JAC HFC4DA1-2C engine. Instruction — part 1
Maintenance instruction for sunray hfc4da1-2c china-IV diesel engines
1
Contents
Chapter I Technical Characteristics of Engine . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11
Section I Technical Requirements for Fuel, Oils, and Auxiliary Materials . . . . . . . . . . . . . . 11
Section II Main Technical Specification of Engine . . . . . . . . . . . . . . . . . . . . . . . 14
Section III Performance Curve of Engine . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15
Section IV Main Checking and Adjustment Parameters . . . . . . . . . . . . . . . . . . . . .. 16
Section V Tightening Torque for Critical Bolts of Engine . . . . . . . . . . . . . . . . . . . . . 17
Section VI Main Fitting Clearances and Allowable Wear Limits of Engine . . . . . . . . . . . . ... 21
Section VII Specification of Main Attachments and Accessories . . . . . . . . . . . . . . . . . .. 24
Chapter II Maintenance for Main Structures of Engine . . . . . . . . . . . . . . . . . . . . . . ... 25
Section I Disassembly of Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Section II Assembly of Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Section III Crankshaft and Flywheel System . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Section IV Piston and Connecting Rod Group . . . . . . . . . . . . . . . . . . . . . . . . ... 69
Section V Valve Distribution Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . ... 70
Section VI Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Section VII Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Section VIII Turbocharger and Inter-Cooler System . . . . . . . . . . . . . . . . . . . . . . 73
Section IX EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Section X Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Chapter III Working Principle of Engine Control and Actuator Units . . . . . . . . . . . . . . . . ... 77
Section I Overview of Diesel Common Rail System . . . . . . . . . . . . . . . . . . . . . . .. 77
Section II Working Principle of Low Pressure Fuel Line System . . . . . . . . . . . . . . . . . 79
Section III Working Theory of High Pressure Fuel Line . . . . . . . . . . . . . . . . . . . . .. 82
Section IV Electronic Control Unit of High Pressure Common Rail System . . . . . . . . . . . . .. 84
Chapter IV Engine Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Section I. Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Section II. Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Section III. Fault Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Section IV. DTC List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 115
Section V. Fault Diagnosis for Electronic-Controlled Common Rail Diesel Engines . . . . . . . . . 133
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Maintenance instruction for sunray hfc4da1-2c china-IV diesel engines
3
Chapter I Technical Characteristics of Engine
Section I Technical Requirements for Fuel, Oils, and Auxiliary Materials
I. Diesel
HFC4DA1-2C diesel engine adopts electronically controlled, high pressure common rail, fuel injection system and
conforms to Euro-IV emission regulation and thus extends higher requirements over the fuel. To guarantee the
reliability of the fuel supply system, make sure to use the qualified clean diesel produced by national well-established
fuel company, in order to prevent the blockage or early wear of fuel injector due to poor fuel.
Add the fuel only at the well-established gas station. The use of poor diesel or other diesel intended for
other than vehicle engine application is strictly prohibited.
Make sure to use the fuel conforming to national standard GB 19147. The grade number of the diesel chosen is related
to the temperature of working environment. When the environment temperature is reduced, the paraffins within the
diesel will precipitate to block the fuel pipeline, leading to difficult fuel supply and start failure of the engine.
Therefore, choose different grade number of diesel depending on the environment temperature in different seasons
and regions, in accordance with the table shown below.
Environment temperature
Above 5℃ Above
-5℃ Above
-10℃ Above
-25℃
Recommended grade
number of diesel
0# light diesel
-10# light diesel
-20# light diesel
-35# light diesel
Notice!
The cam of the high pressure fuel pump is being lubricated by the fuel. Never cause engine flameout due to depletion
of fuel in the fuel tank, or it will lead to serious wear of the high pressure fuel pump. After adding new fuel, make sure
to firstly use instruction fuel pump to bleed the air from the fuel pipe and high pressure fuel pump and thoroughly fill the
fuel pipe and high pressure fuel pump with fuel before starting the engine, in order to prevent the wear of high
pressure fuel pump due to fuel shortage.
Procedure for air bleeding and refueling:
1. Loosen the air bleeding screw;
2. Push down the instruction fuel pump with hand and then release. Repeat above operation, till there is no air bleeding
out from the air bleeding screw;
3. Tighten the air bleeding screw and pump the fuel with instruction fuel pump, till the fuel injection pump is thoroughly
filled with fuel.
The diesel filter embodies the fuel-water separation function:
The water content in the diesel will bring about great harm to the fuel system. Upon the detection that the diesel filter
water level warning lamp on the instrument panel lights up, it indicates the presence of waste water in the diesel filter.
The waste water shall be drained timely, or it will lead to the rusting and wear of high pressure fuel pump, high
pressure fuel rail, and fuel injector and bring about unnecessary losses.
Procedure for water drainage:
1. Unplug the water level sensor connector;
2. Loosen the water level sensor to drain the waste water, till the diesel flows out.
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Maintenance instruction for sunray hfc4da1-2c china-IV diesel engines
4
3. Tighten the water level sensor and plug the water level sensor connector.
II. Engine Oil
HFC4DA1-2C diesel engine shall use the diesel engine oil with the quality grade at API CH-4 or above, of which the
viscosity is related to the environment temperature. When the environment temperature is reduced, the viscosity of the
engine oil is increased to increase the start resistance so that the diesel engine can’t reach the start speed and cause
difficult start. Therefore, in different seasons and regions, choose the correct engine oil with different viscosity grade
under different environment temperature, in accordance with the table below.
Environment
temperature
-15℃~40℃ -20℃~30℃
-30℃~25℃
Extreme cold region
Engine oil
trademark
10W-40/50 or 15W-40
10W-30/40/50
5W-40/50
0W-40/50
Check engine oil level:
z Stop the engine and wait for several minutes;
z Pull out the engine oil dipstick;
z Wipe the oil dipstick with clean cloth and re-insert the oil dipstick to the end;
z Pull out the oil dipstick again and observe the engine oil level. Check whether the oil level is between the upper
and lower limits of the oil dipstick. If insufficient, add the engine oil.
Notice!
z Make sure to periodically check the engine oil level.
z The apparatus used for refueling shall be clean.
z In event of sudden rise or drop of engine oil level, check for cause immediately.
Upper limit
Lower limit
Notice: Make sure to horizontally park the vehicle while
measuring the engine oil level. Stop the engine and wait
for several minutes, till the engine oil can return to the oil
sump.
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Maintenance instruction for sunray hfc4da1-2c china-IV diesel engines
5
z Never mix different trademarks of engine oils.
z Periodically replace the engine oil as per the maintenance regulations.
III. Coolant
Make sure to use clean automotive antifreeze coolant featuring antifreeze in winter, anti-boiling in summer, and
anti-corrosion, anti-rusting, and anti-scaling.
Take cautions during the operation:
a. Always use coolant throughout the year and pay attention to the use continuity of the coolant.
b. Depending on the temperature of the region in which the vehicle is used, choose the coolant with different freezing
point. The freezing point of the coolant shall be at least 10ºC below the lowest temperature of the region, in order to
maintain the antifreeze function.
c. Purchase the qualified coolant product, in order to prevent damaging the engine and causing unnecessary economic
losses due to use of disqualified product.
d. Never mix different trademarks of coolants nor use such mixed coolant, in order to prevent the chemical reaction
from impairing the respective comprehensive anti-corrosion performance.
e. Never add the hard water such as well water or running water. Upon the detection of suspended material, sediment,
or smelliness phenomenon in the coolant, it indicates that the coolant is deteriorated and becomes ineffective due to
chemical reaction. In such case, timely clean the cooling system and thoroughly replace the coolant.
f. The glycol coolant is one toxic substance and is harmful to the liver. Never swallow the coolant. In event of skin
exposure to the coolant, thoroughly clean with water immediately. In addition, the nitrite anti-corrosion additive in the
coolant is one carcinogenic substance. Do not dispose the used coolant randomly, in order to prevent contaminating
the environment.
Notice!
z Upon the detection of sudden drop in coolant level, check for cause immediately.
z The cooling system is under pressurized state! Never open the cap of the coolant compensation tank or radiator
while the engine is still hot, or it will lead to scalding danger!
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Maintenance instruction for sunray hfc4da1-2c china-IV diesel engines
6
Section II Main Technical Specification of Engine
Model HFC4DA1-2C
Type
Inline 4-cylinder, longitudinal layout, water-cooled, 4-stroke, turbocharged
inter-cooler, high pressure common rail, and direct injection engine
Nominal power/speed
85/3600(kw/rpm)
Top torque/speed
250/1800~2800(Nm/rpm)
Minimum fuel consumption
of external characteristic
≤ 218g/kw·h
Top idling speed
4000rpm
Exhaust temperature (before
turbine)
≤ 700℃
Idling speed
800±50 rpm
Number of cylinders × bore
× stroke:
4×93 mm×102 mm
Total piston
displacement
2.771 L
Compression ratio
17 :1
Fuel grade
-10#
Working sequence
1-3-4-2
Fuel supply advance
angle
Electronically controlled
Flameout mode
Fuel cut-off
Engine mass
270kg
Emission limit (test value)
China-IV emission standard
compliant
Noise limit
≤ 95dB(A)
Engine oil trademark
Above grade CH-4
Engine oil capacity
7.2L
Engine oil/fuel consumption ratio (24h at full speed)
≤ 0.10%
Temperature of engine oil in oil sump (under nominal working
condition)
≤130℃
Engine oil pressure
Idling: ≥98 kPa
Coolant capacity
30L
Applicable altitude
≤3500m
Thermostat type
Wax type
Maximum outlet temperature of
coolant
≤ 110℃
Thermostat opening
temperature
82℃
Thermostat full open temperature
95℃
Applicable temperature
of diesel engine
With heated cold starter and with heater plug in engine
Overall dimensions (L×W×H) 728.9mm×715.6mm×753.3mm
Length of cylinder
block
479mm
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Maintenance instruction for sunray hfc4da1-2c china-IV diesel engines
7
Section III Performance Curve of Engine
0
50
100
150
200
250
300
100
0
120
0
140
0
160
0
180
0
200
0
220
0
240
0
260
0
280
0
300
0
320
0
340
0
360
0
转速(r p m )
扭矩
(N
m
)
0
10
20
30
40
50
60
70
80
90
功率
(k
w
)
扭矩
功率
200
210
220
230
240
250
260
270
280
100
0
120
0
140
0
160
0
180
0
200
0
220
0
240
0
260
0
280
0
300
0
320
0
340
0
360
0
转速(r pm )
油
耗
率
(
g/
kw.h
)
0
5
10
15
20
25
油耗
量(
k
g
/
h
)
油耗率
油耗量
Torque
Power
To
rq
u
e
Po
we
r
Speed
Fuel consumption
Fuel consumption
Fuel consump
tion (g/kw
.h)
Fuel c
ons
ump
tion (kg/h)
Speed
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Maintenance instruction for sunray hfc4da1-2c china-IV diesel engines
8
Section IV Main Checking and Adjustment Parameters
1、At rated power:
(1) Exhaust temperature (master pipe) (ºC)
(2) Thermostat opening temperature (ºC)
(3) Thermostat full open temperature (ºC)
(4) Temperature of engine oil in main oil way (ºC)
(5) Engine oil pressure (kPa)
≤700
82
95
≤130
400~600
2. Engine oil pressure at minimum stable speed (kPa)
≥98
3. Timing phase (in rotation angle of crankshaft)
(1) Open of intake valve (before top dead center)
(2) Close of intake valve (after bottom dead center)
(3) Open of exhaust valve (before bottom dead center)
(4) Close of exhaust valve (after top dead center)
24.5°
55.5°
54°
26°
4. Valve clearance (mm)
0.3~0.4
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Maintenance instruction for sunray hfc4da1-2c china-IV diesel engines
9
Section V Tightening Torque for Critical Bolts of Engine
Comparison Table of Tightening Torque for Critical Bolts
☆
No.
Description
N.m
1
Fixing bolt of rockshaft
55
2 Heater
plug
25
3
Nut and washer for fuel injector body
40
4 Fuel
injector
34
5
Fixing bolt of thermostat housing assembly
25
6
Installation torque of rocker arm assembly
55
7
Camshaft thrust plate bolt
25
8
Camshaft timing gear bolt
110
9
Fixing bolt of rockshaft
50
10
Fixing bolt of engine oil pump filter screen assembly
20
11
Engine oil pump fixing bolt
20
12 Oil
sump
bolt
23.5
13 Flywheel
baffle
bolt
85
14
Flywheel bolt
25 for first step
70 for second step
120 for third step
15
Crankshaft bearing cap bolt
20 for first step
110 for second step
170 for third step
16
Tightening bolt of engine oil pump
25
17
Socket nut of engine oil pump
30
18
Torque for cylinder head bolt:
65 for first step
85 for second step
105 for third step
19 Rockshaft
support
bolt
55
20
Main bearing cap bolt
170
21
Torque for drive shaft nut
66
22 Transmission
bracket
nut
69
23
Clutch cover – flywheel housing bolt
M10:46
M12:91
24
Engine rear bracket nut and bolt
M10:40
M12:69
25
Front exhaust pipe bolt
37
26
Clutch working cylinder bolt
19
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Maintenance instruction for sunray hfc4da1-2c china-IV diesel engines
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No.
Description
N.m
27 Belt
pulley
bolt
210
28 Fan
pulley
12.5
29
Crankshaft bearing cap bolt
170
30
Connecting rod bearing cap bolt
25 for first step
85 for second step
31 Camshaft
timing
gear
110
32
Fuel injection pump nut
30
33
Idler gear bolt
20
34
Engine oil pipe perforated bolt
20
35
Crankshaft belt pulley bolt
210
36 Fan
silicone
oil
clutch
12.5
37
Connecting rod bearing cap
20 for first step
85 for second step
38
Piston cooling oil pipe bolt
M8×1.25 25
M6×1.00 7.5
39
Oil pressure regulation valve
M6×1.5 30
40
Socket nut of engine oil pump
30
41
Engine oil pump assembly bolt
25
42 Oil
sump
bolt
23.5
43
Cylinder head bolt
65 for first step
85 for second step
105±5 for third step
44 Rockshaft
support
bolt
55
45
Tightening bolt of water outlet pipe
19
46
Protrusion size of water pump impeller
24.6mm
47
Fan center distance
79.2~79.8 m
48
Open temperature of thermostat valve
82 ℃
49
Full open temperature of thermostat valve
95℃
50
Open pressure of vacuum valve at center of radiator
cap valve seat
88.2~117.6 kPa
51
Water pump fixing bolt
25 N.m
52
Alternator fixing bolt
40 N.m
53
Alternator adjustment plate fixing bolt
25 N.m
54
Lock nut, A/C compressor idler gear
27 N.m
55
Nut of engine oil cooler water pipe
25
56 Oil
drainage
plug
80
57
Fixing bolt of oil pump assembly
20
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Maintenance manual for sunray hfc4da1-2c china-IV diesel engines
11
No.
Description
N.m
58
Tightening socket nut
30
59
Bolt and nut of starter motor
81
60
Fixing nut of starter cable
9
61
Exhaust branch pipe bolt
30
62 Bolt
of
heat
shield
25
63 Support
bolt
40
64 Front
exhaust
pipe
nut
40
65
Crankshaft belt pulley bolt
210
66 Exhaust
pipe
nut
67
67
Torque of engine bracket bolt
M10:40
M12:69
68
Cylinder head cover nut
13
69
Connecting nut between turbocharger and exhaust
manifold
25
70
Connecting bolt between exhaust manifold and
cylinder head
30
71
Bolt of exhaust pipe heat shield
25
72
Connecting bolt of turbocharger air bleeding pipe
25
73
Perforated bolt of lubricating oil pipe
M12:41
M14:55
Comparison Table for Standard Bolt Specification and Tightening Torque
☆
Bolt Identification
Torque (N.m)
Specification
Less than grade 8.8
(low carbon steel)
Grade 8.8 (High
carbon steel)
Grade 10.9 (Alloy
steel)
M6×1.0 4~8
5~10
. ...
M8×1.25 8~18
12~23
17~31
M10×1.25 21~35
28~47
38~64
M10×1.5 20~34
28~46
37~61
M12×1.25 50~75
62~93
77~116
M12×1.75 46~70
58~86
73~109
M14×1.5 78~117
95~142
116~174
M12×2.0 73~109
90~134
109~163
M16×1.5 106~160
138~208
163~245
M16×2.0 102~152
132~198
156~234
M18×1.5 154~230
199~299
234~352
M20×1.5 210~316
275~413
323~485
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Maintenance manual for sunray hfc4da1-2c china-IV diesel engines
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M22×1.5 256~422
370~555
433~649
M24×2.0 360~550
439~725
565~847
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Maintenance manual for sunray hfc4da1-2c china-IV diesel engines
13
Section VI Main Fitting Clearances and Allowable Wear Limits of Engine
No. Name Standard
Size
(mm)
Fitting
nature
Assembly
Clearance for
New Engine
(mm)
Wear Limit
(mm)
1
Contact width between
valve and seat ring
Intake valve
1.7
2.2
Exhaust valve
2
2.5
2
Valve sinkage
Intake valve
0.73
1.28
Exhaust valve
0.71
1.2
3 Backlash
0.05-0.13
0.3
4
Axial run-out clearance of
idler gear A
0.07
0.2
5
Outside diameter of tappet
010
.
0
028
.
0
13
−
−
Φ
Clearance
0.01~0.046
0.10
Tappet bore
018
.
0
0
13
+
Φ
6
Radial run-out of push rod
0.3
7 Deflection
of
rockshaft
0.3
8
Outside diameter of
rockshaft
0
02
.
0
19
−
Φ
Clearance
0.01~0.05
0.20
Rocker arm bore
03
.
0
01
.
0
19
+
+
Φ
9
Rod diameter of intake
valve
039
.
0
054
.
0
8
−
−
Φ
Clearance
0.039~0.071
0.20
Valve guide bore
017
.
0
0
8
+
Φ
10
Rod diameter of exhaust
valve
064
.
0
079
.
0
8
−
−
Φ
Clearance
0.064~0.096
0.25
Valve guide bore
017
.
0
0
8
+
Φ
11
Free height of valve spring
48
Perpendicularity of valve
spring
Φ1.4
12
Outside diameter of idler
gear A shaft
025
.
0
055
.
0
55
−
−
Φ
Clearance
0.025~0.080
0.2
Inside diameter of idler gear
A bearing
03
.
0
0
55
+
Φ
13
Cylinder sleeve bore
065
.
0
020
.
0
93
+
+
Φ
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Maintenance manual for sunray hfc4da1-2c china-IV diesel engines
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No. Name Standard
Size
(mm)
Fitting
nature
Assembly
Clearance for
New Engine
(mm)
Wear Limit
(mm)
Name Standard
Size
(mm)
Fitting
nature
Assembly
Clearance for
New Engine
(mm)
Wear Limit
(mm)
13
Protrusion height of
cylinder sleeve
0~0.08
14
Axial run-out clearance of
camshaft
Clearance
0.05~0.13
0.20
Cam height of camshaft
42.02±0.05 0.38
15
Inside diameter of camshaft
bush
025
.
0
0
50
+
Φ
Clearance
0.025~0.080
0.12
Diameter of camshaft
journal
025
.
0
055
.
0
50
−
−
Φ
16
Deflection of cam bush
0.02
0.1
17
Outside diameter of piston
pin
0
005
.
0
34
−
Φ
Clearance
0.002~0.015
0.03
Piston pin bore
010
.
0
002
.
0
34
+
+
Φ
18
Thickness of connecting
rod large end
0
07
.
0
33
−
Φ
Clearance
0.175~0.320
0.35
Opening of crankshaft
connecting rod journal
250
.
0
175
.
0
33
+
+
Φ
19
Clearance of intake and
exhaust valves (cold state)
Clearance
0.3~0.4
20
Main journal
068
.
0
086
.
0
70
−
−
Φ
Clearance
0.031~0.066
0.11
Main bush bore (after
assembly)
003
.
0
033
.
0
70
−
−
Φ
21
Outside diameter of piston
pin
0
036
.
0
34
−
Φ
Clearance
0.008~0.026
0.05
Inside diameter of
connecting rod bush
020
.
0
038
.
0
34
+
+
Φ
22
Crankshaft connecting rod
journal
070
.
0
085
.
0
53
−
−
Φ
Clearance
0.029~0.069
0.1
Connecting rod bush bore
(after assembly)
016
.
0
041
.
0
53
−
−
Φ
23
Grouping of piston outside
diameter
Grouping
clearance
0.053~0.075
Group A
92.957~92.968
Group B
92.968~92.979
Group C
92.979~92.990
Group D
92.990~93.001
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Maintenance manual for sunray hfc4da1-2c china-IV diesel engines
15
No. Name Standard
Size
(mm)
Fitting
nature
Assembly
Clearance for
New Engine
(mm)
Wear Limit
(mm)
Grouping of cylinder sleeve
inside diameter (after
pressed-in)
Group A
93.021~93.032
Group B
93.032~93.043
Group C
93.043~93.054
Group D
93.054~93.065
24
Opening of piston ring
1
st
compression ring
0.2~0.4
1.5
2
nd
compression ring
0.65~0.85
1.5
Oil control ring
0.25~0.50
1.5
25
End clearance of piston ring
1
st
compression ring
0.078~0.139
0.15
2
nd
compression ring
0.045~0.09
0.15
Oil control ring
0.03~0.07
0.15
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Maintenance manual for sunray hfc4da1-2c china-IV diesel engines
16
Section VII Specification of Main Attachments and Accessories
Lubrication
system
Engine oil pump type
Externally engaged gear pump
Flow rate of engine oil pump
≥ 23L/m (at 1,000r/m and 0.4MPa)
≥ 23L/m (at 1,800r/m and 0.44MPa)
Open pressure of engine oil pump
relief valve
0.7±0.08MPa
Engine oil filter type
Filter element type
Cooling
system
Water pump type
Centrifugal type
Flow rate and head of water pump
(water temperature at 80±5ºC)
Head ≥6.5m (at 3,000r/m) at 100L/min flow rate;
Head ≥12m (at 4,000r/m) at 120L/min flow rate;
Thermostat type
Pellet thermostat
Temperature of thermostat
Initial open: 82ºC; full open: 95ºC
Fan type
Independent electric fan
Electric
system
Preheating plug type
Ceramic type
Voltage of preheating plug
12V
Starter specification
12V,2.8kW
Alternator specification
14V,90A
Battery voltage
12V
Intake system
Turbocharger
Radial flow variable section turbocharger
The top speed of turbocharger is ≤220,000r/m, with
turbocharger ratio at ≤2.2.
EGR
Type of EGR valve
Position feedback type
Voltage of EGR valve position
sensor
5V
Electronically
controlled
common rail
fuel system
Fuel
filter
type
Spin-on type, with fuel-water separator, manual fuel
delivery pump, and diesel heater
High pressure fuel pump
BOSCH CP1H, radial three-plunger pump, with fuel
delivery fuel pump and solenoid valve control
Fuel injector
BOSCH CRI2.2, solenoid valve control
High pressure common rail
Maximum rail pressure: 160MPa
Electronic control unit (ECU)
BOSCH EDC17, with working voltage at 12V
Crankshaft speed sensor
Working clearance: 0.5~1.2mm
Camshaft position sensor
Working clearance: 0.5~1.5
Air flowmeter
HFM6, with working voltage at 12V and flow measurement
range at 40~840kg/h.
Water temperature sensor
NTC type
Rail pressure sensor
Voltage output: 0.5~4.5V
Accelerator pedal position sensor
Voltage: 5V
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Maintenance manual for sunray hfc4da1-2c china-IV diesel engines
17
Chapter II Maintenance for Main Structures of Engine
Section I Disassembly of Engine Assembly
I. Special Notices:
a) Before overhauling the engine, make sure to firstly disconnect the negative cable of the battery, or it will damage
the harness and other electric units;
b) Unless otherwise specified, rotate the ignition switch to LOCK position;
c) Whenever the air cleaner is disassembled, make sure to plug the intake port, in order to prevent the ingress of
foreign material, which may enter into cylinder and cause serious damage.
II. Disassembly Procedure
z Turn the ignition switch to LOCK position and disconnect the negative cable of the battery.
z Open the oil drainage bolt of the oil sump and fully drain and collect the oil.
z Fully drain the coolant.
z Disassemble the water inlet and outlet hoses of the engine.
z Disassemble the electronic control harness for engine ECU, engine, and complete vehicle.
z Disassemble the power supply wires for alternator, starter, and oil pressure and water temperature sensors.
z Remove the connecting hose between intake connecting pipe and air cleaner.
z Loosen the connecting pipe of inter-cooler.
z Shut off the fuel pipeline and unplug the fuel pipe and return pipe.
z Disconnect the power supply of the radiator fan and when necessary loosen the radiator bracket and take out the
whole radiator.
z Loosen the clutch connecting pipe.
z Disassemble relevant connecting pipes of air conditioner and power steering pump.
z Disconnect the exhaust manifold and exhaust muffler pipe.
z Loosen the connecting mechanism between transmission and the complete vehicle.
z Loosen the fixing bolts between engine and transmission suspension bracket.
z Steadily lower the engine with elevator.
z Loosen the connecting bolts between engine and transmission and separate the transmission from the engine.
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