JAC HFC4DA1-2C engine. Service Manual — part 1

Maintenance manual 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

Maintenance manual 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 manual 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 manual 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 manual 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.

Maintenance manual for sunray hfc4da1-2c china-IV diesel engines

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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.

Maintenance manual for sunray hfc4da1-2c china-IV diesel engines

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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!

Maintenance manual 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

Maintenance manual for sunray hfc4da1-2c china-IV diesel engines

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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

Maintenance manual for sunray hfc4da1-2c china-IV diesel engines

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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

Maintenance manual for sunray hfc4da1-2c china-IV diesel engines

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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

Maintenance manual 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

Maintenance manual for sunray hfc4da1-2c china-IV diesel engines

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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

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

Maintenance manual for sunray hfc4da1-2c china-IV diesel engines

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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

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

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)

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

Maintenance manual for sunray hfc4da1-2c china-IV diesel engines

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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

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.