midi service manual

Chapter I Outline of vehicle

Section I Summary

The model MP.Midi is a brand new sedan independently developed and designed by BEIJING FOTON MOTOR CO.LTD, which is displayed in the world by its sculptural outlook, smooth and robust line and active visual effect.

It uses the engine, model 4G13S-7L/4G18S-7L, which is characterized by strong power, stable operability, smooth drivability, reliability, durability and easy maintainability

Product classification of the Foton, MP.Midi Maintenance Manuals:

By the classification of model uses: the model Foton MP.Midi is divided in to dual-purpose type and passenger type

Section II Technical parameters of main models

1. Size parameters of main model structures Parameters

Size Passenger type Duo-purpose type

Outer dimension(LWH)(mm) free load 4288/1725/1728 4338/1725/1768

Trunk(cargo space)capacity(m3) 6242800 8243000 Axle base(mm) 269 2695

Front 1420 1420 Wheel base(mm) Rear 1440 1440

Front suspension(mm) 830 830 Rear suspension(mm) 763 813

Drive type FF FF Dynamic displacement and gearbox

pattern 1.3.L/1.6L,5MT 1.3.L/1.6L,5MT

Number of seats 6/7 7 Type of front rear suspension bracket McPherson/vertical arm torsion bar McPherson/vertical arm torsion bar

Drive brake type Front disc/rear drum Front disc/rear drum Steering system type Power steering by rack/pinion Power steering by rack/pinion

2. Vehicle mass parameters Mass parameters Passenger type Duo-purpose type

Full mass (kg) 1290 1320 Full mass state

Front/rear shaft load(kg) 748/542 722/598 Number of seats 2 2 Vehicle mass 1440 1470 Half loaded state Front/rear shaft load(kg) 830/610 804/666 Number of seats 5 5 Full loaded mass 1665 1695 Full loaded state Front/rear shaft load(kg) 883/782 857/838

Max. passengers 7 7 Max. designed load mass(kg) 525 650

Max. designed mass (kg) 1815 1970 Max. designed total mass state

Front/rear shaft load(kg) 873/942 881/1089

3. Parameters of wheel positioning Parameters of front wheel positioning Steering angle of

front wheel Type of product Front axle type Introversion

of master pin

Backward tilt of master

pin

Wheel camber

Toe-in of front wheel

Internal corner

External corner

BJ6438MC6VA-1 BJ6438MC6VA-2 BJ6438MC6VA-P1 BJ6438MC6VA-P2

Steering booster 10830 23030 1530

13 mm (1510)

37 31

BJ6438MC6VA-P1 BJ6438MC6VA-P2

Mechanical steering 10830 130 1530

13 mm (1510)

37 31

Parameters of rear wheel positioning Type of product Main reduction ratio

Wheel camber Toe-in of rear wheel BJ6438MC6VA-1 4.052 BJ6438MC6VA-2 4.333 BJ6438MC6VA-P1 4.052 BJ6438MC6VA-P2 4.333

-12530 -2010 or -1-3mm

4. Mobility and traffic abilityFunctional parameters Passenger type Duo-purpose type Min.turning diameter(m) 5.65 5.65 Min. ground clearance(mm)(free/full load) 156/124 154/121 Approach angle ()(Full load) 16 16 Departure angle()(Full load) 24 22

5. Dynamic and economic parameters Passenger type Duo-purpose type

Functional parameters (4G18S) (4G13S) (4G18S) (4G13S)

Power ratio(w.t-1) 57.5 48.4 56.2 47.3 Moment ratio (N.m.t-1) 103.9 83.7 100.7 81.8

Max.speed(Km/h) 161 154 160 152 Max. gradeability (%) 40 30 40 30

Acceleration time:0-100km/h (s) 15.5 19.3 16.36 19.6 Acceleration time of the direct gear:

80-120Km/h (s) 20.39 24.41 20.39 24.41

Min. steady speed of the direct gear (km/h) 21 20 21 20 Fuel consumption: 90 km/h 6.66 6.51 6.66 6.51

Fuel consumption of integrated operating mode (L/100km) 7.6 7.6 7.6 7.6

Chapter II Engine The vehicles, Model-MP.Midi have been fitted, on demand, with the engine model 4G13S-7L/4G18S-7L produced by Harbin Andong Automobile Engine Manufacturing Corp.Litd. The engine, Model-4G13S-7L/4G18S-7L is the ideal dynamic of the family multi-purpose vehicles and sedans with displacements of 1.3l/1.6l. In comparison with homologue type, the engine is characterized with the compact construction, large power per liter, good fuel economy, high speed and less noise etc., By adopting the electronically controlled fuel injection system, which reduces considerably the harmful constituents in off-gases, the engine is worth of the Green Earth power fully meeting the III of new National Emission Regulations III.

Section I Introduction to engine products

1. Engine diagram

Figure 2.1 Engine assembly outlook

Figure 2.2 Engine left-side outlook

Figure 2.3 Engine right-side outlook

Figure 2.4 Engine front-view outlook

Figure 2.5 Engine rear viewoutlook

II. Engine technical performance and structural parameters Table 2.1 Engine technical performance and structural parameters

Model 4G13S-7L 4G18S-7L

Type L4/16VSOHCMPI Displacement 1299cm3 1584cm3

Cylinder bore 71.0mm 76.0mm

Stroke 4 4

Compression ratio 9.5

Max.power 62.5Kw /6000r/min 74.2Kw /6000r/min

Max.Torque 108N.m / 4500r/min 134N.m / 4500r/min

Min. fuel consumption 272g/Kw.h Rated Speed rpm 6000r/min

Idle 75050r/min Steering Counterclockwise(seen from rear to front)

Ignition sequence 1-3-4-2 Oil pressure 150kpa(750r/min)\54050kpa(2000r/min)

Overall dimension Overall lengthwidthheight=617.8mm613.3mm622.2mm

Net weight 1132kg 1152kg

Fuel Unleaded gasoline over 93#

Use of oil SAE5W-30(in winter, north); SAE15W-40(through year, south or in summer, north) Emissions regulation to meet National 3

Number of cylinders 4 4

Combustion chamber Roof type Roof type

Stroke mm 82 87.3

Valve and drive mechanism SOHC-4 SOHC-4

Cylinder center distance 82 82

Cylinder height 201 201

Central distance between the connecting big/small rods 131

131

Intake valve 8 8 Number of valves

Exhaust valve 8 8

Emissions regulation to meet National 3 National 3

Lubrication system Oil supply under pressure Oil supply under pressure

Fuel supply mode Electric fuel pump, non-return oil system electric fuel pump non-return oil

system

Type of oil pump Cycloidal gear pump. Cycloidal gear pump.

Cooling system Forced water cooling cycle Forced water cooling cycle

Type of water pump Centrifugal, impeller Centrifugal, impeller

III. Characteristic curves of engine

Figure 2.6 Characteristic curves of engine, Model 4G13S-7L

Figure 2.7 Characteristic curves of engine, model 4G18S-7L

IV. Position of engine No.and cylinder No.

e.g:

4G13S Engine Model

Engine no. print area 7L 79A0001 79A0001production serial number 72007 9Septermber A0001Production S/N Identification sign of the engine model

Section II Use and maintenance of engine

I. Use of engine 1. Coolant Checks to see whether the engine coolant is sufficient or not, if insufficient, adds the coolant adequately.

Attention: The cooling system includes the water pump, water pipe and water jacket etc.,.When the engine runs, the cooling system has to be sufficient of the coolant, to ensure the normal operation of engine, otherwise the car will be boiling. The gasoline consumed engine operating under the overheating condition will affect the service life and in serious case, cause the malignant failure such as cylinder score.

2. Oil Checks the level of engine oil. In case of oil shortage, the adding should be made in tiem.

Attention: The oil insufficience will cause the oil pressure of gasoline engine very low, poor lubrication, worsen engine wear and bad cooling, which are easy to come about with the failures and affect the service life of gasoline engine.

3. Fuel grade Fuel uses the unleaded gasoline graded higher than RON93# and 93#.

4. Engine startup When starting the engine, twists the ignition switch key on the Startup position. The engine is activated by thestarter. Once the engine ignited, the key should be released, and the power supply of starter cut off.

Attention: Do not let the starter running more than 5s per each duty time. If the gasoline engine fails to start, try to restart in 10s, otherwise it will damage the starter. If failed to

startup after several attempts, please check the fuel system and electric system, or call on the automobile manufacturer and our service station for maintenance.

5. Idle After the engine started, you should keep it run at idle speed for several minutes for engine preheating.

Attention: The idle emission level of our engine products prior to delivery is strictly limited within the specified range by the national standard. The idle speeds of gasoline engine, models 4G13S-7L/4G18S-7L are set at 75050r/min. The idle mechanism of the gasoline engine delivered with the car has been properly adjusted, there is no need for user to change it. In case of necessary adjustment, you should call on the special maintenance department for assistance. When the emission is tested, the engine should be in warm state, i.e. the water temperature over 80; the oil temperature over6 0 (Idle speed: 75050r/min). The idle speed and emission level are changeable all time. During the usage, the engine should be regularly inspected and adjusted at the testing point.

6. Drive

During the drive in the car, the coolant temperature should be kept at 8090. At the moderate speed, be careful that the oil pressure be 54050kPa.

7. Stopping When the engine is working, especially running at high speed under heavy duty, do not shut down the engine, you should shut down the engine after it has run at the low speed for 5mins instead of doing it immediately.

8. Driving in rainy day or wading When driving on the puddle in rainy day or wading, be sure that the air filter be well sealed, otherwise it will cause the engine cylinder inflowed and the connecting rod etc. damaged.

Attention: The water can not be compressed liquid. After the cylinder inflowed, the connecting rod will bear the pressure of several times under the inertia action of car and bend or break up the connecting rod.

9. Preheating in winter As the temperature in winter is lower, the viscosity of oil increases. For the time being, the lubrication effect of engine is worser than in summer. Hence, the engine after started up can not operate at high speed as well as under heavy duty, instead, you should preheat the engine at idle speed for 10mins and start driving only after increasing the oil and coolant temperatures and lubricating the engine sufficiently.

Attention: When the gasoline engine is driving without adequately lubricated in wintergine, it will cause the parts such as camshaft excessively worn and even, locking.

10. Electric injection system In case of the engine inspection, do not randomly modify the electrical devices or wiring, otherwise it will cause the electric devices overloaded, short-circuited and sparking. When the electric system is inpected, the neg. cable should be disconnected fron the battery terminal. Prior to connect or disconnect the neg.cable, be sure to turn off the ignition switch and lighting switch(If not, it will burn up the semiconductor elements).

II. Regular check and maintenance of engine Table of the regular checkand maintenance of engine

Each item is expressed by the running distance and time (month), and whichever comes first (distance or time) is taken as the check basis.

Maintenance job code: IInspection; RReplacement; CCleaning;

Interval of maintenance(the odometer reading and month, whichever comes first) Month - 6 12 18 24 30 36 42 48 54 60S/C

Odometer reading 1000km 1 10 20 30 40 50 60 70 80 90 100

1 Checks the driving belt of A/C generator to see if there is any crackles, flying debris and wears on the driving belt and ajusts its tightening

I I I I I I I I I I I

2 Checks the ignition cable for any damages I I I I I General conditions of use I I I R I

3 Replaces the engine timing belt Harsh conditions of use R: per 70,000km

4 Checks to see if the vapor control system of crankcase is normal. I I

5 Replaces the spark plug I I R I I R I I R I 6 Replaces the engine coolant R R R R R

General conditions of use I: per 5,000KM 7

Checks the air filter elements for any chocks and damages Harsh conditions of use I: More frequently

General conditions of use R R R R R R R R R R 8 Replaces the air filter elements Harsh conditions of use R: More frequently

General conditions of use R: per 5000KM 9 Oil replacement

API Class. SJ grade

Harsh conditions of use R: per 3001KM

General conditions of use R: per 5002KM 10 Replaces the Oil filter Harsh conditions of use R: per 3003KM

11 Checks the liquid level in the clutch hydraulic reservoir I

12 Checks the engine idle and carbon monoxide I I I I I I I I I I 13 Checks the ignition timing I I I I I 14 Checks the crankcase air hoses I I I I I I I I I I

15 Checks if there is any leakage on the exhaust pipe connectors I I I I I I I I I I

16 Throttle body C C C C C C C C C C 17 Injector C* C* C* C* C* C* C* C* C* C*18 Checks the valve clearance I I I I I I

Note: C* for the cleaning and maintenance of the injection nozzle, it is recommended to use the special cleaning analyzer of injection nozzlecheck once per 3months or per 5000km. the failures such as vapor lock on the nozzle and block etc. are not considered as the quality problems of product, the maintenance of which is charged by the user.

The Use speficiation under the harsh conditions is only applicable to the vehicles used under the harsh conditions.

The harsh conditions of use include the following subjects:

(1) Driving in the dusty areas, or the car often at exposure to the salty air or seawater.

(2) Driving on the uneven road, puddle or hill road.

(3) Driving in the cold areas.

(4) The engine runs at idle for longtime or drives in short-distance in cold season

(5) Uses frequently the brake and often makes panic stops.

(6) Used as the tractor-trailer.

(7) Used as the taxi or rent car.

(8) At the temperature more than 32, the driving time in the city of heavy traffic exceeds 50% of the total driving time.

(9) At the temperature more than 30, the driving time at speed of 120km/h or higher exceeds 50% of the total driving time.

(10) Overloaded driving

III. Internal inspection of engine 1. Checks the driving belt of A/C generator to see if there are anycrackles, flying debris and wears and adjusts its tightening.

The driving belt condition of A/C generator: checks if there are anycrackles, flying debris and wears while turning the driving belt of A/C generato.

The driving belt tightening of the A/C generator

Mode of bolt structure adjustment

(1) Unscrews the nuts of A/C generator bearing bolt;

(2) Unscrews the locking nut of belt tensioner;

(3) Turns the adjusting bolt to adjust the belt tightening

(4) Tightening locking nut.

(5) Tightens the nut of A/C generator bearing bolt

(6) Checks the deflection of driving belt, re-adjusts it if necessary.

Regulating bolt

Locking nut

Specifications Check method

Check time When the new belt is fitted On inspection

Driving belt deflection of A/C generator

(under acting force of 100N) 5.6~6.7(mm) 8.3~10.4(mm)

Driving belttension of A/C generator 785~981(N) 392~588(N)

2. Checks any of damage on the ignition cable

(1) Checks the ignition cable and rubber lid, incl. the installing condition to see if there are any damages or fragility.

(2) Checks if the ignition cable, spark plugs and ignition coil joints are condaminated by any filths and dirt deposit etc.

(3) The dirts if any should be cleaned outany damages shoud necesit the replacement. 3. Replaces the timing belt of engine

Under the general conditions of use, one piece replaced per 80,000km; Under rigorous conditions, one piece replaced per 70,000km .

4. Checks if the vapor control system of crankcaseis normal.

(1) Checks if there are any crackles or damages on the channeling gas hose.

(2) If necessary, the interior of the channeling gas hose should be cleaned out.

Check of the forced ventilation device of crankcase.

Removes the air hose from the forced ventilation valve of crankcase

Removes the forced ventilation valve of crankcase under the rocker arm cover.

Refixes the forced ventilation valve of crankcase on the air hose.

Starts up the engine and keeps it run at idle speed.

Fingers at the openture of the forced ventilation valve of crankcase to prove if any vaccum inside the intake manifold can be felt.

Note:

Now, the plunger in the forced ventilation valve crankcase will move back and forth.

If no vaccum is felt, the forced ventilation valve of crankcase should be cleaned or replaced.

Forced vent valve of camshaft case

Forced vent valve of camshaft case

Check of the PCV valve

Inserts, in general, a thin rod shown as in Figure (mounting side of the rocker chamber cover) into the forced ventilation valve of crankcase, and moves it around to confirm if the plunger is moving.

If the plunger is immobile, it means there is a chock inside the forced ventilation valve of crankcase. In such case, the valve should be cleaned or replaced.

5. Replacement of spark plug

The replacement is to be made each time per 30,000km. In case of replacement, remember that the model is BKR5E-11 or K7RF-11 with the thread M141.25 6. Replacement of engine coolant (1) Shuts down the engine after it has been fully preheated.

(2) Adds the detergent for cleaning the cooling system of engine into the engine coolant trough the radiator filler, then starts up the engine.

(3) Removes the drainage cover of radiator at the cold state of engine, and drains the coolant out.

(4) Adds the clean water into the cooling system via the filler of radiator, then cleans the cooling system. After the cooling system cleaned out, tightens the drainage cover of radiator.

(5) Determines, depending on the conditions of use, the amount of coolant of long service life, antifreeze or antirust agent.

Attention: Uses neither alcohol or methanol antifreezer, nor the engine coolant mixed with the alcohol or methanol antifreezer. Use of uncorrect antifreezer may cause thecorrosion of aluminum parts. (6) Slowly poors the the engine coolant through the filler of radiator into the radiator until it is fully filled, while filling reserve tank with the engine coolant until the level reaches the mark lime FULL(alternative dependint the availability of car).

(7) Fixes tightly the radiator lid.

(8) Starts up the engine and lets it run unti the thermostat turns on(touches by hands the radiator hose to verify if the hot water is flowing).

(9) After the thermostat is turned on, keeps the engine run idle at the high speed for several times, then shuts down the engine.

(10) After the engine cooled, fills the reserve tank with the engine coolant as long as the level reaches the FULL line. If the level is still lower, please repeat the procedure from (9).

Drainage valve of cylinder

Attention: Do not open the coolant tank lid or radiator lid when the engine remains in hot state. The cooling system in the hot state is under a certain pressure. If opening the lid, the hot coolant will spray out and scald the people around. Drains the engine coolant through thedrainage plug of cylinder.

1) Removes the drainage plug, then radiator lid, and drains out the coolant from the engine.

2) Removes the drainage plug of cylinder and drains the engine coolant.

3) Removes the reserve tank and drains out the engine coolant (alternative dependint the availability of car)

4) After the engine coolant drained out, fills in the clean water through the radiator lid to clean up the pipleline of engine coolant.

5) Applies the specified sealant on the drainage plug thread of cylinder and thghtens as per the moment as specified.

6) Firmly tightens the drainage plug of radiator.

7) Fits the reserve tank (alternative dependint the availability of car).

8) Removes the bleed bolt and replaces the seal washer (alternative dependint the availability of engine).

9) Fills the radiator with the engine coolant until it overflows from the bleed bolt. Then closes the bleed bolt (alternative dependint the availability of engine)

10) Slowly poors the engine coolant through the filler of radiator into the radiator until it is filled up, while filling the reserve tank with the engine coolant unti the level is up to the FULL line (alternative dependint the availability of car).

11) Fits tightly the radiator lid.

12) Starts up the engine and lets it run unti the thermostat turns on(touches by hands the radiator hose to verify if the hot water is flowing).

13) After the thermostat is turned on, keeps the engine run idle at the high speed for several times, then shuts down the engine 14) After the engine cooled, fills the reserve tank with the engine coolant as long as the level reaches the FULL line. If the level is still lower, please repeat the procedure from (13).

7. Checks if there are any blocks and damages on the air filter elements.

(1) Checks if there any blocks and damages on the filter elements

(2) Removes the dirt deposit on the filter elements as per the method as below.

Tpas one side of filter elements. Blows the compressed air from the internal side of filter elements. (3) Scraps out the dirts in the air filter.

(4) For the gasoline consumed vehicles, places, while installing, the dirty part of filter elements at intake port of channeling gas (prevent the greasy dirt from spreading) if the old filter elements are intended to be reused.

8. Replacement of air filter elements.

(1) Removes the air filter cover and filter elements. Scraps the filth in the filter.

(2) Fits the new air filter elements.

Procedure of replacement: In the process of use, the air filter elements will get dirty and dusty, which significantly reduces the filtering effect. In such time, they should be replaced by the new ones.

Releases the bucle of the air filler cap. Removes the air filter elements and fits the new ones. Be sure to keep the air filler cap fully closed when holding it down. 9. Oil replacement. (1) Removes the filler lid set on the rocker chamber cover of engine.

(2) Removes the oil drain plug on the engineoil sump and drains out the oil.

(3) Renews the spacer of drainage bolt.

(4) Tightens the drainage bolt.

(5) Poors in the renewed oil through the filler into the crankcase.

(6) Pulls out the dipstick from the engine, and checks if the oil level remains between the marks MAX and MIN.

(7) Fitss the filler cap.

(8) Checks the oil level after the road test.

Selection of oil:

SAE5W-30(in winter, north), SAE15W-40(through year, south or in summer, north)

Note: The quality class (API): SJ or higher than SJ. 10. Replacement of oil filter (1) Starts up the engine and lets it preheating until the temperature of engine coolant is up to 80-90. (2) Removes the filler cap on the rocker chamber cover.

(3) Removes the oil drain plug on the oil sump to drain out the oil. Be careful! The oil temperature could be very high.

(4) Removes the oil filter of engine with special tools as shonw in Figure.below.

(5) Cleans out the fitting side of filter bracket.

(6) Applies a few of oil on the O-ring of the oil filter.

(7) Once the O-ring of oil filter touches the flange, please use the special tool shown in Figure to tighten it up to the specified moment.

(8) Fits the oil drain plug on the oil sump and poors in the oil through the filler on the rocker chamber cover.

(9) Runs the engine at high speed for 2-3 times, then checks the fitting side of filter and be sure no oil leakage is allowed.

11. Checks the idle of engine and the content of carbon monoxide. (1) Prior to the check and adjustment, get the engine ready under the following conditions:

Temperature of engine coolant: 80-95 All car lamps, electric cooling fan and accessories: OFF Gearbox: N-gear

(2) When making check on the ignition timing, adjusts it if necessary.

(3) Fits the tachometer after the ignition switch turned on the position OFF.

(4) Starts up the engine and let it run at idle speed.

(5) Keeps the engine running at idle for 2 mins.

(6) Checks the idle and accesses the reading of idle according to the tachometer.

Remark: The idle control system (ISC) will adjust the idle automatically.

(7) If there is any deviation from the standard value, please refer to the maintenance manual for the check of MPI elements.

(8) Fits the tester of carbon monoxide.

(9) Keeps the engine running at 2000-3000r/min for more than 10s.

(10) Checks the mixture of idle.

O-ring

Or marketed tools

12. Check of the ignition timing (1) Prior to the check and adjustment, get the engine ready under the following conditions:

Temperature of engine coolant: 80-90 All car lamps, electric cooling fan and accessories: OFF Gearbox: N-gear

(2) Inserts a paper clip along the wiring side into the connector between the primary side of ignition coil and the tachometer.

(3) Connects a tachometer for the primary voltage to the paper clip.

(4) Fits the timing lamp.

(5) Starts up the engine and let it run at idle speed.

(6) Checks if the engine idle is within the range of standard value.

13. Check of the air hose of crankcase (1) In case of need, checks with reflector the full peripheryand length.

(2) Checks if all clippers are well tightened, whether there are any leakages on the joints.

(3) If there are any clear signs of deterioration or damage, the replacement should be made at once.

14. Checks the valve clearance.

(1) Starts up the engine and preheats the engine until the coolant temperature is up to 80-90. (2) In order to facilitate inspectio, removes all spark plugs from the cylinder head.

(3) Removes the cover of rocker chamber.

Timing indication panel

Side of timing belt

Identification sign

Notch

(4) Turns clockwise the crankshaft until the notch of pulley aligns with the markT on the timing dashboard.

(5) Moves up and down the rocker arms of the 1st and 4th cylinders to be sure that the pistons of both cylinders are located at the top dead center of compression stroke. If there are the clearances between the rocker arms of both intake and exhaust valves, the pistons in the cylinder correspongding to those rocker arms should be positioned in the top dead center of the compression stroke

(6) When the pistion of the cylinder No.1 is sited at the top dead center of compression stroke, The valve clearance can be checked and adjusted with the rocker arm indicated by the white arrowand when the pistion of the cylinder No.4 is sited at the top dead center of compression stroke, the valve clearance can be checked and adjusted with the rocker arm indicated by the solid arrow;

(7) Check of valve clearance

If the valve clearance is non-conform to the specified requirements, you may unscrew the locking nut of rocker arm, and turns the governing screw while measuring with a feeler gauge the clearance and makes the adjustment.

Standard values: Ambient temperature(C) Valve 0~15 15~25 25~40

Engine in hot state

Intake valve 0.120.03mm 0.140.03mm 0.160.03mm 0.20mm Exhaust valve 0.170.03mm 0.190.03mm 0.210.03mm 0.25mm

Note: The variation of the valve clearance against the external temperature: every 1 degree rise in temperature , the valve clearance is added by 0.0018mm.

(8) Fixes the governing screw with the screwdriver to prevent it from turning, tightens the locking nut up to the specified moment.

(9) Turn s the crankshaft by 360, and aligns the notches on the crankshaft pulley with the markTon the timing dashboard.

(10) Repeats the procedures (7) and (8) and adjusts the clearances of other valves.

(11) Fits the cover of rocker chamber.

(12) Fits the spark plugs and tightens them as per the specified moment.

15. Checks if there are any leakage on the exhaust pipe joint. (1) Be sure that the exhaust pipe cause no interferences on any parts of car.

(2) Checks if the exhaust pipe has been damaged due to the impact by the gravel etc.

(3) Starts up the engine, to check if there is any leakage on the exhaust pipe joint.

16 Cleaning of the throttle assembly In case where the following cases occur in your car, you should clean the throttle assembly:

(1) After completed the travel of 10,000kms or 6 months, whichever comes the first.

(2) When the following problems occur to your car: insteady idle, throttle valve lock, high idle and low idle.

The portion to be cleaned as below:

Ball head of stepping motor Taper hole matching with the ball head Throttle valve plate The inner wall of the main chanel in the throttle valve 17. Check of water pump leakage

During the use of water pump, it is normal to see a few of water from the drainage hole of water pump. When the water pump is mechanically sealed, the mechanical seal needs the cooling waterto lubricate the sliding surface. Hence, in normal closing state, the coolant will be drained out in form of steam or mist. In view of the water pump structure, the coolant drained out needs to be discharged from the drain and steam holes.

Causes of leakage 1) The most cases of leakage are temporary instead of permanent. Such leakage should be originated from the drain hole of water pump or the cooling water form the steam hole.

2) In addition, in terms of the water pump structure (mechanical seal), the temporary leakage will not reduce the cooling performance (overheating etc.)(less or more cooling water etc.).

3) The after sales service will judge whether the water pump is qualified according to the fowling methods and prevent the misjudgment of water pump leakageIn case of true leakage, replaces the water pump.

Whether the water pump leaks or not will be determined as per the following procedures:

Drain hole

IV. Tightening moment of main bolts of engine

Items Nm

Intake manifold and exhaust manifold

Intake manifold stay bolt (M8) 15~20 Intake manifold stay bolt (M10) 27~34 Intake manifold bolt 15~20 Exhaust manifold stay bolt (M8) 15~20 Exhaust manifold stay bolt (M10) 27~33 Exhaust manifold housing bolt 27~33 Bolts of engine lugs 15~20 Rocker arm, rocker arm shaft and camshaft Rocker chamber cover bolt 3~4

Leakage inspection of water pump

Identification of water leakage traces. Visually confirms the leakage traces of drain hole, steam hole and fitting surface.

Hydraulic pressure testing Pressure increased with the tester of the radiator cover Pressure1000kpa Pressurizing time20min

Visually confirms whether there is any water leakage

Turbine driver test Engine heater Idle turbine driver20min

Visually confirms whether there is any water leakage

Continues to use after wiping out the water traces(normal)

Pump replacement Normal

NON

YES

YES

NON

YES

NON

Items Nm assembly bolt, rocker arm shaft 28~34 governing screw 8~10 Cylinder head and valves

Cylinder headbolt

Tightens up to 49Nm Releases 202 90 to 94 90 to 94

Oil pump and oil sump Gearbox bracket bolt(1020-7T) 42~54 Gearbox bracket bolt(840-7T) 19~27 Oil drain plug 34~44 Oil sump bolt(M6) 6~8 Oil sump bolt(M8) 22~25 Oil filter 12~16 Front cover bolt 12~15 Connecting rod Connecting rod nut 16.72.090 to 94 Crankshaft and cylinder body Flywheel bolt 127~137 Backboard bolt 8~12 Flywheel shell bolt 8~12 Rear seal shell bolt 10~12 Bearing cap bolt 34.32.030 to 34 Engine and vehicle interface Fitting bolts, exhaust manifold and exhaust front tube 40~50 Fitting nuts, engine right bracket and vehicle frame 575 A/C generator and ignition system Pulley bolt, water pump 7~11 A/C generator stay bolt (side of the A/C generator) 20~25 Master-pin bolt, A/C generator 34~54 Dipstick guided-tube bolt 19~28 crankshaft bolt M141.5 176~186 Spark plug 20~29 A/C generator nut 34~54 Ignition coil 8~12 Camshaft position sensor bolt 7.5~8.5 Camshaft position sensor, bracket bolt 12~15 Camshaft position sensor, tooth plate bolt 17~26 Timing belt Fitting bolt, timing belt shell, 10~12 Fitting bolt, timing belt tensioner 20~27 Fitting bolt, crankshaft, winkel-sensor (speed sensor) 6~10

Items Nm Nut and bolt, engine right bracket (M10) 30~42 Fitting bolt, engine right bracket (M8) 17~25 Fuel injection and control system Sensor bolt, air intake temperature pressure 4~6 Fitting bolt, canister solenoid bracket 8~10 Fitting bolt, throttle assembly 15~22 Fitting bolt, oil rail assembly 10~13 Fitting bolt, , knock sensor 15~25 Water pump and intake pipe Water thermostat 10~12 Joint, water pipe 17~26 Temperature sensor, cooling water 20~40 thermostat shell bolt 19~28 Intake pipe bolt 10~15 water pump bolt 12~15

V. Main failures of engine and troubleshooting 5.1 Difficult start-up of engine Failure phenomenon and causes Troubleshooting

1. The terminal connection of battery loosens or insufficient power.

Tightens or unscrews

2. Some parts of circuit are disconnected.

Inspection and maintenance The starter doent run

3. The starter is damaged Repair or replace 1. The ignition timing is not

well adjusted Adjustment

2. Poor grounding Repair 3. The ignition coil is damaged. Replacement 4. Inappropriate clearance

between the spark plugs or burnt out.

Adjustment or replacement The spark plug fails to strike

5. Failures in the electronic ignition system.

Repair or replace

1. Insufficient supply of gasoline pump

Repair or replace The oil supply system fails to work 2. The gasoline hose and filter

are jammed. Cleaning

1. The cylinder pads are broken Replacement 2. The valve clearance is poorly

adjusted or damaged. Adjustment, repair or replace

3. The intake manifold loosens and the air flows in.

Tightening The compression pressure of cylinder weakens.

4. The pistons, piston rings and cylinder are worn.

Repair or replace

5.2 Insufficient power during the running Failure phenomenon and causes Troubleshooting

The throttle pedal and the throttle valve are inappropriately adjusted.

Adjustment

The compression pressure of valve decreases

1. Checks the valves, spark plugs and valve pads for any leakages 2. Cylinder grinding

The ignition timing is inaccurate. Adjustment Insufficient supply of gasoline Adjustment or reparation Insufficiency of air intake Checks the intake system Air exhaust jam Checks the air exhaust system and

cleans out the carbon deposit

Insufficient rate during the running.

Inappropriate clearance between the spark plugs or damage

Adjustment or replacement

5.3 Piston clicks in the engine Failure phenomenon and causes Troubleshooting

Bearing, camshaft cam and rocker arm worn

Replacement

Crankshaft, connecting rod shaft and piston pins seriously worn.

Repair or replace

Piston ring damaged Replacement Inappropriate valve clearance Adjustment

There are the pistion clicks heard from the engine.

Stop clearing of crankshaft too large.

Adjustment

5.4 Engine overheated Failure phenomenon and causes Troubleshooting

Ignition timing not well adjusted Adjustment Inappropriate clearance between the spark plugs or carbon deposit

Cleaning or adjustment

The intake manifold loosens and the exhaust manifold blocked

Tightening or cleaning

Insufficient tension of fan tape Adjustment Insufficient coolant or water pipe blocked.

Adding orcleaning

Inappropriate clearance of water pump or damaged

Repair or Replace

Insufficient oil supply Adding Oil pipeline blocked or oil pump damaged

Cleaning or replacement

Cylinder pad damaged Replacement Clutch sliding Repair or Replace

Engine overheated

The radiator is blocked by scald deposit.

Cleaning or replacement

5.5 Excessive oil consumption

Failure phenomenon and causes Rroubleshooting Oil seal of valve duct worn or damaged

Replacement

Oil ring worn or damaged Replacement Excessive oil consumption The interface of piston ring is not staggered as per provision.

Adjustment

Failure phenomenon and causes Rroubleshooting Cylinder pad damaged Replacement Valve and valve duct worn Replacement

Excessive oil consumption Engine overheated, internal pressure increased, a part of lubricant is discharged through the vent.

Checks the relevant parts and exclude them therefrom.

5.6 Noise in the clutch S/N Failure phenomenon and causes Troubleshooting

1 Release bearing worn or damaged Replacement 2 Output shaft bearing damaged Replacement 3 Clutch hub loosened Repair 4 Crackles existing on the clutchplaten Replacement 5 Platen and diaphragm spring loosened Maintenance or replacement 6 Clutch friction plate soaked with greasy stains Cleaning or replacement 7 Glue stick or spring of clutch damping broken Replacement

VI. Engine sealed for safekeeping and seal removal 6.1 Storage of engine oil seal

1. Drains out the coolant of cylinder body.

2. Wipes out the apparent surface with the cleaning gasoline.

3. Wraps or seals, with plugs, the engine inlet port, In/outlet port of water pipes and all sensors etc.

4. Puts the engine into the packing case.

6.2 Seal removal of engine

1. Cleans out the outer grease of engine.

2. Adds the oil.

3. Adds the coolant.

4. Removes all plugs.

VII. Engine maintenance 7.1 Maintenance rules

1) Prepares the spare parts kit and part rack used for the detached, disassembled parts. They have to be disposed in order and marked if necessary to prevent the disorder and misplacement.

2) Be very careful when overhauling the aluminum alloy parts so as to prevent the damage on the process surface.

3) Gets ready with adequate auxiliary material so that they are readily accessible during the overhaul.

4) Where there are the standard tightening moments imposed for the bolts and other fasteners, the tightening has to be made with the special tool as per the specifieid values.

5) After the overhaul, the deposable parts should be rejected and replaced by new ones.

6) Uses the correct disassemble tools for assembly and disassembly.

7) Refers the maintenance manual during the work.

8) In case of any technique problems difficult to resolve encountered during the overhaul, it is recommended to consult with our Products Sale Department.

7.2 Materials necessary for the overhaul

The materials listed in the table below are indispensable for the overhaul of the engine. Therefore, gets them prepared for readily accessible all times. In addition, the specified type of washing liquid and lubricant should be applied as far as possible.

Table of the auxiliary materials for DA Engine:

S/N Name Inteded use Specification and grade

1 Oil Oil filling, oil for assembly Mobil Super 9900 or Esso Superflo SJ/CF 5W30

2 Silica gel Oil pump, water pump, oil sump LT5699

3 Sealant Oil pressure switch, water drain screw plug, flywheel bolt LT243

4 Sealant Water temperature sensor LT648 5 Silica gel Rear seal shell, crankshaft LT5699 6 Gasoline Unleaded gasoline 93# and higher 7 Sealant Stud bolt LT271

Table of the auxiliary materials for gearbox:

S/N AOS materials and Model Actually used materials and

model Assembly position

1 Lubricant Shift fork 2 Lubricant

Mobilith SHC220 or Spartan syn EP 220 Release bearing

3 Lubricant Input shaft oil seal 4 Gear oil Gearbox assembly 5 Lubricant

Mobil HD80W-90 or Esso Gear Oil GX 80W-90

Shifting block 6 Sealant TB1501 LT480 Air respirator 7 Anti-rust oil Mobil Lama LT or Rust-Ban330 Input shaft 8 Gear oil Input shaft needle bearing 9 Gear oil

Mobil HD80W-90 or Esso Gear Oil GX 80W-90 Input shaft needle bearing

10 Sealant TB1303 LT243 Differentialbolt 11 Sealant TB1216 LT5699 Gearbox shell joint surface

12 Gear oil Mobil HD80W-90 or Esso Gear Oil GX 80W-90 Control shaft and shifting lever

13 Sealant TB1216 LT5699 Control box sub-assembly

Table of the auxiliary materials for cylinder head assembly: S/N Actually used materials and model Assembly position

1 Oil Mobil Super 9900 or Esso Superflo SJ/CF 5W30 Valve head

2 Oil Mobil Super 9900 or Esso Superflo SJ/CF 5W30 Camshaft, rocker arm, rocker arm shaft

3 Sealant TB1386D LT271 Stud bolt

4 Oil Mobil Super 9900 or Esso Superflo SJ/CF 5W30 Camshaft oil seal

S/N Actually used materials and model Assembly position

5 Sealant LT962T Spark plug guide bush, cylinder body/cylinder head Bowled expansion plug, filler neck

7.3 Signs of the lubricant, sealant and binder

-------------------When the lubricant has no trade mark(lable), it means multi-puropose lubricant

------------------Sealant and adhesive

-----------------Brake fluid, automatic gearbox fluid or air compression oil

--------------------Engine or gear oil

7.4 Engine inspection tools Tools Number Name Intended use

MB990767 Terminal fork clip

When unscrewing or tightening the bolt(clamps the sprocket wheel of camshaft with the tool MD998715)

MD998718 Setting tool for the rear oil seal of crankshaft For fitting of the rear oil seal of crankshaft

MD998054 Oil pressure switch wrench Removal and fitting of oil pressure switch

MD998304 Setting tool for the front oil seal of crankshaft For fitting of the front oil seal of crankshaft

MD998305 Front oil seal guide bush of crankshaft

Guided installation for the fornt oil seal of crankshaft

Tools Number Name Intended use

MD998713 Setting tools for the camshaft oil seal Fitting of the camshaft oil seal

MD998719 or MD998754 Pins

When unscrewing or tightening the bolt(clamps the sprocket wheel of camshaft with the tool MD990767)

MD998727 Disassemble tool for the oil sump Removal of the oil sump

MD998772 Valve spring compressor Compression valve spring

MD991671 Setting tool for the oil seal of valve rod Fitting for the oil seal of valve rod

MD998780 Positioning tool of the piston pin Removal and fitting of the piston pin

MB991659 Guide bushD Guide bush for the removal and press-fitting of the piston pin.

MD998735 Compressor of valve spring Compression of valve spring

MD998781 Flywheel stopper Locks the flywheel on the fixed position

MB991653 Wrench for the cylinder head bolts Removal and fitting for the cylinder head bolts

Section III Disassembly of engine

I. Specifications of maintenance

Items Standard value Limit values Camshaft

Air intake 37.298 36.8 Camshaft height in mm

Air exhaust 37.161 36.66 Diameter of the camshaft journal in mm 44.92544.94 Cylinder head and valve Surface plainness of the cylinder pad in mm Lower than 0.03 0.1 Total thickness of the cylinder head in mm 119.9120.1

Intake valve 1.35 0.85 Thickness of valve edge in mm Exhaust valve 1.85 1.35 Diameter of valve rod in mm 5.5

Air intake 0.020~0.036 0.1 Clearance between the valve rod and valve duct in mm Air exhaust 0.030~0.045 0.15 Coneangle of valve 45~45.5

Intake valve 53.21 53.71 Proturding of the valve rod in mm Exhaust valve 54.1 54.6

Intake valve 111.56 111.06 Total length of the valve in mm Exhaust valve 114.71 114.21

Free height of the valve spring in mm 50.87 50.37

216/44.2 Load/fitting height of the valve spring in N/mm

588/34.7 verticality of the valve spring Less than 2 4 Contact width of the valve seat in mm 0.9~1.3 Valve duct I/D in mm 5.5 Protruding of the valve duct in mm 23

Extra.0.05 10.605~10.615 Extra.0.25 10.805~10.815 Aperture of the valve duct for oversized cylinder head, in mm Extra.0.50 11.055~11.065 Extra.0.3 28.425~28.445

Air intake Extra.0.6 28.725~28.745 Extra.0.3 26.425~26.445

4G13S-7L Air exhaust

Extra.0.6 26.725~26.745 Extra.0.3 30.425~30.445

4G18S-7L Air intake Extra.0.6 30.725~30.745 Extra.0.3 28.425~28.445

Hole diameter of the housing washer for the oversized valve, in mm

Air exhaust Extra.0.6 28.725~28.745

Oil pump and oil sump Tooth top clearance of the oil pump, in mm 0.06~0.18 Clearance of the oil pump, inmm 0.04~0.11 Clearance of the oil pump shell, in mm 0.100.18 0.35

Item Standard value Limit value Pistons and connecting rod

4G13S-7L 71 Reference O/D of the pistons, in mm 4G18S-7L 76

1st ring 0.03~0.07 0.1 Lateral clearance of the piston ring, in mm 2nd ring 0.02~0.06 0.1

1st ring 0.20~0.35 0.8 2nd ring 0.35~0.50 0.8

4G13S-7L 0.20~0.50 1.0 Opening clearing of the piston ring, in mm

Oil ring 4G18S-7L 0.10~0.40 1.0

O/D of the piston pin, in mm 18.0 Press-fitting load of the piston pin(at the room temperature) N 4900~14700

Oil clearance of the crank pin(clearance of the connecting rod journal), in mm 0.02~0.04 0.1

Clearance of the large head of connecting rod, in mm 0.10~0.25 0.4 Crankshaft and cylinder body Axial clearance of the crankshaft, in mm 0.05~0.18 0.25 Main journal diameter of crankshaft, in mm 48.0 Journal diameter of connecting rod, in mm 42.0 Main journal clearance of crankshaft, in mm 0.02~0.04 0.1

Surface plainness of the cylinder body spacer, in mm Lower than 0.03 0.1

Overall height of cylinder body, in mm 256 Cylindricity of cylinder body, in mm 0.01

4G13S-7L 71.0 Reference I/D of the cylinder body, in mm 4G18S-7L 76.0 Clearance of the pistons with the cylinder, in mm 0.02~0.04

II. Removal and breakdown procedure for each part Removes firstly the starter, clutch and gearbox from the engine.The order of breakdown is shown as below:

2.1 A/C generator and ignition system

Removal and installation procedures

Removal procedure:

1. Dipstick 9. Crankshaftpulley

2. Dipstick duct 10. Spark plug cable assembly No.1

3. O-RING 11. Spark plug cable assembly No.3

4. Timing belt 12. Spark plug

5. Water pumppulley 13. Camshaft position sensor

6. A/C generator bracket A 14. CPS bracket

7. A/C generator 15. CPS tooth plate

AB 8. Pulley bolts of crankshaft 16. Ignition coil asssembly

Essentials of the removal operation:

A Removal of the crankshaft bolts. Uses the special tool shown in Figure to lock up the flywheel or drive plate on the relevant places, then unscrews the crankshaft bolts.

Essentials for the installation operation

A CPS Bracket installation

Shown as in Figure., applies the field-shaping curl spacer in thickness of 3mm (FIPG).

Special sealant: LT5699

B Installation of the crankshaft bolt. Uses the special tool shown in figure to lock up the flywheel or drive plate on the relevant position, then tightens the crankshaft bolts

2.2 Timing belt


Removal procedure

1.Timing belt upper cover B A 7.Camshaft timing gear bolt

2. Timing belt lower cover 8.Camshaft timing gear

A C 3. Timing belt 9.Engine bracket

B 4. Tensioner spring

B 5. Timing belt tensioner

6. Crankshaft timing gear assembly

Essentials for the removal operation:

A Removal of the timing belt /tensioner spring/timing belt tensioner:

(1) Clamps the entended end of the tensioner spring with the pliers, removes it from the stopping block of oil pump shell, then removes the tensioner spring.

(2) Removes the timing belt tensioner.

(3) If the timing belt is intened to be reused, draws an arrow with the chalk on the belt to show the turning direction prior to the removal. This will ensure the correct installation of timing belt when it is reused.

B Removal of the timing gear bolt of camshaft

(1) Uses the special tool shown in figure to lock up the timing gear of camshaft on the relevant position.

(2) Unscrews the timing gear bolts of camshaft.

Essentials for installation operation:

A Installation of the timing gear bolts of camshaft

(1) Uses the special tool shown in Figure to lock up the timing gear of camshaft on the relevant position.

(2) Tightens the timing gear of camshaft up to the specified moment.

B Installation of the timing belt tensioner /tensioner spring.

(1) Locks up the timing belt tensioner on the position shown in Figure

(2) Hooks the one extended end of tensioner spring on the clevis part of the timing belt tensioner and fits the tensioner on the oil pump shell.

(3) Clamps the other extended end of tensioner spring and hooks it on the lug of oil pump shell shown as in Figure

(4) Removes the timing belt tensioner as shown in figure and tightens the belt in time.

C Installation of the timing belt

(1) Aligs the timing mark on the timing gear of camshaft with that on the cylinder head.

Tensionner ofthe timing belt

(2) Aligs the timing mark on the timing gear of camshaft with that on the front shell.

(3) Keeps the tension side of timing belt tightened, and fits orderly, the timing belt into the timing gear of crankshaft and tensioner pulley.

(4) Unscrews the fitting bolts of tensioner pulley by the turn of 1/41/2, enabling the tension effect of tensioner springto act on the timing belt.

(5) Turns the crankshaft for two cycles in the normal direction of rotation (clockwise) to check if the timing marks is properly aligned.

Attention: by this method, the tension effect acts evenly on the timing belt by the driving

Timing gear of the camshaft

Belt pulley of tensionner

Timing gear ofthe crankhaft

moment of the crankshaft. The crankshaft has to be turn as per the above-said direction instead of turning counterclockwise the crankshaft.

(6) Tightens the fixing bolts of tensioner pulley.

2.3 Fuel control system


1. Engine sub-assembly 2. Throttle body assembly

3. Throttle spacer 4. Bolted spacer

5. Bolted spacer 6. Harness bracket

7. Flange bolt A 8. Oil rail assembly

Essentials for installation operation

A Installation of oil rail assembly

(1) Prior to the injector installation, a layer of the clean oil should be applied on the surface of the O-rubber ring for easy installation.

(2) Be careful not to damage the O-ring when fitting the injector.

(3) Fixes up the 8 with the bolt 5 on the intake manifold 1.

2.4 Water pump and cooling water hose


1. Cooling waterhose 7. Thermostat shell

2. Cooling waterhose 8. Thermostat spacer

E 3. Water temperaturesensor B 9. Water inlet pipe

D 4. Water thermostat B 10. O-RING

5. Water inlet pipe joint B 11. O-RING

C 6. Thermostat A12. Water pump essentials for installation operation

A Installation of water pump

Applies the 3mm field-shaping space (FIPG) on the mounting surface.

Specified sealant: LT5699

B Installation of O-ring/water inlet pipe

Replaces the O-ring of water inlet pipe with a new one, then applies the coolant on the O-ring, so that it can be easily inserted in to the shells of water pump and thermostat.

Attention: 1. Be sure not to apply the engine oil or other greasy substances on the O-ring. 2. The water pipe behind the thermostat shell has to be firmly fitted. C Installation of thermostat.

When fitting up the thermostat, the highest position of the beat vavle should be used.

D Installation of water thermostat.

If the water thermostat is intended to be reused, the specified coolant should be applied on its threads.


D Installation of water temperature sensor

If the water temperature sensor is intended to be reused, the specified coolant should be applied on its threads.


2.5 Intake manifold and exhaust manifold


Removal procedure

1. Engine sub-assembly 7. Intake manifold bracket

2. Intake manifold 8. Bolted spacer

3. Intake manifold spacer 9. Bolted spacer

4. Bolted spacer 10. Engine lugs

5. Nut 11. Air intake temperature pressure sensor

6. Spring spacer 12. Bolted spacer

13. Bolted spacer 14. Vacuum booster joint

15. Bolt spacer assembly 16. Canister control valve bracket

17. Canister control valve 18. Exhaust manifold spacer

19. Exhaust manifold 20. Flat spacer

21. Nut 22. Flat spacer

23. Nut 24. Oxygen sensor

25. Thermal shield of air exhaust 26. Flange bolt

27. Bolted spacer

2.6 Rocker arm and camshaft


Removal procedure

1. Air hoses C 11. Rocker arm A

2. Oilfiller cap 12. Rocker arm B

3. PCV VALVE A 13. Rocker arm shaft

4. PCV spacer B 14. Governing screw

5. Rocker chamber cover 15. Adjusting nut

6. Rocker chamber cover pad 16. Rocker arm C

D 7. Oil seal B 17. Rocker arm shaft

8. Oil seal A 18. Governing screw

C 9. Rocker arm and rocker arm shaft assembly(air intake) 19. Adjusting nut

C10. Rocker arm and rocker arm shaft assembly(air exhaust) 20. Camshaft


A Installation of governing screw.

Places the screw into the rocker arm for a while. Puts it inside and keeps the the bottom of screw in line with falling edge of rocker arm or slightly protruding (less than 1mm)).

B Installation of rocker arm shaft

(1) Places the large inclined plane toward the side of timing belt.

Note: there are 8 oil holes on the rocker arm shaft of air intake valve.

(2) Faces the oil holes side of rocker arm shaft on the cylinder head.

C Installation of rocker arm/rocker arm shaft assembly

When assembling the rocker arm and rocker arm shaft, attentions should be paid on the identification sign. Then, fits this assembly on the cylinder head.

D Installation of camshaft oil seal

Drives the oil seal into the cylinder head with the tool shown in Figure

Side of the timing belt

Identification sign

2.7 Cylinder head and valve


Removal procedure

A D 1. Cylinder headbolt 9. Intake valve

2. Cylinder head asssembly 10. Exhaust valve

3.Cylinder pad 11. Cylinder head

B C 4. Lock pin

5. Intake valve spring holder

B 6.Valve spring

C A 7.Valve duct

8.Valve housing washer

Essentials for removal operation:

A Removal of cylinder head bolts

Unscrews the cylinder head bolts with the special tool shown in Figure

B Removal of lock pin

Attaches the labels on the knocked down valves, springs and other parts, and marks out their cylinder number and position for reassembly. Safekeeps those parts.

C Removal of valve oil seal


A Installation of valveoil seal

(1) Installation of valve spring seat

(2) Fits the new oil seal of valve with the special tool shown in Figure

Attention: 1. The valveoil seal can be reused. 2. The correct special tools has be used for installing the valveoil seal. Incorrect installation may cause the oil leakage when passing through the valve guide bush. B Installation of valve spring

When fitting up the valve spring, keeps the end to be painted position at the side of rocker arm.

Spring seat of valve

Oil seal of valve rod

Spring seat of valve

Printing side

C Installation of lock pin

D Installation of cylinder head bolts

(1) Prior to reuse the cylinder head bolt, checks if its nominal length has exceeded the specified limit value. If the measuring result is beyond the limit value, the bolt should be replaced.

Limit values: 103.2mm

(2) Fits up the spacer as shown in Figure

(3) Applies the engine oil on the spacer of bolt thread.

(4) Tightens the bolt as per the order shown in figure until all bolts have reached the moment 49Nm(5kgf.m)

(5) Fully unscrews the bolt

(6) Retightens the bolt as per the order shown in figure until all bolts have reached the moment 202Nm

Side of timing belt

(7) Marks the plaint signs on the cylinder head bolts and cylinder head(shown in figure )

Print mark

(8) Each bolt is screwed by a plus 90 as per the tightening order.

(9) Each bolt is tightened by 90 to check whether the paint mark on the bolt head is aligned with that on the cylinder head.

Attention: If the tightening angle of bolts is less than 90, it is impossible for them to have sufficient power to fasten theif the tightening angle of bolt is larger than 90, they should be removed down and refixed.

(10) If the old cylinder head bolts have been replaced during the maintenance, the overhaul should be carried out as per the sequence (2)~(9).

(11) If no used cylinder head bolts have been replaced, the overhaul should be effected following the order of (2),(3),(6),(7),(8) and(9).

2.8 Oil pump and oil sump


A Removal of oil sump

(1) Removes the fitting bolts of oil sump.

(2) As shown in figure drives the special tool between the oil sump and cylinder body.

(3) Taps the side of special tool and makes it move along the sealing side of oil sump /cylinder body, than removes the oil sump.


A Installation of front oil seal shell (oilpump shell)

(1) Cleans out the sealant painted surface of cylinder body and front oil seal shell.

(2) Applies the 3mm field shaping curl spacer on the overall periphery of the oil sump fange.


B Installation of front oil seal

(1) Places the special tools in front of the crankshaft, and applies engine oil on its pheripher.

(2) Applies the engine oil on the sealing lips, then pushes by hands the oil seal along the guide bush until it touches the oil seal shell. Taps the oil seal with the special tool to make it in position

C Installation of oil sump

(1) Cleans out the fitting surface of the cylinder body and oil sump.

(2) Applies the field-shaping curled pearl spacer on the overall pheriphery of the oil sump flange.


D Installation of oil drain plug spacer

Uses the new oil drain plug spacer, fits up the spacer as showin in figure

Attention: If the spacer is fitted in a wrong direction, it will cause the oil leakage.

E Installation of oil filter

(1) Cleans out the oil filter mounting surface on the oil pump shell.

(2) Applies the engine oil on the O-ring of oil filter.

(3) Tightens the oil filter until the O-ring sets on the mounting surface, then screws again the oil filter by one cycle to tighten the moment up to 12~20Nm.

Attention: Th oil filter has to be tightened with the filter pliers sold in the market. If the filter is tightened with hand, the leakage will occur due to the insufficient tightening moment.

2.9 Pistons and connecting rod


Side of printing shell

Removal procedure

G 1. Connecting rod nut C 7. 2nd piston ring

A F 2. Connecting rod cap B 8. Oil ring

E 3. Connecting rod bush B A 9. Piston pin

D 4. Pistons and connecting rod assembly 10. Pistons

5. Connecting rod bush 11. Connecting rod

C 6. 1st piston ring 12. Connecting rodbolt


A Removal of onnecting rod cap

In favor of the re-installation, marks the cylinder number on the large head side of connecting rod.

B Removal of piston pin

(1) Inserts the tappet from the side of the arrow sign in front (special tool), tten fits the guide bush D.

(2) Puts upward the sing in front of piston, fits the pistons and connecting rod assembly on the foot mounting of piston pin (special tool).

(3) Presses oug the piston pin with a press.

Attention: After the piston pins removed, puts the pistons, piston pins and connecting rod together. Do not put the pistons, piston pins and connecting rod of each cylinder together. Essentials for installation operation

A Installation of piston pins

(1) Measures the following lenghs (shown in figure )

A: Outer size between the pistons bosses

B: Inner size between the pistons bosses

C: Length of piston pin

D: Thickness of the small head of connecting rod

(2) Fills the measured values into the following formula:

Cylinder no.

Base

Guide bush D

Front sign

Push rod

Fron

t sig

n

( A C ) ( B D)L=

2

(3) Inserts the tappet (special tool) into the piston pin, then fits the guide bush A(special tool).

(4) When the pistons and connecting rod are installed, the signs in front of them should be located in the same side.

(5) Applies the engine oil on the outer circle of piston pin.

(6) Started from the guide bush A, presses theguide bush A, piston pin and tappet into the side of signs in front of the pistons.

(7) Screws the guide bush B into the guide bush A. the clearance between both guide bushes is 3mm plus the value L approached from the calculation in Step 2.

(8) In case where the sign in front of the piston is down, fits the pistons and connecting rod on the foot mounting of piston pin.

(9) Fits the piston pin by a press. If the load I overrated, replaces the piston pins, piston assembly and connecting rod or both replaced.

Guide bush B

Guide bush A

Piston

Piston pin

Link rod

Standard value: 1000500 kg.f

A Installation of oil ring

(1) Fits up the spacing ring of oil ring into the piston ring groove, then fits the upper and lower steel rings.

Attention: 1. The spacing ring and steel ring may be fitted in any of directions. There is no difference between the upper and lower steel rings 2. Color codes used for the spacing ring and steel ring sizes are shown as follows:

Sizes Colors Standard None Extra, 0.50mm Blue Extra, 1.00mm Yellow

(2) In order to fit up the steel ring, fits the one end of steel ring into the groove as shown in figure, then press-fits the other parts into the places.

Steel ring

Spacing ring

Push rod

Piston pin

Front sign

Guide-bush A

Base

Guide-bush B

Front sign

Attention: Do not fit the steel ring with the expander of piston ring, otherwise they are likelyto be broken. (1) After the steel ring fitted up, checks whether they are slidable in both directions.

C Installation of the 2nd and 1st piston rings

Fits the 1st and 2nd piston rings with the expander of pistion ring. Their dentification signs should face upward (top of the piston).

Identification sign:

The 1st piston ring: 1T

The 2nd piston ring: 2T

Attention: The following signs of size are marked on the piston rings:

Sizes Size sign Standard None Extra, 0.50mm 50 Extra,1.00mm 100

Expander of pistion ring

Side of steel ring

D Installation of pistons and connecting rod assembly

(1) Applies the oil on the pistons, piston rings and piston pins.

(2) As shown in figure ains at the apentures of the air ring and oil ring (steel ring andspacing ring).

(3) Ains the arrow sign in front of the top of piston at the side of timing belt, from the upper side of cylinder, press-fits the pistons and connecting rod assembly into the cylinder.

(4) Presses tightly the piston ring with the suitable pressing tool of piston ring, then press-fits the pistons and connecting rod together into the cylinder. Do not knock forcely the pistons, otherwise, the piston ring will be broken and the connecting rod journal crackled.

E Installation of connecting rod bearing

Please confirm the identification signs on the crankshaft and connecting rod as shown in figure selectsthe bearings as per the following table.

1st ring

2nd ring

1st ring

Piston pin

Steel ring

Steel ring

2nd ring and loop

ID sign of 1T

ID sign of 2T Sign of size

Crankshaft identification sign Identification sign of connecting rod Identification sign of bearingsWhite 1 None 1 I.Yellow

Yellow 2 White 1 None 2 II.None

Yellow 3 White 2 None 3 III.White

Yellow 3

4G13S-7L Crankshaft 4G18S-7L Crankshaft

ID color

Col.code position Col.code position

ID sign position ID sign position

1# 4#

3# 2#

2# 1#

4#

3# 1#

2#

2#

3#

4#

1#

3#

4#

F Installation of connecting rod cap

(1) Aimiing at the sign made at the time of break-down, fits the connecting rod bearing cap on the connecting rod. If the connecting rod is a new one, there is no sign, the bearing locking notches have to be on the same side.

(2) Checks whether the lateral clearance of the large head of connecting rod is conform to the provisions.

Standard value: 0.100.25mm

G Installation of connecting rod nut

Attention: If the cylinder head has been fitted prior to the installation of connecting rod nuts, the spark plugs have to be removed first.

(1) The connecting rod bolts and nuts are tightened by the tension method of plastic deformation. Prior to the reinstallation, the bolts have to be checked to see there are any parts crackled. In order to do such, screws with the hand the nut for a full length of thread. Only when the nut has been screwed fully down to the end of thread than can prove there are no scratches on the thread part, otherwise the bolt has to be replaced.

(2) Before the nut is installed, applies the engine oil on their threading part and mounting surface.

(3) Fits the nuts on the bolts and screws then Tightlu. Afterward, the nuts have to be tightened alternatively to ensure the correct installation of connecting rod cap.

(4) The tightening moment of nuts: 16.720Nm.

(5) As shown in figure the paint mark has to be made on the top of each nut.

Cylinder No.

Notch locking

(6) Starting from the paint mark on the nut, turns clockwise toward the angle 90~94, and makes the paint mark on the bolt.

(7) Turns the nut until it is aligned with the paint mark on the bolt and that on the nut.

Attention:

1. If the turning angle of nut is less than 90, the fastening power of connecting rod cap will be insufficient.

2. If the turning angle of nut is more than 94, they should be fully unscrewed, and renews the tightening steps.

1.10 Crankshaft and cylinder body

Printing sign

Printing sign

Nut Bolt


1. Flywheelbolt 7. Lower partition B 13. Main bearing (lower)

3. Flywheel D 8. Crankshaft rear oil seal 14. Crankshaft

6. Upper partition 9. Crankshaft rear seal shell B 15. Main bearing (Upper)

C 11. Bearing cap bolt C 12. Main bearing cap AA16. Oil pressure switch

17. Cylinder body


A Removal of oil pressure switch

(1) Disengages the terminal from the oil pressure switch.

(2) Removes the oil pressure switch with special tool

Attention: The sealant is painted on their threads. When the oil pressure switch is removed, please be careful not to bend it.

Installation operating essentials

A Installation of oil pressure switch

Applies the specified sealant on the threads, then fits up the oil pressure switch with the special tool as shown in Figure

Specified sealant

Attention: 1. When the sealant is applied, do not let the sealant beyond the end do thread. 2. Do not overtighten the oil pressure switch. Moment: 15~22Nm.

Pushing direction

B Installation of crankshaft bearing

(1) Selects the bearings according to the identification sign or color code of crankshaft (refer to the following table). If they are not identied, the diameter of the crankshaft should be measured and the suitable bearing selected to match it.

Crankshaft journal Aperture of the cylinder bearing holes Bearing

Range Color code Identification

sign Diameter of journal Identification sign Identification sign

0 1

1 2 1 Yellow 1 47.995~48.000

2 3

0 2

1 3 2 None 2 47.988~47.995

2 4

0 3

1 4 3 White 3 47.982~47.988

2 5

4G18S-7L Crankshaft 4G13S-7L Crankshaft

Class impact print

1st main shaft diameter

Axile diameter 1 Axile diameter 2

Axile diameter 3 Axile diameter4

Class impact print

1st main shaft diameter

2nd main shaft diameter

3rd main shaft diameter

4th main shaft diameter

5th main shaft diameter

Axi

le d

iam

eter

1

Axi

le d

iam

eter

2

Axi

le d

iam

eter

3

Axi

le d

iam

eter

4

1st m

ain

shaf

t dia

met

er

2nd m

ain

shaf

t dia

met

er

3rd m

ain

shaf

t dia

met

er

4th m

ain

shaf

t dia

met

er

5th m

ain

shaf

t dia

met

er

Class impact print

The shaft diameter level is classified as 5, 4, 3, 2 and 1 counted from front to back.

(2) The identification sign representing the bearing aperture of cylinder is the position engraved by the number 1 in front of the engine. The selection and installation of bering have to be made on the basisi of these identification signs have to be.

(3) On the basis of the verification of identification signs according to the steps (1) and (2), the bearings are to be selected from the above table.

The example is given as below:

1. If the measured result of a journal is 48.000mm, it corresponds the class 1 in the above table.

2. If the identification sign of the bearing aperture of a cylinder is the number, the bearing with the identification sign 2 should be choosen.

(4) Except the intermediate bearing, all bearings are grooved. The intermediate bearings are fitted with spport lugs instead of the grooves. The upper parts of the intermediate bearings are identical.

(5) All lower bearings are without grooves.

Side of timing belt

Hole dia.of cylinder journal

Grooveless Groove

Grooveless

Up/lower axle bearings (intermediate)

lower axle bearing(1#,2#,4#and 5#)

Upper axle bearing (1#,2#,4#and 5#)

C Installation of main bearing cap

(1) There the number and an arrow on the surface of each main bearing cap. Started from the side of the timing belt, the bearing caps are to be fitted following the number sequence. The arrow has to aim at the side of the timing belt.

(2) After the bearing fitted up, the axial clearing of crankshaft is to be measured. If the measured value exceeds the specified limit, the crankshaft bearing should be replaced.

Standard value: 0.05-0.18mm

D Installation of rear oil seal

Press-fits the rear oil seal with the special tool as shown in Figure

2.4 Inspection and maintenance operation 1) A/C generator and ignition system

2) Timing belt

1. Timing belt

Checks carfuly the timing belt. In case of the following defections shown, it should be

Axle bearing cap no. The arrow refers to the front of engine

Oil seal shell

Oil seal

replaced by a new one:

(1) The vulcanization on the opposite side (the rubber in reverse is smooth and inelastic, which is hardened to the extent that no traces are left when scratching with nails).

(2) The crackles are shown on the reverse side of rubber.

(3) The canvas is torn and (or) separated with the rubber.

(4) The tooth roots are crackled.

(5) The lateral sides of belt are crackled.

(6) The belt sides are abnormally worn .

Attention: If the belt sides are as sharp as the knif cutting, it should be considered as normal.

(7) Abnormal wear on the teeth

Initial phase:

(Canvas fibers loosened, rubber destructed, white faded, canvas texture unidenfied)

Final phase:

Crack Crack

Crack side

Tooth root with crack

Separated

Edged fillet

Abnormal wear (Exposed core)

Canvas worn up, rubber exposed(the tooth width dimished)

(8) Teeth disappeard

2. Tensioner pulley

Checks if the pulley rotates steadily and there are any clearances and abnormal noise. When

necessary, one or two pulleys should be replaced.

3) Fuel and emissioncontrol system

4) Water pump andcooling water hose

5) Intake manifold and exhaust manifold

6) Rocker arm and camshaft

1. Camshaft

Check of the cam height. If the height is over the limit value, the camshaft should be replaced.

Air intake 36.8 Height limit of camshaft, in mm Air exhaust 36.666

Worn cancas and exposed rubber

Toothless

7) Cylinder head and valve

1. Cylinder head

(1) Prior to clean up the cylinder head, check it to see if there are any water/air leakage, any crackles and other damages.

(2) Eliminates all oil, water scales, sealants and carbon deposits. After the oil rail cleaned, blows the compressed air to the oil rail to ensure it is free of jam.

(3) Checks with the ruller or clearance gauge to see if there are any deformations on the surface of cylinder head spacer. If the degree of deformation exceeds the specified limit value, the surface of spacer has to be ground according to the specification.

Standard value of spacer surface deformation: less than 0.03mm

Height of cylinder head (new): 1200.1mm

Attention: The grinding margin allowable for the fitting surface of cylinder head and cylinder body is not larger than 0.2mm. 2. Valve (1) Checks the valve surface to see if it is in correct contact. If the contact is not uniform or complet, the surface of valve seat should be refixed. (2) If the edge thickness is less than the fixed value, the valve should be replaced.

Standard value: Limit values:

Intake valve: 1.35mm Intake valve: 0.85mm

Exhaust valve: 1.85mm Exhaust valve: 1.35mm

(3) Total length of measured valve. If the measured result is less than fixed value, the valve should bereplaced.

Standard value: Limit values:



3. Valve spring

(1) Measurement of the free height of valve spring. If the measured result is less than fixed value, the valve spring should be replaced

Standard value: 50.87 Limit values: 50.37

(2) Measurement of the vertical height of valve spring. If the measured result is less than fixed value, the valve spring should be replaced

Standard value : 2 Limit values : 4

4. Valve duct

Measurement of the clearance between the valve guide bush and valve rod. If the clearance exceeds the limit value, one or two parts should be replaced.

Standard value :

Intake valve guide bush: 0.0200.036mm

Exhaust valveguide bush : 0.0300.045mmm

Limit values :

Intake valve guide bush : 0.10mm

Exhaust valveguide bush : 0.15mm

Contact (within the

surface center)Edge thickness

Verticality

Free height

3. Valve seat

Fits up the valve, then measures the protrusion height between the end surface of valve rod and surface of valve spring seat. If the measured result is less than fixed value, the valve seat should be replaced.

Standard value: Limit value:



Operating essentials for the valve seat correction

(1) Prior to correct the valve seat, checks the clearance between the valve guide bush and valve. When necessary, the valve duct should be replaced.

(2) Corrects the valve seat with the suitable special tools or valve seat grindert to reach the specified width and angle of seat surface.

(3) After the valve seat revised, grinds the valve and valve seat with grinding paste. Afterward, checks the flange height of valve rod (refer to the previous check procedure of valve seat).

Operating essentials for valve seat replacement

(1) To reduce the wall thickness, cuts out the replaced valve seat from the inner side, then removes the valve seat.

End face of valve rod

Extruding height of valve rod

Face of the valve spring seat

Valce duct

Valce duct I/DValce rod O/D

(2) Rebores the hole of valve seat on the cylinder boring head to match it with the selected extra diameter of valve seat.

Aperture of intake valve seat (Extra. 0.3mm)

Intake valve 4G13S-7L : 28.425-28.445mm

Intake valve 4G18S-7L: 30.425-30.445mm

Aperture of intake valve (Extra. 0.6mm)



Aperture of exhaust valve seat (Extra. 0.3mm)

Exhaust valve 4G13S-7L: 26.425-26.445mm


Aperture of exhaust valve seat (Extra. 0.6mm)



Cut off

Heigh of the valveseat

I/D of extra.aperture

(3) Prevents the cylinder head holes from being grazed by the valve seat cooled by liquid nitrogen prior to assembly.

(4) Corrects the valve seat to match it with the specified width and angle(refer to the operating essentials of valve seat) Operating essentials for the valve duct replacement (1) Pushes out the valve duct with a pressing machine from the side of cylinder body.

(2) Rebores the hole of valve duct on the cylinder boring head to match it with the extra-sized valve duct . Attention: Do not fit the valve guide bush of same size Aperture of the valve duct:

Extra,0.05: 10.605-10.615mm

Extra,0.25: 10.805-10.815mm

Extra,0.50: 11.055-11.065mm

(3) Press-fits the valve duct until its flange height reaches the fixed value.

Standard value: 23.0mm

Attention: 1. The valve duct has to be fitted in from the upper side of cylinder head. 2. The duct length on the air intake side is different from that on the air exhaust side. 3. After the duct valve fitted in, inserts the new valve and checks if it slides smoothly. 8) Pump and oil sump

1. Pump

(1) Fits the rotor into the front cover.

(2) Checks the tooth top clearance with the thickness gauge

Extruding heigh


(3) Checks the lateral clearance with the ruler and clearance gauge.


(4) Checks the shell clearance with the clearance gauge.

Standard value: 0.100.18mm Limit values: 0.35mm

9) Pistons and connecting rod

1. Piston ring

(1) Check of the piston ring clearance. If the clearance exceeds the specified limit, the ring/pistion or both of them should be replaced.

Standard value: Limit values :

The 1st ring: 0.030.07mm The 1st ring: 0.1mm

The 2nd ring: 0.020.06mm The 2nd ring: 0.1mm

(2) Places the piston ring into the cylinder hole, pushes it down with the piston. The top of piston has to be used to contact the piston ring, so as to form an anle 90 between the ring and the cylinder. Then measures the open clearance with the clearance gauge. If the open clearance is too large, the piston ring has to be replaced.

Standard value:

The 1st ring: 0.200.35mm

The 2nd ring: 0.350.50mm

Oil ring 4G13S-7L: 0.200.50mm

Oil ring 4G18S-7L: 0.100.40mm

Limit value: The 1st ring: 0.8mm

The 2nd ring: 0.8mm

Oil rings 4G13S-7L and 4G18S-7L: 1.0mm

2. Clearance of the connecting rod bearing (plastic wire gauge)

(1) Wipes out all oil from the connecting rod journal and connecting rod bearing.

(2) Places on the connecting rod journal, the plastic wire gauge, which is cut in same width with the bearing. The plastic wire gauge has to be sited in the center of the connecting rod journal and parallel with its axial line.

(3) Gently places the connecting rod cap on its position and tightens the bolt till its specified moment.

(4) Removes the bolt andslowly detaches the connecting rod cap.

(5) Measures with the marker printed on plastic wire gauge, the extruded part of the plastic

Pistion ring Opening clearance

Push in with the piston

wire gauge at the widest point.

Standard value : 0.020.04mm

Limit values : 0.1mm

10) Crankshaft and cylinder body

1. The clearance of crankshaft can be easily measured out with the plastic wire gauge. In order to measure the clearance of crankshaft with the plastic wire gauge, the procedure below should observed:

(1) Wipes out all oil in or on the surfaces of the crankshaft journal and bearing.

(2) Fits the bearing.

(3) Cuts the length of plastic wire gauge into that matching with the width of bearing.

Then places it on the journal along the axial line of journal.

(4) Softly fits the bearing cap of crankshaft and tightens the bolt till the specified moment.

(5) Removes the bolt and softly detaches the cap form the crankshaft bearing.

(6) Measures the extruding part of the plastic wire gauge with the ruler printed on the plastic wire gauge bag.


Limit values: 0.1mm

Plastic wire guage

Attention: The connecting rod journal of crankshaft and main journal have been subject to the rolling process, it is unnecessary to reduce the size by the machine tool. 2. Cylinder body

(1) Vusually checks the crackles, rust and corrosion, and examins the cylinder body with the defection tester. Repairs the defections as much as possible or replaces the cylinder body.

(2) No spacer debris and other dyed stuff are allowed on the top surface. Checks the deformation on the top of cylinder with the ruler and clearance gauge.

Standard value: less than 0.03mm

Limit value: less than 0.1 mm

(3) Checks if there are signs of cylinder crackles or scors on the cylinder wall. If the defection is distinct, all cylinders should be bored to the extra size or replaced.

(4) Measures the aperture of each cylinder and the cylindricity with the cylinder gauge. If any of the cylinders is seriously worn, it should be bored to the extra size and the piston and piston ring replaced accordingly. The measuring points are shown as below.

Fillet rolling area

Standard value:

Cylinderaperture: 71.0mm(4G13S-7L)

76.0mm(4G18S-7L)

Cylindricity: less than 0.01mm

3. Boring hole of cylinder

(1) All extra-sized pistons should be determined as per the cylinder with the max. aperture

(2) Extra pistons with the following extra sizes: 0.25mm, 0.50mm, 0.75mm and 1.00mm.

Piston diameter for measurement. After the cylinder bored, the clearance between the piston and cylinder has to meet the standard value. The points shown in Figure should be used to measure the diameter of pistons

(3) Calculates the boring size according to the diameter of piston.

[ Boring size]=[Piston O/D][Clearance between the Piston and Cylinder(0.020.04)mm][Grinding Marge(0.02mm)]

(4) Bores each cylinder to the calcultated boring size. Attention: In order to prevent the heating deformation, please proceed with the cylinder boring as per the following order: 2nd cylinder, 4th cylinder, 1st cylinder, and 3rd cylinder.

(5) Grinds the cylinder to the final process size(piston O/Dclearance between the piston and cylinder ) (6) Checks the clearance between the piston and the cylinder.


Section III OBD diagnosis and maintenance

The on-board diagnostic system (hereafter refered as to OBD) is referred to a diagnosis system which is integrated in the engine control system and able to monitor and effect the

Sealant application

Piston O/D

failure parts of exhaust emission as well as the engine state of primary performance. It has the function of identifying, saving and dislaying the failure information through the self-diagnostic malfunction indication lamps (MIL).

To guarantee the durability of the emission control performance during the use of vehicle, In China, it is clearly stated in the Contaminant Emission Limits of Light-Duty Vehicles and Measure Method (Phases III and IV in China)that All vehicles have to be fitted with OBD system, which is able to ensure the identification of worsen of failure parts during the whole service life of vehicle.

When the vehicle fitted with the OBD system is maintained, the service men are able to rapidly and accurately locate the failure parts through the diagnostic set, which largely increases the maintenance quality and efficiency.

The model Foton MP. Midi is equipped with the Kingtec Failure Diagnostic Set.

The OBD technology is involved with many brandnew concepts. The following pages will be contributed to the introduction of same basic knowledge relevant to the OBD technology, so as to facilitate the understanding of the follow-up content.

I Failures Once the following cases are detected by the OBD system, they are considered as Failures.

The conversion efficiency of catalytic converter decreases, and the emissions exceed the OBD value.

The engine catches fire, the contaminants of air exhaust will surpass the OBD value, or cause the catalyst temperature too high or damaged.

The oxygen sensor damaged or aged to the extent that the contaminants of air exhaust will be higher than OBD value.

The parsts connecting the ECU and relevant to the emission are ineffective, and possibly cause the contaminants of air exhaust over the OBD value.

The power trai

midi service manual

Documents