can be used.
IV. Generator
Traditional internal voltage detection type AC generator does not consider status of batteries and controls charging
voltage according to change of external loads. Therefore, insufficient charging and over-charging may occur
sometimes. This is because load fluctuation causes voltage ripple, and hence flashing of instruments and light.
Following are internal circuit diagrams of AC generator and voltage regulator.
Three diodes Charging indicator
DPower
transistor Battery
Starter coil
Magnetic
coil
Voltage regulating
1. Stator
2. Rotor
3. Rear support
4. Brush
5. Electronic regulator
6. Rectifier
7. Fan
8. Sheave
9. Front support
10. Vacuum pump
- 376 -
Removal and installation
20-25
1. Eyebolt
2. Oil pipe
3. Oil hose
4. Locking bolt
5. Nut
6. Bracket bolt
7. AC Generator
8. Regulating bracket
Note: Install in the reverse order of removal.
Torque: Nm
Installation
AC generator assembly
Regarding belt tension, reference adjustment procedure in EM (engine maintenance).
Caution:
☆ First install engine oil hose on the generator.
When installing generator, connect engine oil hose to the connector at oil tray side. Clamp hose at straight
segment of connector.
☆ To install an oil hose, avoid sharp bending and contact with engine body.
- 377 -
Decomposition and reassembly
1. Check valve
2. Connector
3. Vacuum pump outer shell
4. O ring
5. Rotor
6. Sliding blade
7. Vacuum pump plate
8. O ring
9. Pulley fan
10. Spacer
11. Seat
12. Rotor assembly
13. Rear bearing
14. Bearing retainer
15. Front bearing
16. Front support
17. Stator assembly
18. Plate
19. Regulator & brush bracket
20. Rectifier assembly Note: Install in the reverse order of removal.
21. Oil seal
22. Back support
- 378 -
Decomposition
Front support
1. Insert screw driver between front support and
stator core; pry down to separate stator and
front support.
2. When it is difficult to separate by prying with
screw driver, plastic hammer can be used to
lightly tap the support.
Caution:
Do not insert screw driver too deep to avoid
damaging stator core.
Welding
Stator assembly, regulator and brush holder
Rectifier point
Caution:
☆ During tack welding or weld-off, avoid
electric iron being near diode for too long.
Complete such welding in a short time as much
as possible.
☆ Avoid using excessive force on diode lead B plate
wire.
1. To remove stator, weld off 3 stator lead wires

from main diode.
2. To remove rectifier from brush holder, weld Oil seal
off the 2 bonding points.
Oil seal
Use a screw driver to push out and remove oil seal.
Boot Rotor
Inspection
Vacuum pump
Check the following parts; in case of defect, replace parts.
1. Check rotor end face for crack and damage;

2. Check for crack or damage on hood surface in contact with Sliding blade
O ring
rotor;
3. Check for damage and crack of sliding blade.
- 379 -
Rotor
1. Check rotor coil conduction. Confirm
conduction among slip rings. Measure rotor
resistance; if too small, rotor short circuit has
occurred. In case of no conduction or short
circuit, replace rotor assembly.
Standard value: 3-5Ω
2. Check grounding of rotor coil and confirm no

conduction between slip ring and rotor core.
In case of conduction, replace rotor assembly.
Stator
1. Check stator conduction and confirm
conduction among coil lead wires. In case of
no conduction, replace stator assembly.
2. Check coil grounding. Confirm no conduction

between coil and stator core. In case of
conduction, replace stator assembly.
- 380 -
Rectifier
1. Inspection of (+) radiator board assembly
Use circuit tester to check conduction between (+)
radiator board and stator coil. If conduction exists
in both directions, the diode has been broken down.
Replace rectifier assembly.
2. Inspection of (-) radiator board assembly

Check conduction between (-) radiator board and
stator coil wiring post. If conduction is detected in
both directions, the diode has been broken down
and rectifier assembly shall be replaced.
3. Inspection of 3 groups of diodes

Use circuit tester to connect the two terminals of
each diode. Check conduction of these three diodes.
If a diode in conducting or not conducting in both
directions, this diode is damaged. Replace rectifier
assembly.
Brush
1. If wear reaches wear limit line, it is necessary
to replace the brush.
Abrasion limit line
- 381 -
2. Weld off brush wire to expose brush and spring.
Wrapped fiber
and nylon
strap
3. To install a new brush, push brush into holder as

shown and weld wires.
Re-installation
Rotor assembly
Back
1. Before installing rotor on rear support, insert Steel support
wire
a steel wire into the small hole on rear support
Brush
to lift the brush. After installation, remove the steel
wire
steel wire.
2. To install rotor on AC generator rear support,

wind Vinylon on spline to prevent damage of
oil seal.
Fiber and
nylon strap
- 382 -
Rotor and sliding blade
Vanes
1. Check hood and rotor for debris and foreign Round end
matter. Then apply engine oil and install.
2. Install sliding blade with round end facing
outside.
3. Apply lubricating grease in O-ring. Fit it into
hood groove when tightening bolts.
4. When tightening the hood, lightly push it in

the direction of the arrow so that the clearance
at “A” is the smallest. Then evenly tighten
bolts.
Caution:
After installation, ensure performance test Push into the
carried out to check that final vacuum value is shield along
within specified value. with direction
Standard value of final vacuum: 600mmHg or A
higher (at 3000rpm).
Tests
Measurement of generator output line voltage
drop
This test determines if the line between generator
terminal “B”and battery (+) is normal by means of Generator
voltage drop method.
Preparations
1. Turn ignition switch to “OFF”.
Caution:
To check for connector abnormity, during this
Ammeter
test, do not use the method to check 2 terminals
and 1 connector at the same time.
2. Connect a digital ammeter between generator
terminal “B” and battery (+). Connect
voltmeter (+) to “B”and (-) to battery (-). Battery
Voltmeter
- 383 -
Testing conditions
1. Start engine;
2. Turn on head lights, fans, and motors etc., and read voltmeter at this time.
Results
1. Voltmeter can display standard value.
Standard value: max. 0.2V
2. If voltmeter reading is larger than expected value (max. 0.2V or higher), the fault may be on line. Check line
from generator “B”to battery (+). Check for loose connection, and color change of harness due to heating
etc. Repair before testing again.
3. After the test, set engine to idle speed and turn off head lights, fans, motors and ignition switch.
Output current test

This test determines if generator output current is normal.
Preparations
1. Before testing, check the following items; repair if required.
1） Check for normal operation of batteries installed on the vehicle. Refer to chapter “Batteries”for method of
inspection. Batteries used to test output current shall be partly discharged. If fully charged batteries are used,
correct results cannot be obtained due to insufficient load.
2） Check generator driving belt tension. For this inspection, refer to relevant chapters in “Engine machinery”.
2. Turn off ignition switch.
3. Disconnect battery ground wire.
4. Disconnect generator output line from generator terminal “B”.
5. Connect a DC ammeter (0 to 100A) between “B”and disconnected output wire. Ensure that ammeter
negative pole wire (-) connected to disconnected output wire.
Caution:
Tighten each connector; due to large current passing, do not rely on clamps.
6. Connect a voltmeter (0 to 20V) between

terminal “B” and ground wire. Connect (+) Voltmeter Ammeter
wire to generator terminal “B”and (-) wire to
ground.
7. Connect engine tachometer and battery Generator
ground wire. inspection
8. Open engine cover.
- 384 -
Testing
1. Check if voltmeter reading is the same as battery voltage. If voltmeter reading is 0V, the fault may be open
circuit on line between generator terminal “B”and battery (-), melt fuse or poor grounding.
2. Start engine and turn on head lights.
3. Set headlights to high beam and turn heater/fan to HIGH. Fast accelerate engine to 2500rpm and read max.
output current on ammeter.
Caution:
After engine start, charging current will drop fast. Therefore, above operations must be performed
quickly to read correct max. current.
Results
1. Ammeter reading must be higher than limit value. If this reading is lower than limit value but engine output
wire is normal, remove generator from the vehicle for testing.
Limit (95A engine): 63A /min
Caution:
Rated output current is marked on generator nameplate.
Value of output current changes with electric load and generator temperature. Therefore, you may not
obtain rated output current. In such case, keep headlights on to discharge batteries, or add lights of other
vehicles to increase electric load. If temperature of generator or air temperature is too high, rated output
current may not be reached. In such case, lower temperature before testing again.
2. When output current test is completed, reduce engine speed to idle speed and turn off ignition switch.
4. Remove ammeter, voltmeter and engine tachometer.
5. Connect generator output line to “B”.
6. Connect battery ground wire.
Ammeter
Test of regulated voltage
The purpose of this test is to check if electronic
voltage regulator can correctly regulate voltage.
Preparations
1. Before test, check the following items; correct
if required.
☆ Check for full charging of batteries on vehicle;
refer to chapter “Batteries”for method.
☆ Check generator driving belt tension. For Voltmeter
method, refer to chapter “EM”.
2. Turn ignition switch to “OFF”.
4. Connect a digital voltmeter between generator terminal
“S(L)”and ground wire. Connect voltmeter (+) lead wire to
generator “S(L)”terminal. Connect (-) lead wire to ground
wire or battery (-) pole.
- 385 -
5. Disconnect generator output line from generator terminal “B”.
6. Connect a DC ammeter (0 to 100A) in series between “B”and disconnected output wire. Connect ammeter
(-) lead wire to disconnected output wire.
7. Fit engine tachometer and connect battery ground wire.
Testing
1. Turn on ignition switch and check if the value displayed on voltmeter is the following value.
Voltage: battery voltage
If the reading is 0V, the fault may be open circuit between generator terminal “S(L)”and battery (+) or melt fuse.
2. Start engine and turn off all lights and accessories.
3. Run engine at about 2500rpm. When generator output current falls to 10A or smaller, read voltage.
Results
1. If voltage reading is consistent with value listed in the following table, voltage regulator is functioning
correctly. If reading is not within standard value range, voltage regulator or generator is faulty.
Table of regulated voltage

Voltage regulator ambient temperature ℃ Regulated voltage (V)
-20 14.2-15.4
20 13.9-14.9
60 13.4-14.6
80 13.1-14.5
2. After completion of the test, slow down engine to idling speed and turn off ignition switch.
4. Remove voltmeter, ammeter and engine tachometer.
5. Connect generator output line to terminal “B”.
6. Connect battery ground wire.
Test of generator output line voltage drop

This test determines if the line (including fuse) from generator terminal “B”to battery (+) is normal.
1. Before testing, check the following items.
☆ Generator installation and line connectors;
☆ Generator driving belt tension;
☆ Fuse
☆ Abnormal noise of generator during generator operation.
- 386 -
2. Turn ignition switch to OFF.
3. Disconnect battery negative pole lead wire.
4. Disconnect generator output line from generator terminal “B”. Connect a DC ammeter (0-100A) in series
between terminal “B”and disconnected output line (connect ammeter (+) lead wire to terminal “B”and
ammeter (-) lead wire to disconnected output line).
Caution:
Induction type ammeter is recommended. This ammeter can perform measurement without disconnecting
generator output line. Use of this ammeter can reduce possible voltage drop due to loose terminal “B”
connector.
5. Connect a digital voltmeter between generator terminal “B”and battery (+) pole (connect voltmeter (+) pole
lead wire to “B”and voltmeter (-) lead wire to battery (+) pole).
6. Re-connect battery (-) pole wire.
7. Connect a tachometer or speed measurement tool.
8. Start engine.
9. With engine operating at about 2500rpm, turn headlights and other lights on and off to adjust generator load
so that ammeter reading is slightly higher than 30A.
Limit value: max. 0.3V
Caution:
When generator output current is high and value displayed on ammeter cannot be lowered to 30A, set the
value to 40A. Read value on voltmeter. In such case, limit value changes to max. 0.4V.
10. If voltmeter reading is still higher than limit value, generator output line may be faulty. Check line (including
fuse) between generator terminal “B”and battery (+) pole. If terminal connector is not tightened or harness
color is changed due to overheating, repair or test again.
11. After the test, idle the engine.
12. Turn off all lights and turn ignition switch to OFF.
13. Disconnect tachometer or testing tool.
14. Disconnect battery (-) pole wire.
15. Disconnect ammeter and voltmeter.
16. Connect generator output line to generator terminal “B”.
17. Connect battery (-) pole wire.
- 387 -
Ammeter
Generator
Voltmeter (digital)
Battery
V. Starting system
General
The starting system consists of batteries, starter
motor, EM switch, ignition switch, protection
switch (only available with vehicles of auto
transmission), connecting line, and batteries wires.
When ignition key is turned to start position,
current passes and energizes starter EM coil. EM
plunger and clutch shifting lever will be driven
(activated), and clutch pinion will engage ferrule to
start the motor.
To prevent damage due to excessive rotation of
starter motor pivot during engine start, clutch
pinion will undergo overspeed.
- 388 -
Inspection of starter motor relay
Remove starter motor relay and check conduction
between terminals. If conduction is not in specified
range, replace the relay.
Terminal No.
85 86 87 30
Condition
Not energized ○ ○
Energized ○ ○ ○ ○
Inspection of ignition switch

Remove ignition lock switch and check conduction
between terminals. If conduction is not in specified
range, replace the switch.
Terminal No.
1 2
Condition
Push on ○ ○
Release
1. Bolt
2. Start
Torque
- 389 -
Adjustment of pinion clearance
1. Disconnect excitation coil lead wire from
terminal M of EM switch.
2. Connect a battery between terminal S and starter
motor body (connect battery (+) to terminal S)
Caution:
To prevent coil overheat, this test must be
completed fast (within 10s or less).
3. When battery is connected, the pinion moves out.

At this time, use finger to push pinion rearward
and measure pinion stroke (along the path of
pushing). This will be pinion gap.
4. If pinion gap cannot reach specified value, add
or reduce fiber shims between EM switch and front
support. Using more shims can obtain smaller gap.
EM switch suck-in test

With a battery connected between terminals M and
S of EM switch, if plunger is sucked in so that
pinion moves out, the suction coil is normal. If
pinion does not move out, replace EM switch.
Caution:
For the purpose of this test, connector must be
disconnected from terminal M. This test must
be completed within 10s.
Retentivity test of EM switch

Connect a battery between terminal S and EM
switch. Manually move pinion up to connect to
pinion stopper. If when pinion is released, the
pinion can be kept out, the switch coil operates
normally.
Caution:
This test must be completed within 10s.
- 390 -
Return of EM switch
Connect a battery between terminal M and EM
switch body. Use hand to pull out pinion to pinion
stopper. If when released, the pinion can return
immediately, switch coil operates normally.
Caution:
This test must be completed within 10s.
No-load test
1. As shown in the figure, connect starter motor,
batteries, ammeter, voltmeter and variable
resistor to one circuit.
2. When the switch closes and is at max.
variable resistor, if starter motor operates
smoothly and stably, this motor is in good
status. Adjust variable resistor so that voltage
reading is 11.5V. If after this adjustment, both
current and rotation speed exceed limit values,
carry out troubleshooting according to the
following table and repair as required.
Phenomena Possible causes

Large current, low rotation Polluted bearing
speed (torque is also small) Friction between armature coil and pole plate
Grounding of armature and excitation coil
Armature coil short circuit
Large current, no rotation Grounding of EM switch
Grounding of armature and excitation switch
Sticking of bearing
No current, no rotation Damaged armature and excitation coil
Damaged brush and leading out wire
Incorrect contact between brush and converter
Small current, low rotation Improper connection with excitation coil (note: open circuit or improper
speed (and small torque connection to shunting coil will generate high rotation speed)
Large current, high rotation Short circuit of excitation coil
speed (and small torque)
- 391 -
Decomposition and reassembling
1. Screw 15. Gasket 29. Front support

2. EM switch 16. Plate
3. Fiber board 17. Screw
4. Screw 18. Central support
5. Screw 19. Packing gasket
6. Rear support 20. Rod spring
7. Brush holder assembly 21. Gasket
8. Positioning support assembly 22. Gear
9. Armature 23. Rod
10. Front bearing 24. Split ring
11. Rear bearing 25. Check ring
12. Screw 26. Pinion
13. Cover 27. Spring
14. Split ring 28. Pinion shaft assembly
Note: Reassembling sequence is the reverse of removal sequence.
- 392 -
VI. Preheating system
Size and parameters

Maintenance service specification
Item Automatic preheating system
Water temperature sensor resistance [at 20℃] kΩ 2.92-3.58
Preheat plug resistance [at 20℃] mΩ 250
Torque parameters
Item Nm
Water temperature sensor 8-10
Preheat plug 15-20
Preheat plug plate connecting nut 1-1.5
Sealant and adhesive

Item Specified sealant and adhesive
Water temperature sensor 3M lock nut adhesive 4171 or equivalent
Maintenance adjustment process

Preheating system operation inspection
Inspection conditions:
Battery voltage: 12V
1. Connect a voltmeter between preheat plug
plate and plug ground.
2. With ignition switch ON, check voltmeter
display.
3. After the ignition switch is turned on, check
preheat indicator at once (which shall light up
for 6s) and voltage (about 9V or higher) shall
be displayed for about 36s (at cooling water
temperature of 20℃)
Note: Time of conduction changes with cooling
water temperature.
4. After inspection of step 3, turn ignition switch
to START.
5. If during and after engine start, batteries
generate voltage (about 9V or higher) for
about 6s, the system is normal (cooling water
temperature is 20℃)
6. If voltage or connection time is not normal,
check terminal voltage and single parts in
preheat control element.
- 393 -
Inspection of preheat control element
Check terminal voltage in preheat control element
and conduction at harness side.
1. Check for good connection of preheat control element connector (M14)
Terminal Connection area or Measured Tester Inspection Standard value

measurement point item connection status
1 Preheater relay Voltage 1-ground Ignition switch: After closing, battery
On voltage will be
displayed for about 30s
2. Remove preheat control element connector and check harness side connector (M13)
Terminal Connection area or Measured Tester Inspection status Standard value

measurement point item connection
1 Ignition switch Voltage 1-ground During engine start Battery voltage
2 Preheat indicator Voltage 2-ground Continual Battery voltage
3 Ignition switch (IGN Voltage 3-ground Ignition switch on Battery voltage
power source)
4 Water temperature Resistance 4-ground -20℃ 24.8±2.5kΩ
sensor 0℃ 8.62kΩ
20℃ 3.25kΩ
40℃ 1.05kΩ
5 Empty terminal - - - -
6 Control element ground Conduction 6-ground Continual Conduction
wire
7 Generator terminal L Voltage 7-ground Ignition switch on 1-4V
- 394 -
Inspection of ECT sensor

1. Remove ECT (engine coolant temperature)
sensor from intake manifold.
2. Check if ECT sensor resistance is in standard
value range.
Standard value: 3.25kΩ (at 20℃)
3. After inspection, apply specified adhesive at

ECT sensor screw and install the sensor on
intake manifold.
Specified adhesive: 3M lock nut glue 4171 or
equivalent
Inspection of starter motor relay

1. Remove starter motor relay from relay holder.
2. Connect battery power source to terminal 1
and check for conduction between terminals.
Ground terminal 3.
With Between terminals 4
Conduction
power and 5
Between terminals 1
Conduction
W/o and 3
power Between terminals 4 No
and 5 conduction
- 395 -
16-20
1． Preheating plug plate

2． Preheating plug
Note: Install in the reverse order
of removal.
Torque: Nm
Inspection
Preheat plug
1. Check conduction between terminal and plug
as shown. If there is no conduction or
resistance is large, replace preheat plug.
Standard value: 0.25Ω
Caution:
Before measurement, remove engine oil on
preheat plug. This is because preheat plug
resistance is very large.
2. Check for rusting of preheat plug plate.
3. Check for damage of preheat plug.
- 396 -
Intercooler
1. Fixing support; 2. Relay; 3. Radiating cooler; 4. Temperature switch;

5. Radiating cooling fan; 6. Support; 7. Air pipe A; 8. Air pipe B
End gas recirculation system (EGR)
EGR solenoid switch valve
Generator
EGR valve
EGR two-way controlling
Vacuum valve No.1 Diesel
pump controlling
module
ENG speed
Throttle valve
ENG water
temperature
- 397 -
EGR valve is located on connection channel between exhaust pipe and intake pipe. Openness of this valve is
regulated according to input degree of vacuum to control amount of recirculation end gas.
EGR control valve converts control element valve openness control electric signal to vacuum degree signal
required for EGR valve.
Engine management system

Glow plug control system
Glow plug control is integrated in EDC electric control unit and includes two parts: preheating and postheating.
Preheating: Since direct injection diesel engine has good startup performance, preheating is only required when
temperature is lower than +9℃. Cooling water temperature sensor provides accurate temperature signals to the
electric control unit and driver can learn preheating conditions through preheating alarm lamp on the instrument
panel.
Postheating: After engine starts, it enters postheating stage. Postheating can reduce engine noise, improve engine
performance under idling conditions, and reduce hydrocarbon emission. This stage ends when engine rotation
speed reaches 2500rpm.
Engine speed
Glow plug preheating indicator
Coolant temperature ECU

Glow plug relay
Fuse
Glow plug
- 398 -
VII. Circuit diagram

Charging system
Diesel engine With current at the

Keep power on ON or START shift
Fuse
block
Fusible Fusible
piece piece
120A 40A
Refer to the fuse block in

the passenger compartment
Battery Refer to the Connector

power supply
distribution Idle speed
control module
Instrument
Charge cluster
Body ground
Generator
- 399 -

5 2.8L Diesel Engine

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Refine MPV Workshop Manual Engine General

Chapter II Diesel Engine Mechanic System [2.5TCI]

I. Engine exterior view

II. Technical data, size and parameters

Type Standard value Limit value

III. Torque parameters

IV. Common troubleshooting

Phenomenon Possible causes Repair

Phenomenon Possible causes Repair

Balance shaft bearing installation Installation of balance shaft rear

Bearing installation device spacer Removal of right balance rear

Tool (No. and name) Graphic Purpose

Connecting rod small head liner Replacement of connecting rod

Camshaft oil seal installation device Installation of camshaft oil seal

Cylinder head bolt wrench Loosening and tightening of

Valve seat tool pilot Correction of valve seat

Valve seat 45°reamer Correction of valve seat

Tool (No. and name) Graphic Purpose

Valve seat 30°reamer Correction of valve seat

Valve spring compressor Compression of valve spring

Valve stem sealing installation Installation of valve stem seal

Valve guide pipe installation device Removal and installation of valve

Tool (No. and name) Graphic Purpose

Engine oil pressure switch wrench Removal and installation of engine

Fuel injection pump sprocket Removal of fuel injection pump

Section II Engine maintenance

I. Maintenance of lubrication system

Inspection of engine oil

Selection of engine oil

Replacement of engine oil

5. Fill new engine oil by means of open engine oil cover.

6. Fit engine oil cover.

Replacement of engine oil filter

Engine oil filter: 12-16Nm

II. Maintenance of cooling system

Main valve opening pressure:

3. Check that the pressure is maintained at set limit value or above.

1. Use a hydrometer to measure coolant specific

Relation between coolant concentration and specific weight

Recommended anti-freezing fluid

Glycol base (Al water tank)

III. Maintenance of valve system

Inspection and adjustment of valve clearance

2. Check engine timing and idling speed; adjust if

7. If the clearance is not within standard value,

8. Hold adjusting screw with a screw driver so that

IV. Inspection and adjustment of belt

Back for 1-2 circles

3. Rotate crankshaft in normal direction

5. Rotate crankshaft in reverse direction to align

6. Install timing belt upper hood.

Tension adjustment for timing belt “B” Timing

On the top dead

2. Remove access cover.

3. Loosen timing belt “B” tightener pulley

4. Tighten tightener pulley mounting nuts and bolts.

1. Install access cover.

Water pump pulley