Byd S6, S6a, S6K

BYD S6, S6A, S6K Service Manual
BYD S6, S6A, S6K

Repair Manual
Engine Accessories
Foreword
This Repair Manual provides information about diagnosis and repair procedures, adjust-
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If you need information about product brand, part number or special tool mentioned in this
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mation, illustrations and product description used in this Manual are applicable to situa-
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Without permission of BYD Auto Industry Company Limited, do not copy, store any part of
this manual on retrieval system or spread it by means of electronic, mechanical, copy or
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BYD Auto Industry Company Limited
Date
All rights reserved
1
Engine Accessories
Contents
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Caution
Warning: in order to reduce possibility that person and/or property is damaged, please observe
the following descriptions:
1. This Manual is prepared by BYD Auto Industry Company Limited. for qualified professional
technicians. Anyone without proper training, tools and equipment who tries to repair and
maintain this car may cause self or other persons to be injured.
2. Correct repair and maintenance methods are important for the personal safety of repair
technicians, safe and reliable operation of the motor vehicle. Please use the same origi-
nal part as one part which you need to replace, or the part specified by BYD Auto Industry
Company Limited. Do not use replacement parts unauthorized by BYD Auto Industry Com-
pany Limited.
3. Repair procedures recommended or described in this Manual are effective methods for re-
pair and maintenance. A specially designed tool needs to be used in some procedures.
Therefore, you must ensure that personal safety or safe operation of vehicle will not be
threatened when you use replacement parts, repair procedures or tools which have not au-
thorized or accepted by BYD Auto Industry Company Limited.
4. This Manual contains information under “Warning”, “Special Note” and “Notes” which
should be complied with to avoid injury in repair and maintenance. Improper maintenance
may damage vehicle or bring potential risk to the vehicle. These “warning”, “special notes”
and “Notes”do not cover all cases. BYD Auto Industry Company Limited. cannot give warn-
ing and compensate for potential risk due to violation of these notes.
5. This Manual includes repair procedures for vehicle equipped with safe airbag system
(hereinafter referred to as the “air bag”). Refer to “Warning”, “Special Notes”, “Notes” and
“Warnings” in “Protection Device ”. Please refer to parts of air bag and line position draw-
ing in “Protection Equipment” before repairing parts of air bag or its line or adjacent to the
airbag. Violation of information under “Warning” will cause the air bag deployment, personal
injury or unnecessary repair of airbag.
Violation of information under “Warning” will cause the air bag deployment, personal injury
or unnecessary repair of airbag.
II
Report errors and recommendations
If you find any error in this Repair Manual or have any recommendation for this Repair Manual,
please contact BYD Auto Industry Company Limited. by letter or fax. Details of contact are as fol-
lowing:
Technical Service Department BYD Auto Sales Co., Ltd.
Address: Room 1-446#, BYD Auto, Pingshan Industrial Park, Longgang District, Shenzhen
Zip code: 518118
Fax: 0755-8992-4437
Please fill the following information in the Quality Report in contact:
Your name
Name of Sales and Service Store
Telephone and fax numbers of Sales and Service Store
Description of your concerns
Other necessary information (such as sample or marked page number)
Any applicable electronic information (such as parts identification number)
BYD Auto Industry Company Limited. will answer your questions in follow procedure:
Forward your questions to the relevant repair motorer
Consult the relevant repair motorer
Provide you with answers to your questions within 10 working days
5HSDLU0DQXDO4XDOLW\5HSRUW
To Manager of Technical Service Department
Name of Manual Publication Date
Dealer Name Reporter name
Subject
Description of problem
Revision comments
III
I Epitome
Contents
Section 1 Technical 3erformance and 3arameters of Finished Automobile1-1

0DLQWHFKQLFDOSDUDPHWHUVRI¿QLVKHGDXWRPRELOH ..........................................1-1
1.2. Engine performance parameter:.......................................................................1-2
1.3. Engine accessory and chassis assembly type and parameter: .......................1-2
1.4. Body structure type ..........................................................................................1-3
1.5. Body accessory ................................................................................................1-3
1.6. A/C system structure and parameter................................................................1-4
1.7. Electric System Structure and Parameters ......................................................1-5
1.8. Lubricating oil and fuel, and capacity ...............................................................1-6
Section 2 Vehicle identification1-
9HKLFOHLGHQWL¿FDWLRQQXPEHU 9,1 ...................................................................1-8
2.2 Warning note label position: .............................................................................1-9
Section Maintenance rule 1-9
3.1. Warning and notes ..........................................................................................1-9
3.2. Instructions: ...................................................................................................1-10
Section Overhaul Specification 1-2
4.2. Electric control system ...................................................................................1-28
4.3. Corrective maintenance procedure ................................................................1-36
Section 5 Abbreviations and Color Symbols of Electric Wires 1-
5.1. Abbreviations..................................................................................................1-38
5.2. Color symbols of electric wires.......................................................................1-40
1-I
1. This manual description (4) Removal steps are exactly reverse as

installation steps. Therefore, detail ad-
(1) This manual is prepared accoding to in- ditional installation steps.
ternational standard and technical stan-
dard of BYD Auto Industry Company (5) Only describe key points in text section.
Limited. Indicate specific steps and other details
in illustration.
(2) Repair operation includes main proce-
dures as following: (6) Steps in this Manual are provided in
various modules:
ķ Diagnosis
ķ Illustration indicates what and
ĸ Dismantle/install, replace, disas- where to do
sembly/assemble, check and ad-
just ĸ Title indicates what job to be done
Ĺ Final inspection Ĺ Descriptive text focuses on how

to complete this job and provides
(3) This manual describes the first two other information such as specifi-
procedures in maintenance procedure. cations and warnings
There is no description about “”final
check””. 4. Repair specification
(4) This Manual does not describe the fol- “Specification Description” is indicated
lowing basic operations which should in bold type in necessary position of
be complied with strictly in practice: this Manual.
ķ Using a jack or a lifter 5. Definition of terms
ĸ Wash removed parts when neces- Warnings indicate that it may cause se-
sary rious personal hurt to a maintainer.
Ĺ Visual inspection Special notes indicate that it may dam-

age the vehicle or parts.
2. Preparation
Notes indicate that it is helpful to com-
Prepare special tools and special repair plete maintenance in an effective meth-
materials which might be used accord- od.
ing to repair conditions; always use
special tools and special repair materi- 6. National standard units
als when necessary. Carry out repair
operations in strict accordance with Units used in this Manual are national
correct steps. Please refer to the in- standard units
struction of related repair and operation
parts in this manual.
3. Repair steps
(1) Provide composition diagram in each

section as required.
(2) Specify non-reusable parts, lubricated

parts, pre-painted parts and torque re-
quirement in the composition diagram.
(3) Focus on tightening torque, lubricated

parts and non-reusable parts in de-
scription of repair steps.
1-II
Section 1 Technical 3erformance and 3arameters of Finished Automobile

11 Main technical parameters of finished automobile:
Content Design parameter
Product model S6, S6A,S6K
Basic type Integral body constructure, 5-door, 2-compartment, 1-cover
Drive type Front-mounted engine, front wheel drive
Length 4810
Outline dimension Width 1855
(mm) Height (without
1725 (1680 with luggage rack) (without load)
load)
Axle distance (mm) 2720
Front 1580
Wheel track (mm)
Rear 1555
Front overhang(mm) 1010
Rear overhang(mm) 1080
Minimum ground clearance (mm) 190
Model S6 S6A S6K

Mass parameters Complete vehicle
1620 1665 1695
(kg) kerb mass
Full load mass 1995 2040 2070
Rated seating
5
capacity (pc.)
Trafficability Approach angle 23.5
characteristics (full
load) Departure angle 22
Minimum diameter
of turning circle 11.8
(m)
Luggage compart-
˄ 1084L/ lay down the second row seats 2398L ˅±5 L
ment capacity (L)
Maximum grade-
30
ability (%)
1-1
12 Engine performance parameter:
Item Unit Type and parameters
Model BYD483QB BYD488QA
Cylinder bore mm 83 88
Stroke mm 92 96
Displacement L 1.991 2.362
Compression ratio 9.6 : 1 9.8 ĩ 1
Rated power kW/rpm 95/5800 118/5800
Maximum torque Nm /rpm 172/4750 229/4000
Fuel feed type Electronic fuel injection
Ignition type Spark ignition type
1 Engine accessory and chassis assembly type and parameter:
Assembly Structure parameter
Exhaust system Two-stage muffler, with three-way catalyst device
Intake system Intake pipe, air resonant cavity, air filter

Including fuel tank, fuel pump, fuel filter, fuel pipe, accelerator pedal, accelerator
Fuel supply system
cable and fuel tank.
Cooling system Water cooling type, engine electronic fan
Model S6 S6K S6A
Dry single plate, dia- Dry single plate, dia-
Clutch
phragm spring constant —— phragm spring constant
type
pressure pressure
Type Manual Automatic Manual
Model 5T19 BYD6DT35 BYD6T25
Transmission 1st gear 3.583 3.462 3.769
2nd gear 1.947 2.05 2.087
3rd gear 1.379 1.3 1.324
Gear ratio 4th gear 1.03 0.902 0.977
5th gear 0.767 0.914 0.975
6th gear —— 0.756 0.814
Reverse 3.416 3.989 4.549
1-2
Drive shaft Type Breaking type
Front suspension Mcpherson independent suspension

Suspension
Rear suspension Mcpherson three connecting rod independent suspension
Tyre type Tubeless radial tire

Wheel and tyre
Tyre size 225/65R17
Steering gear type Pinion-and-rack, hydraulic power steering

Steering
Steeringgear Four-spokesteeringwheel,diameter 370mm
Status No load
Front wheel camber -0º40´±45´
Front wheel toe-in 0±1 mm

Angle of toe-in of
Wheel alignment 10º40´±45´
kingpin
Kingpin inclination 2º35´±45´
Rear wheel camber -0º45´±45´
Rear wheel toe-in 1.5±1 mm

Hydraulic dual pipe, anti-lock brake system (ABS), 10-inch vacuum
Structure type booster, boosting ratio ratio 7.3 dual cavity brake master cylinder, diam-
eter 22.22mm, stroke 21+21
Brake system
Front brake Ventilation disc brake, clearance automatic adjustment
Rear brake Solid disc brake, clearance automatic adjustment
1 Body structure type
Content Design parameters

Bodytype Loadingtype,metalframestructure,5-door
Door assembly Window frame type, open clockwise, with side bumper bar
Engine cover Opening upwards, mechanism hinge, common stay bar
Luggage compartment Mechanism hinge, gas spring support, (365L/1084L/2398)±5 L
15 Body accessory

Door lock Snap plate type door lock
Front/rear bumpers Plastic, color is the same as the body
Instrument panel Injection moulding
Interior guard plate Injection moulding framework
ABC pillars Injection moulding, buckle connection
Roof Moulding press, non-woven surface layer
Sun visor High configuration, with make-up mirror
1-3
Front windshield: double curved surface, sandwich glass, 5mm thick
Rear side wall window: double curved surface, full tempered glass, right
printed antenna, 4mm thickness
Front angle window: double curved surface, full tempered glass, 3.5mm
Windscreen
thick
Rear windscreen: hyperboloid, full-tempered glasses,3.5mm thick
Side window: double curved surface, area tempered glass, 3.5mm thick,
electric window regulator
Sunroof Openable wide front sunroof
Outside rearview mirror: convex reflectors on the left and right, electri-
cally regulated, heatable, foldable (economy, comfortable and honour-
able versions are manual, foldable and heatable; flagship version is
Rearview mirror electric, foldable and heatable, with a camera).
Inside rearview mirror: manual anti-dazzle type, double position inside

mirror, direction indicator
Front row seat: electric 6-direction adjusting luxury leather driver seat,
with heating function and headrest; electric 4-direction adjusting luxury
leather auxiliary driver seat, with headrest.
Seat
Middle row seat: 6:4 backrest foldable, cushion adjustable back and
forth, luxury leather seat, with headrest;
Rear row seat: optional
Front row seat is provided with three-point seat belt (each for main and
Seat belt auxiliary driver seats), middle row seat is provided with three-point seat
belt
16 A/C system structure and parameter
Structure type Steam compression type refrigeration, water heating
Automatic constant temperature air conditioner, multi-zone sepa-

Operation rate temperature adjustment, with humidity adjustment function
and air filter.
Air conditioning
Refrigerating fluid HFC-134a, filling amount: 600±50g
system
Compressor Vortex, displacement: 106ml/revolution model: WXH-106-F2
Parameters Vortex, displacement: 106ml/revolution model: WXH-106-B11
Blower Centrifugal, air flow is not less than 550 m3/h
1-4
17 Electric System Structure and 3arameters
Circuit Single wire system, negative earth, DC voltage 12V
Generator AC generating power 14V , 110A

Power supply,
483QB: electromagnetic control, 1.2KW
starter, charging Starter
488QA: electromagnetic control, 1.4KW
system
Electric fan Two-stage speed regulation double fans
Battery Maintenance-free lead-acid battery 12V, capacity 70AH

High beam: 12V-60W, 2 sets
Front combi- Low beam: 12V-55W, 2 sets
nation light Steering lamp: 12V-21W, 2 sets
Position lamp: 12V-5W, 2 sets
Side steering
12V-5W, 2 sets, installed on outer rearview mirror
lamp
Front fog light 12V-55W, 2 sets

Reverse lamp: 12V-21W, 2 sets
Rear combi- Steering lamp: 12V-21W, 2 sets
nation lamp Brake lamp/tail lamp: LED
Rear fog lamp: 12V-21W, 2 sets
Rear license
Power: 12V-5W, 2 sets
lamp
Front/rear
Power: 12V-5W, 6 sets
interior lamps
Top lamp Power: 12V-8W

Lighting, signal
system
Rear interior
Power: 12V-5W,2 sets
light
Rear luggage
compartment Power: 12V-5W, 2 sets
lamp
Door courtesy
Power: 12V-1.08W
lamp
Foot illumina-
Power: 12V-0.54W, 2 sets
tion light
Door lamp 12V-5W, 4 sets
Combination
instrument LED
lamp
High-mounted
12V-5W,2 sets
brake lamp
1-5
Combination Combination instrument: fuel meter, speedometer, engine tachometer and

instrument coolant temperature gauge etc.
Including: left/right steering indicator lamp, low fuel warning lamp, high beam
indicator lamp, parking brake indicator lamp, safety system indicator lamp, seat
Indicator lamp belt indicator lamp, supplement restraint system indicator lamp, door and trunk
on combina- opening indicator lamp, ABS brake indicator lamp, constant speed cruise control
tion instru- indicator lamp(2.4 AT Luxury type), rear fog lamp indicator lamp, front fog indica-
ment tor lamp, low engine oil pressure indicator lamp, intelligent key system warning
Instrument sys- lamp, small lamp indicator lamp, charging system warning lamp, engine mal-
tem function indicator lamp, SVS indicator lamp etc.
Speed display, reverse radar icon display, outside temperature display and
Multifunction
multimedia information display, coolant temperature indication or and fuel
screen
indication, etc.
Left/right steering indicator lamp, seat belt indicator lamp, intelligent key
Indicator lamp system alarm lamp, vehicle-mounted telephone indicator lamp, car telephone
on multifunc- playing MP3 indicator lamp, reverse radar display, water temperature display,
tion screen time display, speed display, multimedia information display, outside tempera-
ture display etc.
Vehicle-mounted CD(1CD/6CD), 6 loudspeaker (low specification 2 loud-
Audio speaker), audio input interface, multi-disc CD (virtual CD), high configuration
NAVI(DVD) navigation system, MP3 player etc.
Electrical auxiliary
Including cigarette lighter, vehicle-mounted power supply, etc.
system
Communication CAN bus
1 Lubricating oil and fuel, and capacity

Lubricant

483QB: replace engine oil filter and fill 3.3L, do not replace engine oil filter
and fill 3.0L, SG grade and above
Engine oil
488QA: Replace engine oil filter and fill 4.3L, do not replace engine oil and
fill 4.1L, net fill 5.0L, SG grade and above
F4A4B:7.7L, MITSUBISHI ATF SP3
VT2-04O˖4.1L, ESSO EZL799A
Transmission double curved sur-
F5M41: 2.1L, SAE: 80W-90 (in summer in the north); 75W-90 (in winter in
face gear oil
the north); 80W-90 or 85W-140 (all the year round in the south). API: GL-4 or
GL-4 above.
Bearing and ball pin lubricating
Li-based
grease
2. Fuel

Fuel type 92# unleaded petrol for vehicle or above
Fuel tank capacity (L) 70
1-6
3. Steering fluid, brake fluid, coolant, A/C refrigerating fluid
Name Brand Capacity

Power steering fluid DEXRON-III 1.1L
Clutch fluid and brake fluid DOT3 0.8L
Coolant High quality glycol coolant 7.1L
A/C refrigerating fluid HFC-134a(R134a) 600±50g
Windscreen washing fluid About 4.5L
1-7
Section 2 Vehicle identification

21 Vehicle identification number(VIN)
VIN description:
L G X C 1 4 C G X X X X X X X X X
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
Manufacturer Production sequence number
Vehicle brand
Transmission type and drive type
Body type
Restraint system type
Engine characteristics
Check digit
Year
Assembly plant
Identification number position: 4ˊ Vehicle nameplate is on left shock
absorber support. Vehicle nameplate
There are several identification numbers on contains vehicle identification number
the vehicle on different positions. (VIN), engine, vehicle type, engine
1ˊ Engine model/engine number stamped displacement, maximum design total
on the engine set. mass, date of production, etc.
2ˊ Transmission number is located on the

nameplate the top of the transmission.
Do not confuse transmission number

and engine number.
3ˊ Vehicle identification numbers are on

left upper of instrument panel and floor
beam under auxiliary driver seat as
shown in the Fig.Vehicle identification Nameplate of
number is used for registering the own- complete
er. vehicle
VIN
1-8
22 Warning note label position: Section Maintenance rule

Specific position for warning note label about 1 Warning and notes
air bag, radiator and battery as shown in the
Fig.: 1. Description for “warning”, “special
notes” and “notes”
Diagnosis and maintenance procedure in

BYD Maintenance Manual includes general
and specific warnings, special remarks and
SRS warning
sign
notes.
BYD Auto Industry Company Limited. tries to

provide maintenance information and helps
the maintainer diagnose and maintain the
system so that the vehicle can run normally;
but, if the maintainer does not follow recom-
mended method, some procedures may
cause risks to the maintainer. Warning: spe-
cial marks and notes are to prevent the above
risks and not all the risks are foreseen.
This information is located at an obvious posi-

tion of Maintenance Manual. This kind of infor-
mation is edited for the following information:
Child protection 1) Cause serious personal hurt to the
device
maintainer
2) Damage the vehicle
3) Unnecessary vehicle maintenance
4) Unnecessary part replacement
5) Vehicle part maintenance or replace-

ment improper. Any warning or special
remarks in general information is quot-
ed from each maintenance category.
Coolant indicator 2. Warning definition
Cooling fan indicator

Warning: Take some required measures or do
not take measures that are forbidden. If you
ignore “warning”, it may lead to the following
result:
1) Cause serious personal hurt to the

maintainer
2) Cause serious personal injury to other

maintainers in working area.
3) If the vehicle is repaired improperly, it

will cause serious personal hurt to the
driver and/or passengers.
1-9
3. Special remarks definition 2 Instructions:

Special remarks: pay attention to necessary 1. Basic maintenance prompt
measures or forbidden measures. If you ig-
nore “special remarks”, it will lead to the fol- Ł Operation requirements
lowing results:
1) Clothing: keep clean.
1) Damage the vehicle
Pay attention to the operator’s
2) Unnecessary vehicle maintenance
ƺ Working clothes ƺ Shoes ƺ Hands
3) Unnecessary part replacement
4) Operation or performance for main-

tained system or part is abnormal
5) Damage system or part that operates

normally depending on repaired system
or part
6) Operation or performance for any sys-

tem or part is abnormal depending on
repaired system or normal operation
7) Damage fasteners, basic tool or special

tool
8) Coolant, lubricating oil or other fluid 2) Vehicle protection

leakage
Before operation, prepare:
4. Note Definition
ƺ Floor mat ƺ steering wheel sleeve
Note: Declaration emphasizes necessity of
ƺ seat cover ƺ Fender cover
some diagnosis or maintenance procedure.
“Notes” declaration purpose as follows: ƺ Radiator grille cover
1) Clear program ƺ Door edge protector
2) In order to complete one procedure,
provide supplementary information Seat hood
3) Clarify reason that operation shall fol-

low recommended procedure
4) Provide information that completes pro-

cedure in a more effective manner; pro-
vide experience to the maintainer so as
to complete the procedure more easily Fender hood
1-10
Do not place tools and parts on the

top of vehicle, engine hood or trunk
lid.
Avoid metal or hard objects from be-

ing exposed in working clothes. For Keep enough room to open doors and
example: avoid doors from knocking into:
ƺ Belt buckle ƺ Key chain ƺ Fastener ƺ Wall ƺ Tool kit ƺ Desk
ƺ Tools in the pocket (such as wrench)
ƺ watch
3) Safety operation
When two persons or above work to-

gether, safety for other workers shall
be ensured.
Do not lean against the body; do not When the engine runs, keep good
step on the bumper ventilation in workshop.
Keep enough distance between ve- When maintaining high temperature,

hicles. high pressure, rotating, moving or vi-
brating parts, the operator shall wear
Do not place a piece of paper on the appropriate safety equipment. Handle
vehicle for writing; do not use acces- with care to avoid yourself or others
sories supplied with the vehicle, such from being hurt.
as cigarette lighter.
When lifting a vehicle, safety equip-
ment shall be used.
1-11
When jacking up the vehicle, safety production.

support shall be placed on the speci-
fied position. ĸ After precoated parts are loose or dis-
mantled, it is recoated by specified
4) Prepare maintenance tools and mea- sealant before retightening.
suring instruments
Ĺ When reusing precoated parts, old
Before operation, prepare tool rack, special sealant shall be removed and dry the
fault diagnosis tester, gauge, related tools parts with compressed air. Then coat
and instruments, engine oil, cloth and parts sealant on the bolts and nuts.
for replacement.
Special note: tighten them according to
5) Dismantle/install, disassemble/assem- XSSHUOLPLWYDOXHRIWRUTXHWROHUDQFH
ble
Some sealant becomes hardening slowly.
Analyze and diagnose fault phenom- Therefore, you have to wait for a while for
enon thoroughly, then make related hardening.
operation.
Before dismantling parts, check the

assembly installation conditions and
check the appearance for deformation
and damage.
If the assembly is very complicated,

such as electrical connection, a lot of Seal lock glue
bolts or dismantled pipe, they shall be
marked for easy assembling. If neces-
sary, pipe and corresponding interface
are marked temporarily. (4) Washer
If necessary, clean dismantled parts If necessary, apply sealant on the washer to

and check it thoroughly and then in- prevent leakage.
stall it.
(5) Bolt, nut and screw
6) Dismantled parts
Observe all descriptions of specified
Put dismantled parts in order to avoid tightening torque carefully.
mixing or contaminate new parts.
Torque wrench shall be used.
For nonreusable parts, such as wash-
(6) Fuse
er, O ring and self-locking nut, replace
them according to the Manual. When replacing fuse, new fuse with appropri-
ate rated current shall be used. Rated value
If the user requests, we can store dis-
shall not too high or low.
mantled parts for the user.
(7) Buckle
(2) Jack up and support the vehicle
Dismantling and installing methods for body
When jacking up and supporting the vehicle,
trimming part buckles as shown in the follow-
be careful. Jack up and support the vehicle at
ing Fig.
the right positions.
Special note: if these buckles are damaged
(3) Precoat parts
during the course of dismantling, they shall
ķ Precoating parts refer to bolts and nuts be replaced by new buckles.
coated by sealant during the course of
1-12
Shape˄eg.) Dismantling/installation
Jaw vise
Clamp puller
Protective belt
Screwdriver
Protective belt
Scraper
1-13
ShapeǄeg) Dismantling/installation
Dismantling Installation
Screwdriver
Press
Clamp puller
Push out the king pin to remove it and pry

the king pin sheath
Screwdriver
Press
Clamp puller
Screw off the king pin and pry out the

sheath
Press
Screwdriver
Clamp puller
Small clamp puller

Push out the king pin to remove rivet and pry
the king pin sheath
1-14
(8) Hose dismantling and disassembling SRS faults, fault code is the most im-
portant maintenance basis. When over-
When disconnecting hose, first pinch hauling the system, please record the
hose end and entwist to pull it down. status before dismantling the battery
Do not pinch the middle to pull it negative ground wire, because DTC in
forcedly. Otherwise, it may damage other systems will be lost when disman-
the hose. tling the battery negative ground wire.
ĸ Before specific maintenance, first turn

Negative ignition switch to “LOCK”, and disman-
terminal tle the battery negative ground wire,
then wait for more than 3 minutes. Oth-
erwise, air bag may expand acciden-
tally. In addition the removed cathode
terminal shall be insulated by insulation
tape as shown in figure.
Negative
terminal
In order to reassemble the hose, make
a label for easy identification when
disconnecting.
After completing these work, check it

carefully and make sure the hose is
correctly connected.
When using measuring meter, do not

After disconnecting the battery connector
connect the hose to oversized con-
wire, memory contents in clock and audio
nector. Adjust the connector size grad-
system will be deleted. Therefore, before
ually. Note: once the hose is straight-
working, record memory contents in each
ened, it may cause leakage.
memory. When system overhauling is over,
2. Vehicle provided with SRS and seat reset clock and audio system according to
belt pretensioner original method.
BYD S6 is provided with supplementary re- Ĺ After a minor collision, you should check
straint system (SRS) and seat belt pretensioner. the airbag system to be checked even if
the air bag is not deployed.
If correct operation procedures are carried
out during the repair of the airbag system, it ĺ Do not use airbag parts removed from an-
might cause accidental deployment of airbag, other car. If it is required to replace compo-
leading to serious accident. nents, new components shall be used.
In addition, if mis-operation occurs during the Ļ You should remove the airbag ECU be-
course of maintaining system, air bag cannot fore repair if the vehicle might be vibrat-
expand normally. Therefore, before mainte- ed when repairing the airbag system or
nance (including dismantling and installing its components.
parts, check or replacement), please read the
ļ It is forbidden to disassemble and re-
following notes carefully and observe correct
pair DABǃPABǃSABand install air
operation procedures:
bag electronic control unit for reusing
(1) General notes and other reasons.
ķ Because it is very difficult to determine Ľ If DAB, PAB and airbag ECU and other
1-15
components fall down to the ground, control unit, DAB, PAB, SAB and clock
or are vibrated or knocked, or if their spring shall be removed and kept well.
housing, bracket or connector have
crack, indent or other damage, replace Ŀ Do not use detection lamp, common
the relevant parts. voltmeter and ohmmeter when detecting.
Voltmeter and ohmmeter shall be high
ľ It is forbidden to put DAB, PAB, SAB, resistant (minimum 10k¡/V). Do not use
air bag electronic control unit into heat- an ohmmeter on DAB, PAB, SAB or pre-
ing air or flame directly. tensioner, as shown in the Fig.
When painting has effect due to over-

heating (above 93°C), air bag electronic
Don't use the ohmmeter on the airbag or

pretensioner
ƽ You may only conduct operations bags and labels.

specified in this Manual on the airbag
system. Do not test any circuit of the (2) Clock spring
airbag system by electrical testing de- Steering wheel shall be correctly installed on
vice. steering column to ensure clock spring cable
ƽ Attach warning lables on the relevant is in the middle position. Otherwise, the cable
positions in the components of the air- is disconnected or other faults occur.
bag system and inside the car. Conform (3) Driver air bag (DAB), passenger air bag
to instructions specified in components (PAB) and side air bag (SAB)
during operation.
ķ During the course of maintaining air
Before replacing any component, conduct the bag, air bag module shall be installed
self-diagnosis of the system and check com- as soon as it is taken from the con-
pletely that the system functions normally. tainer. If it is necessary to stop working,
Warning for special tool of air bag system air bag module shall be returned to the
container. It is forbidden to keep air
In order to prevent air bag from expanding bag module unattended. When storing
unexpectedly when the system has a fault, dismantled air bag module, be careful
tool equipment specified in this manual shall to avoid collision and vibration. Before
be used and instructions in this manual shall power on:
be observed. If specified tool equipment is
not used according to instructions, air bag Remove dust and dirt, and lubricating
may expand unexpectedly, which leads to grease from mounting surface.
personal hurt and unnecessary air bag sys- Put air bag module on mounting sur-
tem repair. face horizontally.
Normal service life of airbag is 10 years; if Put the arrow on air bag module to-
above service life, you must replace the air- wards the front of vehicle.
1-16
Tighten all fasteners and support fas- ļ In order to prevent air bag module from
teners of air bag module to the speci- expanding unexpectedly, do not dis-
fied torque value. pose unexpanded air inflation module
in the same way of common waste.
During the course of discarding, if the
container is damaged, some substanc-
Correct Error es in unexpanded air inflation module
will lead to serious disease or personal
hurt. According to expanding procedure
in the chapter, unexpanded air inflation
module is discarded safely. If you do
not observe discarding regulation, you
may disobey related regulations and
may lead to personal hurt.
Corr-
ect Error Ľ After air bag expands, if instrument
panel is damaged, replace it.
ľ For the seat with side air bag, there

is a label “SRS SIDE AIRBAG” (side
air bag) on the backrest. Because the
seats with air bag and without air bag
ĸ Do not measure the resistance of air
have different structures (backrest
bag module detonation device. As a re-
cover and seat), correct parts shall be
sult, air bag will expand, which leads to
installed.
serious hurt.
Ĺ Do not apply any lubricating grease on

steering wheel and clean the liner with
any detergent.
ĺ The airbag expansion device contains

sodium azide and potassium nitrate,
which are toxic and highly flammable; if
they contact acid, water or heavy metal,
harmful irritant gas will be generated Side SRS warning sign
(easily generate sodium hydroxide in a
damp place) or combustible compound
forms. The airbag device contains pres-
surized argon gas, and therefore you
should not attempt to decompose the
airbag device and should protect the
airbag expansion device against pierc- When cleaning, do not immerse the seat in
ing and burning. the liquid and do not spray steam towards the
seat. Do not repair damaged or worn backrest
Ļ Do not have the airbag expansion de- cover and then replace it. After side air bag
vice contact electricity and gas. Do expands due to collision, replace with a new
not store it in a place with temperature side air bag. If the back cushion is broken, re-
above 93 °C. place it. If backrest structure is deformed, re-
place it, too. Do not install parts (cover, cush-
No matter what position of the car will ion, seat heater, indicator lamp) purchased
receive electric welding, you must dis- from automobile part market.
connect the airbag system to avoid ac-
cidental explosion before job.
1-17
Ŀ After repair of the airbag system, do done in safety area away from electri-
not hurry to connect the airbag module cal noise.
into the circuit. Firstly you should check
electrical circuit and then connect the Ľ Because seat belt pretensioner will
airbag module when you confirm that be heated after activation, it shall be
everything is correct. cooled before discarding. But, do not
cool it with water.
(4) Seat belt pretensioner
ľ Do not spray oil or water onto outside
ķ Do not measure seat belt pretensioner seat belt of front seat. Do not wash
resistance. This may activate pre- outside seat belt of front seat with any
tensioner, which may lead to personal detergent.
hurt.
(5) Air bag electronic control unit (ECU)
ĸ Do not disassemble seat belt preten-
sioner. ķ It is forbidden to reuse ECU dismantled
from other vehicles.
Ĺ Do not install the seat belt pretensioner
to other vehicles. ĸ Before maintenance, first turn ignition
switch to LOCK, and disconnect the
In order to avoid damaged and unrepaired air battery negative ground wire, then wait
bag due to collision from personal hurt, check for more than 90s. Otherwise, air bag
each seat belt system for safety. If you have may expand unexpectedly.
any doubt about system parts, you have to
replace seat belt system. Ĺ Air bag electronic control unit connec-
tor, clock spring connector, DAB con-
ĺ Ambient temperature for storing seat nector, PAB connector, SAB connector
belt pretensioner shall be below 80°C and pretensioner connector are pro-
(176°F). Do not store it in high humidity, vided with protection mechanism that
keep away from electrical noise. prevents air bag from expanding unex-
pectedly.
When taking away unexpanded seat
belt pretensioner: (6) Wire harness and joint
Do not lift up seat belt pretensioner by All wire harness and joints in the sys-
wire or connector. tem are standard yellow. If system wire
harness or joint is damaged due to ac-
Take seat belt pretensioner through cident or other reasons, it shall be re-
piston pipe. Two hands and fingers placed.
shall keep away from the cable.
3. Electrical control
Make sure open end of seat belt pre-
tensioner is back on to you and oth- (1) Battery dismantling and assembling
ers.
Do not cover opening of seat belt pre-

tensioner piston pipe.
Ļ Wherever electric welding is used, be-

fore working, disconnect power supply
near the battery to avoid the preten-
sioner from being activated unexpect-
edly.
ļ Before discarding a vehicle or seat belt

pretensioner, seat belt pretensioner
shall be activated. Operation shall be ķ Before any electrical part maintenance
1-18
or vehicle maintenance, first disconnect Do not place the battery near open fire
battery negative cable in order to pre- or spark.
vent tool or equipment from contacting
exposed live terminal, which leads to Do not let the battery acid liquid con-
short circuit, personal hurt and/or ve- tact eyes or skin. Once it contact eyes
hicle control system control module or or skin, the following items shall be
other electrical parts damaged. done:
ĸ When connecting or disconnecting the Wash contact sites with water as soon
battery cable, the battery charger or as possible.
bridging the cable, ignition key shall be See a doctor as soon as possible.
turned off, and all electrical loads shall
be turned off, otherwise specified in (2) Dismantling and assembling electronic
Operation Procedure. parts
ķ Special remarks for handling ESD sen-

sitive parts
Electrostatic discharge (ESD) will damage

many solid-state electric parts. Not all parts
that are affected by electrostatic discharge
have ESD marks. Handle all electrical compo-
nents with care. Please observe the following
safety notes to avoid electrostatic discharge
from damaging:
Ĺ When connecting or disconnecting the Before maintaining any electronic

battery cable, the battery charger or component, especially after your body
bridging the cable, ignition key shall slides with the seat, first touch metal
be turned off. Loosen cable terminal earth point to discharge static electric-
nut completely, then dismantle nega- ity in your body.
tive cable from the battery binding post,
Do not touch exposed terminal. Termi-
disconnect positive cable; when recon-
nal may be connected with the circuit
necting, first connect positive cable and
that is easily affected by electrostatic
then connect negative cable. It is for-
discharge.
bidden to twist or pry cable terminal.
When maintaining the connector, do
ĺ When dismantling the battery cable, all
not contact exposed terminal with a
clock data, audio system data and other
tool.
data are cleared, too. Before disman-
tling the battery cable, record required Do not dismantle any part from protec-
data. tive case, unless it is allowed.
Ļ The battery contains corrosive acid, Otherwise specified in diagnosis pro-
which may generate explosive gases. cedure, the following procedures shall
Current intensity generated by the bat- be avoided:
tery may result in burn injury. There-
fore, in order to reduce injury risk near Bridge or ground the part or connec-
the battery, the following rules shall be tor.
observed:
Connect test equipment probe to part
Wear safety goggles. or connector. When using test probe,
first connect ground lead.
Avoid bending above the battery as
far as possible. Before opening protective case of one
1-19
part, first ground it. Do not place solid- 4. Dismantle and install fuel system part
state part on metal working table or
on the top of television, radio or other (1) Dismantling and installing site for fuel
electrical equipment. system part
ķ Gasoline or gasoline steam is very

inflammable. As long as there is fire
source, a fire will break out. In order to
avoid fire or explosion risk, do not dis-
charge or store gasoline or diesel in an
open container. In addition, operation
will be made where no electric welding
machine, grinder, electric drill, electric
motor, stove or other fire sources exist.
Prepare one dry chemical (class B) fire
extinguisher nearby.
ĸ Do not operate in the pit or near the pit

ĸ Disconnect electronic part joint and pull to avoid fuel steam from accumulating
down the joint. It is forbidden to move here.
the cable. (2) Dismantle and install fuel system parts
Ĺ Do not fall down, knock and vibrate ķ Before maintaining fuel system, first
electronic parts, such as a sensor or fuel system pressure so as to power off
relay. If similar phenomenon occurs, it fuel pump and flame out or disconnect
is necessary to replace with a new part. fuel pipe joint to avoid personal hurt.
ĺ When cleaning the engine, electronic After fuel system pressure is released,
parts, air filter and discharge compo- a small amount of fuel overflows at the
nents with water and steam, no water is time of repairing fuel pipe, fuel injec-
allowed to go into them. tion pump or joint. In order to reduce
personal hurt, use cotton cloth to cover
Ļ Do not use impact method to install or fuel system components before discon-
dismantle electronic parts. necting pipes or joints so as to absorb
leaking fuel. After disconnecting, put the
cotton cloth into allowable container.
ĸ When repairing fuel system, you have

to wear safety goggles to avoid fuel
from splashing into eyes.
Ĺ Fuel pressure in fuel system shall not

exceed specified value. Otherwise it will
damage fuel pressure regulator or fuel
pressure gauge.
ĺ In order to reduce fire and hurt risks,

the following items shall be observed
during the course of maintaining fuel
and evaporation discharge pipe:
ļ When checking continuity of electronic During the course of installing, replace

part joint, the probe is connected care- all cracked, scratched or damaged
fully to avoid the terminal from bending. fuel pipes. Do not try to maintain fuel
pipe.
1-20
When installing new fuel pipe, do not When lifting or supporting the engine, do
knock fuel pipe clamps with a hammer not put a jack under oil pan, any metal plate
directly. Fuel pipe damage will lead to or crankshaft pulley. Lifting the engine in a
fuel leakage. wrong way will damage parts.
When heating and maintaining near a (2) Special remarks for engine support
steam discharge pipe, use a wet towel
to cover the steam discharge pipe. At If engine support is broken, it can lead to dis-
the same time, do not expose the ve- location of some parts in drive system. Dis-
hicle at 85°C above for more than one location of drive system parts may damage
hour or expose it at 60°C above for a drive system parts in the end.
long period. Special remarks: if an engine support is
Before connecting fuel pipe joint, broken, the stress applied on other engine
make sure fuel pipe joint is clean so supports will increase. This may cause other
as to reconnect it correctly and avoid engine supports to be broken.
fuel leakage. (3) Special remarks for fault diagnosis tes-
Ļ Do not breathe air in evaporation dis- ter with fault
charge pipe or hose. Fuel steam in A special fault diagnosis tester for BYD au-
evaporation discharge part may lead to tomobile shall be used. At the same time,
personal hurt. any fault for fault diagnosis tester during the
ļ When checking fuel tank, it is neces- course of using shall be indicated. Fault diag-
sary to tighten strap fasteners gradu- nosis tester that has a fault will lead to wrong
ally and alternately until it reaches the diagnosis and unnecessary part replacement.
specified torque. If strap fasteners are (4) Cooling fan
not tightened according to the specifi-
cation, fuel tank bottom will bend up. ķ In order to avoid personal hurt and ve-
When fuel tank has no fuel, fuel gauge hicle damage, if fan blade or fan cover
still indicates that there is fuel. is bent, cracked or damaged, replace it
immediately.
Ľ Do not use fuel containing methyl alco-
hol to avoid damaging or corroding fuel ĸ Even if the engine does not run, elec-
system. tronic fan in the engine compartment,
which may lead to personal hurt. Two
ľ Do not try to straighten any twisted ny- hands, clothes and tools shall keep
lon fuel pipe. Replace any twisted nylon away from electronic fan in the engine
fuel pipe to damage the vehicle. compartment.
Ŀ In order to prevent static electricity, (5) When maintaining the engine cooling
fuel pump, fuel tank and vehicle shall system, in order to avoid scalds, do not
be grounded. Do not water in this area dismantle radiator cover or liquid accu-
to prevent slipping. Do not wash spill- mulator or pipe joint before the engine
age and gasoline with water to avoid cools. If radiator cover or liquid accu-
spreading and fire risk. Put oily cloth mulator cover or pipe joint is opened
into fireproof container. before the engine and radiator do not
ŀ It is forbidden to use electrical equip- become cool, cooling system will give
ment, like electric motor or work lamp, out hot high pressure liquid and steam.
and hammer to avoid spark or high (6) Intake system parts
temperature.
ķ When maintaining intake system, use
5. Dismantle and assemble engine parts clean cloth, adhesive tape or other
(1) Special remarks for lifting engine appropriate materials to cover intake
1-21
system opening and engine opening to tain exhaust system when exhaust
avoid foreign matters from entering into system is very hot. Please maintain the
the system. exhaust system after cooling.
ĸ If it is necessary to dismantle air filter ĸ Modification for engine or other parts

assembly for maintenance, throttle will affect vehicle emission control and
valve opening shall be covered to avoid malfunction indicator lamp may be lit.
foreign matters from entering into the Modification may not make the vehicle
engine. pass required emission check / mainte-
nance test.
Ĺ Compressed valve spring will apply
high tension on valve spring compres- Modification for the following systems
sion tool. If valve spring compression will affect vehicle emission control sys-
tool compresses or releases valve tem and malfunction indicator lamp
spring improperly, valve spring will may be lit:
bounce off violently from compression
tool. Therefore, when you compress ƺ Engine ƺ transmission
or release valve spring on valve spring ƺ Exhaust system ƺ Fuel system
compression tool, dismantling or install-
ing valve stem, you have to be careful. If alternative tyre does not conform to
Improper operation will lead to personal tyre performance standard of original
hurt. tyre, it will affect vehicle emission con-
trol.
(7) Check transmission oil
Modification for these systems or the
When dismantling transmission oil screw tyre that does not conform to original
plug, the vehicle shall be static and horizon- tyre standard will make some repaired
tal. Otherwise, more oil will overflow. Trans- items beyond manufacturer warrantee
mission oil may be very hot. Transmission oil scope. This may not make the vehicle
may inject from oil screw plug. Be careful to pass required emission check / mainte-
avoid scalds! Because actual oil level is un- nance test.
known, you have to keep away from oil screw
plug when you dismantle it. Prepare a con- (10) Knock sensor
tainer to collect oil.
Hot engine coolant may lead to serious
(8) Clutch scalds. Although cooling system is empty,
some coolant still remains in the engine water
(1) When maintaining clutch parts, do not jacket. When dismantling knock sensor, these
grind or polish clutch disc, do not clean coolant shall be discharged.
parts with a dry brush or compressed
air because dust will be generated. Wet (11) Catalytic converter
cloth shall be used (but not immersed
in water). Clutch disc contains asbestos ķ In order to prevent catalytic converter
fiber. If dust is generated, these fibers assembly joint from damaged, the con-
will be mixed in the air. Dust containing verter shall be supported. When mov-
asbestos fiber is harmful to health. ing catalytic converter assembly, do not
collide with and knock the case.
(2) It is forbidden to use mineral oil or pa-
roline in hydraulic system of the clutch. ĸ If a large amount of unburned gas mix-
This oil will damage rubber parts in oil ture goes into catalytic converter, it may
cylinder. overheat catalytic converter and bring
fire risk. In order to prevent this, the fol-
(9) Exhaust system lowing notes shall be observed:
ķ In order to avoid scalds, do not main- Only use recommended oil.
1-22
Avoid idling for 20 minutes. performance.
Avoid spark-over test: Make sure vehicle wire harness con-

nector seal is good to avoid damaging
If necessary, spark-over test can be due to water.
made and completed as soon as pos-
sible. In this case, welding shall not be used
because it may damage this part.
When testing, do not run the engine at
high speed. 6. Dismantle and assemble brake system
parts
Avoid measuring engine pressure for
a long time. If necessary, it shall be (1) Only use brake liquid in a clean and
completed as far as possible. sealed container or BYD special DOT
3 brake fluid. Do not use brake fluid in
When fuel tank is nearly empty, do an open container because brake fluid
not run the engine. Otherwise, engine may become damp.
may misfire so that catalytic converter
is additionally loaded. If any other type of brake fluid except recom-
mended model or contaminated fluid may
(12) Heating type oxygen sensor and oxy- damage hydraulic brake system component
gen sensor or lead to brake failure, even personal hurt.
Brake has irritation to eyes and skin. Once it

contact eyes or skin, the following measures
shall be taken:
Eye contact ˉ wash it thoroughly with

water.
Skin contact ˉ wash it with soap and

water.
Swallow ˉ see a doctor.
ķ Take the oxygen sensor with care to (2) Do not use a container containing pe-
avoid damaging parts. Do not drop or troleum base brake fluid because petro-
mis-operate the oxygen sensor. leum base brake fluid will expand and
age rubber parts in hydraulic brake sys-
ĸ Electrical connector and exhaust port tem while water and brake fluid mixture
are not contaminated. Do not use any will lower boiling point. All brake fluid
detergent to clean the sensor. container shall be covered to prevent
contamination.
Ĺ Do not repair conductor, connector or
terminal. If leading wire, connector or (3) When maintaining wheel brake parts,
terminal is damaged, replace the oxy- please avoid the following operations:
gen sensor.
Do not grind brake lining.
ĺ When maintaining the oxygen sensor,
the following rules shall be observed: Do not grind brake lining with sand
paper.
Do not dismantle or remove oxygen
sensor ground wire (if existing). The Do not clean wheel brake component
vehicle using ground sensor may use with a dry brush or compressed air.
this ground wire as only one ground
(4) When overhauling, a piece of steel wire
point of the sensor. Dismantling
shall be used to support brake caliper
ground wire will lead to poor engine
1-23
to avoid damaging brake pipe. liquid level reading. Air in steering liquid
can lead to cavitation in steering pump
(5) Avoid brake fluid from splashing onto and steering pump will be damaged af-
paint surface, electrical joint, wire or ter a period of running.
cable. Brake fluid will damage paint
surface and corrode electrical parts. (5) Do not start the vehicle when any inlet
If brake fluid contacts paint surface, or outlet hose of power steering en-
wash it off with water immediately. If gine is disconnected. When the hose
brake fluid contacts electrical joint, wire disconnects, openings of all parts shall
or cable, repair cloth, appropriate con- be plugged or covered. Otherwise, it
tainer and fender cover shall be used will contaminate or lose power steering
to prevent brake fluid from contacting fluid and damage the system.
these surfaces. Seal it again and wash
off brake fluid to avoid overflowing. (6) When filling steering fluid or replace
steering fluid completely, it is necessary
(6) Some components in anti-lock brake to use DEXRON ċ power steering liq-
system (ABS) can be repaired sepa- uid or equivalent.
rately. Trying to dismantle or disconnect
some components of the system may If you do not use correct power steering fluid,
lead to personal hurt and/or abnormal power steering hose and seals may be dam-
operation of the system. Only maintain aged, steering fluid leaks and steering fluid
parts that can be dismantled and in- pump has a fault.
stalled. 8. A/C system
7. Dismantle and assemble steering sys- (1) Avoid inhaling A/C system refrigerating
tem parts fluid 134a (R134a) and lubricating oil
(1) Before disconnecting steering column steam or oil fog. These fluids will irritate
or middle shaft from steering engine, eyes, nose and throat. Operation shall
the wheels shall be right ahead and be made in a place with good ventila-
steering column shall be at LOCK position. In order to remove R134a from
tion. Otherwise, clock spring in steering A/C system, you have to use mainte-
column will deviate from the center, nance equipment with SAE J2210 cer-
which damage clock spring. tification (R134a regenerative facilities).
If the system has leakage, working area
(2) Before disconnecting the following shall be ventilated before maintenance.
parts, steering column shall at LOCK Other health and safety information is
position: available from refrigerating fluid and lu-
bricating oil manufacturer.
ƺ Steering column ƺ Middle shaft
(2) After broken glass falls into defroster air
ƺ Lower steering shaft outlet, it may be blown into passenger
After disconnecting the above-men- compartment, which leads to personal
tioned parts, do not move front wheel hurt.
tyre and wheel. If you do not follow 9. Dismantle and assemble body and ac-
these procedures, these parts are not cessory
aligned properly.
(1) Dismantle or connect engine cover sup-
(3) Steering wheel is turned to the limit po- port, the pressure is only applied on its
sition for not more than 3 seconds. Oth- end. It is forbidden to apply pressure in
erwise, it will damage steering pump. the middle of the bar. Otherwise, it will
(4) If power-assisted steering system is be damaged or bent.
repaired, air in steering system shall be (2) When dismantling or installing engine
discharged to obtain correct steering
1-24
compartment cover stay bar, other de- gloves to reduce the risk of personal
vices shall be used to support engine hurt.
compartment cover to avoid vehicle
damage or personal hurt. (2) In order to avoid hurting your body
when you are exposed in welding light
(3) If a door or windscreen is cracked but or plated metal poisonous smoke dur-
intact, protective tape is crosswise ing the course of grinding/cutting any
pasted to the door or windscreen to type of metal or compound moulded
avoid the door or windscreen from be- parts, you have to work in a place with
ing damaged or personal hurt. good ventilation and wear allowed gas
mask, safety goggles, ear plugs, weld-
(4) When installing front windshield glass, ing gloves and protection clothes.
do not use gaskets. Stress generated
from the gaskets will damage front (3) When you work around running engine,
windshield glass. you cannot contact moving parts and
hot surface to avoid being hurt.
(5) In order to avoid personal hurt or ve-
hicle damage, the carpet whose thick- (4) Curing time for maintenance material
ness and size are the same as that is 24 hours at least. Before solidifying,
of original carpet shall be used when do not touch repaired part. If adhesive
repairing or replacing the carpet. Make agent is not completely cured, it may
sure the carpet is installed in original lead to personal hurt.
position.
(5) Correct fasteners shall be used at cor-
(6) When you remove adhesive or foreign rect positions. Part number of alterna-
matters with a shaver blade or other tive fastener shall be correct, which is
sharp tools or cotton cloth, you shall applicable to the application occasion.
be careful to avoid damaging body sur- For parts that require thread sealant,
face. lubricating oil, preservatives or sealant
shall be specially pointed out in Main-
10. For vehicles with mobile communica- tenance Procedure. Unless otherwise
tion system specified, do not apply paint, lubricating
(1) An antenna shall keep away from ECU oil or preservatives on fasteners or joint
and sensor of electronic system on the surface of fasteners. These substances
vehicle. will affect fastener torque and clamping
force of the joint, and may damage fas-
(2) Antenna feeder shall keep 20cm from teners. When installing fasteners, follow
ECU and sensor of electronic system correct tightening sequence to avoid
on the vehicle. damaging parts and system.
(3) Keep antenna and feeder away from (6) When moving flexible separation joint
other wire. To prevent communication from normal installation position, do not
equipment signal and other equipment bend excessively or damage flexible
of the vehicle from mutual interference. separation joint. The maximum bend-
ing for flexible separation joint is 6°.
(4) Check if antenna and antenna feeder It means moving 1 inch per one foot
are debugged correctly. pipe section. The maximum amount of
(5) Do not install high–power mobile com- movement for 3 feet pipe shall not ex-
munication system. ceed 3 inches.
11. Others (7) Do not bend the hose during the course
of installation. In order to facilitate in-
(1) When executing this procedure, you stallation, bend or deform the hose.
have to wear allowed safety goggle and Otherwise, it will damage parts.
1-25
(8) To avoid personal hurt and/or part dam- brake disc.

age, appropriate tool shall be used to
dismantle spiral spring of shock ab- Turn off ignition switch to stop rotating
sorber. When the spring is separate parts of powertrain.
from shock absorber, if all spring force (11) In safety conditions, road test is made
is not released, spiral spring will be at according to traffic regulations. Do not
extreme pressure and may bounce off. attempt any operation that may endan-
(9) When maintenance personnel checks ger the vehicle. Violation for the above-
reported fault location, the vehicle shall mentioned notes will lead to serious
be driven by specified staff. Otherwise, personal hurt and vehicle damage.
it leads to personal hurt. 12. Vehicle Lifting
(10) When performing specified test in work (1) Before lifting or lifting the vehicle, pay
shop, one or more of the following rules attention to:
shall be observed:
Lifting equipment weight class shall
During the test, if it is necessary to meet or exceed vehicle weight.
jack up the vehicle and rotate drive
wheel, please observe the following Lifting equipment shall meet operation
safety notes: standard of lifting equipment manufac-
turer.
When rotating one drive wheel but the
other drive wheel does not move, the Lift the vehicle on a clean, solid and
speed shall not exceed 56km/h. dry level ground.
Under the above-mentioned condi- Lift the vehicle only on the specified
tions, tachometer indicated value is lifting point. Lifting equipment is for-
half of actual speed. Therefore, this bidden to contact any other part of the
limit is necessary. If wheel speed is vehicle.
too high, it may lead to personal hurt.
(2) Before lifting the vehicle, pay attention
If all drive wheels rotates at the same to vehicle conditions:
speed, the speed shall not exceed 112
km/h. If wheel speed is too high, it may The vehicle shall be without load. Take
lead to personal hurt. out or fix all objects in the vehicle to
avoid moving during the course of lift-
Personnel concerned shall keep away ing.
from rotating parts and counter weight
locations to avoid personal hurt. When dismantling main parts from the
vehicle and support the vehicle with a
When the engine works in workshop lifting device, center of gravity for the
for a long time, do not make overheat vehicle may change. Keep the vehicle
the engine and transmission. balancing: place counter weight to
prevent the vehicle from swinging or
During the test, if it is necessary to moving; support the position on the
jack up the vehicle and dismantle opposite side of parts to be dismantled
wheels and brake disc, with a jack.
Please observe the following safety (3) Notes for using jacks and safety sup-
notes: port
Support the suspension at normal During the course of maintenance,
driving height. stop block shall be always used on a
Do not use brake after dismantling level position.
1-26
Safety support with rubber accessory The vehicle on the lifter shall be level
shall be used. as far as possible, and lifter groove
and supporting position of rigid brack-
Vehicle's center et are aligned.
of gravity
Before lifting and during the course of

working, support arm shall be locked.
When the vehicle leaves the ground,

shake the vehicle to check if it is sta-
Position of Jack ble on the premise of safety.
Vehicle's center of gravity (no load)
Surport position; strentch the jack position Preventative measures shall prevent
supporting arm from damaging tyre,
When using a jack and rigid bracket, wheels and body.
they shall support specified locations.
When jacking up front wheels, release

parking brake and place stop block in
the rear of rear wheel; when jacking
up rear wheels, place stop block in the
front of front wheels.
When there is no rigid bracket, do not

use a jack. Vehicle's center of gravity Rubber
(no load) accesory
When lowering a vehicle with front
wheels jacked up, release parking
brake ad place stop block in front of If the above-mentioned procedures are not
rear wheels. followed, it may damage lifting equipment or
vehicle.
Vehicle's center of gravity Rubber

(no load) accesory
(4) Notes for four-column lifting jack
Follow all safety procedures in this

manual.
Adopt supporting arm with rubber ac-

cessory.
Notes: lifter center is close to the cen-

ter of gravity for the vehicle as far as
possible (“L” shall be short as far as
possible).
1-27
Section Overhaul Specification For common faults, even if fault symp-

toms are the same, causes of fault are
4.1. Troubleshooting method diversified, so this method doesn’t ap-
ply.
(1) Inquiry diagnosis method
(5) Empirical method
The inquirer shall be serious, respon-
sible, amiable and careful. To continuously accumulate experi-
ences based on the results of previous
The inquiry shall be overall, grasp em- troubleshooting and improve trouble-
phasis and acquire the details of fault shooting ability.
history and frequency.
To judge according to the difference
Analysis, judgment and preliminary and sameness of fault symptoms and
location shall be made through the through the flexible application of pre-
inquiry of fault symptom with the car vious experiences.
owner.
To summarize special and typical
(2) Observation diagnosis method faults and record the success and fail-
Artificial observation shall be all-round ure of troubleshooting for experience
and systematic in combination with optimization.
fault, emphasize some respects and (6) Logical reasoning method
follow certain sequence.
To analyze the fault and deduce fault
To conduct external examination for point according to detection data and
car, carefully observe the car’s water system principle.
circuit, gas circuit, oil circuit and elec-
tric circuit. To master the operating principles and
functions of motor, electronic fuel in-
To examine related instruments and jection system and parts.
meters of the car, and then determine
the cause of fault. It’s very necessary to make logi-
cal reasoning and analysis for some
To carefully observe fault symptom, faults.
fault code, sound and others, and
judge accordingly. (7) Inverse logical reasoning method
(3) Part replacement method To deduce the fault symptom provided

a part is faulty.
To replace new part for probably faulty
part. To accumulate and summarize the
fault symptoms of part damage to
To fix the probably faulty part in an- quicken fault location.
other car for further confirmation.
(8) Flow chart analysis method
Replacement for any part shall be rea-
sonable rather than random or blind. For complicated faults.
(4) Case application method To operate according to given flow

chart for fault location.
To directly find out cause of fault refer-
ring to the result of typical case, as Other method may be used to aid
can reduce unnecessary examination. analysis and judgment.
Only applicable to faults with the same 2 Electric control system
symptom in the same model of car or
the same kind of system. A lot of ECU control systems are applied
1-28
to BYD S6. Usually ECU control system is tom, please confirm fault symptom and find
viewed as a kind of very complicated system out faulty position, part or component. Please
needing high level professional technical contract the doubtable scope according to
knowledge and skill for troubleshooting. In fault symptom, connect fault diagnosis instru-
fact, if you fully know the system and have ment for symptom simulation test, and judge
basic electrical knowledge, then you can whether the examined system is damaged,
make accurate judgment and necessary re- meanwhile, confirm fault symptom, finally find
pair for troubleshooting. For further details of out the cause of fault referring to system fault
ECU control system of BYD S6, please refer code table.
to relevant chapters.
ķ Vibration method
(1) Use of detection instrument
1) Before using a detection instrument, an Knock slightly

operator must carefully read its instruc-
tions or operation manual.
2) After the detection instrument connects

the system, please turn on the igni-
tion switch and start the instrument. If
the instrument can’t communicate with
ECU control system, then the car or in-
strument is faulty.
If communication is normal when the

instrument is connected with other car,
please examine and diagnose data
line or the car’s ECU circuit.
If communication is still abnormal

when the instrument is connected
with other car, the instrument may be Shake slightly
faulty, and please read the accompa-
nying manual or contact the supplier
for help.
(2) Troubleshooting
Basic procedure is to determine the proce-

dure for troubleshooting of related circuit in
advance. Swing slightly
(3) Fault simulation

The method is used in such a case that it
It’s the most difficult thing that no fault symp- seems that vibration is the primary cause of
toms are found during troubleshooting. In this fault.
case, thorough analysis must be made for
described fault of the car. Then the same or 1) Parts and sensor: lightly knock the
similar condition and fault environment of the suspicious parts by hand and inspect
car shall be simulated. For technical person- whether there is a fault. If the relay is
nel, no matter how experienced and proficient vibrated by applying a great force, it
they are, their failure to analyze or confirm may possibly be opened.
fault symptom may cause delay in repair, 2) Joint: lightly shake the joint up and
miss or misoperation. down.
At the time of simulation test for fault symp-
1-29
3) Wire harness: lightly swing the wire ĺ High voltage load method
harness up and down. Inspection shall
lay stress on the connection part of joint The method is used in such a case that the
and fulcrum position of swing. fault may possibly arises from electronic com-
ponent overloading.
ĸ Heating method
Open the warm air blower, headlight, rear
The method is used in such a case that it is windshield defroster and all the other electric
doubtful that some parts have a fault arising devices, and then inspect whether there is a
from temperature increase. fault.
(4) Circuit inspection

Fault ķ Basic inspection
Resistance measurement condition of

electronic parts
All resistances shall be measured under the

condition of 20°C indoor temperature, unless
otherwise specified. After the vehicle starts,
the temperature will have a great increase,
so if the resistance is measured at this time,
Measured data will exceed the specified val-
Heat the suspicious parts by use of electric ue. So the resistance shall be measured after
drier or something of the kind and inspect the engine cools down.
whether there is a fault.
Connection and disconnection of joint
CAUTION
- When disconnecting the joint, first
1) Heating temperature shall not ex- squeeze the two ends of the joint with
ceed 60°C or the specified value hands,
2) Don’t directly heat the ECU parts
Ĺ Water-spraying method
The method is used in such a case that the

fault may possibly arise from rainy weather or
highly humid condition.
When spraying water onto the vehicle, pay

attention to:
1) Don’t directly spray water onto the en- Error

gine, but water can be sprayed onto the
front end of radiator to indirectly change
the temperature and humidity. Error
2) Strictly prohibit directly spraying water

onto electronic components.
3) If the vehicle leaks when it rains or ever

leaked, ECU electronic components or Correct
joints may be damaged. Special care
must be taken when the test is con-
ducted.
Loosen the lock catch and then press lock
1-30
claw, and disconnect the joint. port and insert it into socket; inspect them
whether there is good tightness when insert-
- When disconnecting the joint, strictly ed and after fully engaged.
prohibit withdrawing and pulling the
wire harness. The joint shall be directly Maintenance method of joint terminal
held to disconnect it.
Correct Error
- Before connecting the joint, inspect it
whether there is deformation, damage
and port loss.
- When connecting the joint, if hearing a

“snap” sound, it shows connection suc-
ceeds.
- When the joint needs to be detected

by use of probe at its back (wire har-
ness side), waterproof joint can not be - If there is dust on the terminal, contact
detected from its back and it shall be point shall be cleaned by use of air gun
detected by connecting wire harness; or with wiping cloth. Don’t wipe contact
when inserting the probe in a mobile point with sand paper, because this will
way, don’t damage the terminal. damage the protective layer.
Joint inspection - If contact pressure is abnormal, replace
the socket. Here it shall be replaced
- When connecting the joint, squeeze its
with the same kind of plug and socket.
two ends to make them completely in-
serted and locked. - The damaged, deformed or corroded
terminal shall be replaced. If the termi-
- When disconnecting the joint, find the
nal is locked in the outer shell, outer
uncoupled terminal, falling terminal,
shell also needs to be replaced.
loose terminal or damaged wire by
lightly pulling wire harness from the Disassembly and assembly of wire
joint back. harness
In addition, visually inspect whether there is - Before disassembling the wire harness,
corrosion, metal fragment, foreign impurity first inspect the connection and fasten-
and water, as well as bend, rust, overheat, ing condition of wire harness in order to
pollution or terminal deformation, etc. reinstall it correctly.
Error Error
Ternimal alike a plug Error
Inspection of terminal contact pres- - Strictly prohibit using distorting and

sure stretching methods to loosen the wire
harness.
Prepare a plug that matches with the joint
1-31
- Strictly prohibit wire harness contacting

high temperature, rotating, moving and
vibrating parts or the parts with sharp
corner. Avoid contact with panel edge,
screw head or other similar objects.
Sensor
- As shown in figure, disconnect joints

A and C and measure the resistance
between them: the resistance shall be
less than 1¡. Caution: wire harness
shall be shaken lightly in the inspection.
- When installing parts, strictly prohibit
mixing wire harness with them. Test connection Specified conditions
Joint A terminal 1—
- Strictly prohibit cutting off or tearing joint C terminal 1
10k¡ or more
off wire harness sheath. If the sheath Joint A terminal 2—
needs to be cut off or torn off for main- <1¡
joint C terminal 2
tenance, it shall be replaced with new
one or repaired with ethylene adhesive If the result accords with the above example,
tape or similar articles. it shows it is open circuit between joint A ter-
minal 1 and joint C terminal 1.
Figure 1
Open
Sensor circuit
ĸ Open circuit inspection

Disconnect joint B and measure the resis-
Open circuit inspection shall be con- tance between joints.
ducted to the wire harness shown in
figure; conductivity and voltage shall Test connection Specified conditions
be inspected according to the require- Joint A terminal 1 —
ments, to determine open circuit posi- <1¡
joint B1 terminal 1
tion. Joint B2 terminal 1 —
10k¡ or more
joint C terminal 1
Resistance inspection
1-32
Short circuit
Sensor
If the result accords with the above example, If wire harness is grounded short cir-
it shows it is open circuit between joint C ter- cuit (as shown in figure), inspect the
minal 1 and joint B2 terminal 1. resistance of car body grounding to
find out the short-circuit part.
Voltage inspection
Inspection of car body grounding con-
- When the circuit is electrified, (ECU ductivity
joint terminal is electrified)
ECU side
Grounding
Sensor W/H side
Grounding
- Disconnect joints A and C and measure

Determine the circuit whether it is in open- the resistance between terminals 1 and
circuit state through voltage inspection. v2 in the joint A and car body ground-
ing: the resistance shall be 10k? or
As shown in figure, when each joint is in con-
above. Caution: wire harness shall be
nected state, respectively measure the volt-
shaken lightly in the measurement.
age value between ECU 5V output terminal
joint A terminal 1, joint B terminal 1 and joint Test connection Specified conditions
C terminal 1 and car body grounding. Joint A terminal 1—car
<1¡
body grounding
- Result example:
Joint A terminal 2—joint
10k¡ or more
C terminal 2
Test connection Specified conditions
Joint A terminal 1— If the result accords with the above example,
5V
car body grounding it shows it is open circuit between joint A ter-
Joint B terminal 1— minal 1 and joint C terminal 1.
5V
car body grounding
Joint C terminal 1— - Disconnect Joint B and then respec-
5V
car body grounding tively measure the resistance value be-
tween terminal 1 in the joint A and car
If the result accords with the above example, body grounding and between terminal 2
it shows it is open circuit between joint B ter- and car body grounding.
Ĺ Short circuit inspection
1-33
Test connection Specified conditions

ECU side
Joint A terminal 1—car
10k¡ or more
body grounding
Joint B2 terminal 1—
<1¡
car body grounding
Grounding
If the result accords with the above example,
it shows it is open circuit between joint B2 ter- W/H side
ĺ Inspection and replacement of ECU Grounding
CAUTION
After the joint is connected with
ECU, inspect the joint from its If the circuit has a fault, it shall be repaired; if
EDFNRQRQHVLGHRIZLUHKDUQHVV the circuit is normal, it shows ECU may pos-
If no special detection conditions sibly have a fault, it shall be replaced with a
are specified, make the engine new ECU, and then inspect whether the fault
stall and turn ignition switch to occurs again.
“ON”DQGWKHQEHJLQWRGHWHFWLW
Inspect the joint whether it is com- - Measure the resistance between
pletely connected; inspect the line ECU grounding terminal and car body
whether there is looseness, corro- grounding: the resistance shall be less
VLRQRUEUHDNDJH than 1¡.
- Disconnect ECU joint and inspect

Inspection of ECU grounding line grounding terminals (ECU and wire har-
ness) whether there is bend, corrosion
Eg. or foreign impurity. Finally inspect the
contact pressure of socket.
Ļ Intermittent contact and poor contact

Grounding
Intermittent contact arises from abnormal
connection between electric component
and electric wire, although magnetic circuit
breaker or solenoidal coil may possibly be
out of order occasionally. When poor contact
is detected, inspect the probably faulty circuit
carefully.
Both connector and plug parts have

poor fit, or binding post is not com-
pletely in the connector (move back).
Binding post is dirty or corroded. Bind-

ing post must be kept clean and must
1-34
not be stained with any other matter resistance may possibly be higher. If
that may possibly obstruct normal any abnormal phenomenon is found,
connection of binding post. However, immediately repair or replace it.
strictly prohibit using sand paper or
similar articles to clean the binding
post.
The connector body is damaged.

Binding post is exposed to humid and
dirty environment, or it is possibly be-
cause the position between binding
post and fit connector or component is
wrong.
Binding post is wrong or damaged.
Utilize the binding post fitting to the corre-

sponding connector and carefully detect the
binding post of each connector in the faulty
circuit, and make sure contact pressure is
enough. If contact is loose, adjust the binding
post to increase contact pressure or replace
the binding post.
Binding post and electric wire are in

poor contact
Lightly shake the wire harness with hand and

inspect poor contact in the faulty circuit. If any
abnormal phenomenon is found, immediately
repair or replace it.
Insulating layer of electric wire is worn

out and the exposed part contacts oth-
er wires or other parts, which causes
intermittent short circuit.
Electric wire in the insulating layer is

broken. In such a case, it had better
conduct conductivity test. However,
for multi-strand wire, only one or two
strands may possibly be intact and its
1-35
Corrective maintenance procedure
The vehicle is driven

into the workshop
Fault analysis described by the user--ask

the vehicle condition and fault occurance
environment
Fault confirmation and test data

(1) Check and measure the battery voltage
(2) Perform the visul check of wire harness,
connector and fuse for open or short circuit.
(3) Preheat the engine to the normal working
temperature.
(4) Confirm the fault phenomenon and
condition,and verify the test data and standard
parameter.
Normal
Abnormal
Test data: verify the

check steps or parts
to be checked
through testing data.
To next page
1-36
Continued
Check for ciucuit and

parts:verify the related system
circuit or parts to be checked
through DTC or testing data.
Maintenance:repair the fault

system or parts according to
overhauling result
Quality inspection:After maintenance,

recheck all fault for complete
elimination.Recheck it again if the DTC
still exists
End
1-37
Section 5 Abbreviations and Color Symbols of Electric Wires

51 Abbreviations
List of automobile English abbreviations that may be used in the factory regulations
ABS Anti-Lock Brake System (ABS) CPU Central processing unit (CPU)
A/C Air conditioning and air conditioner CVT Continuous change
ACL Air filter DPSF Double pump system fluid
A/F Air-fuel ratio DTC Diagnostic trouble code (DTC)
ALR Automatic locking tighetner DPSF Double pump system fluid
ALT AC generator
AMP Ampere Electronic brake force distribution
EBD
(EBD)
ANT Antenna
ECM Engine control unit
API American Petroleum Institute
ECT Engine coolant temperature
APPROX Approximate
EGR Exhaust gas recirculation (EGR)
ASSY Assembly
ELD Electrical load detector
A/T Automatic transmission Evaporator pressure regulator
EPR
ATDC After top dead center (EPR)
EPS Electrical power steering
ATF Automatic transmission oil
Evaporative emission control sys-
ATT Accessory EVAP
tem (EVAP)
ATTS Active torque transmission system EX Exhaust
AUTO Automatic
AUX Accessory F Front
FIA Fuel injection air
BARO Atmospheric pressure FL Front left
BAT Accumulator FP Fuel pump
BDC Bottom dead center FR Front right
BTDC Before top dead center FSR Fail-safe relay
FWD Front wheel drive
CARB Carburetor
CAT/CATA Catalytic converter GAL Gallon
CHG Charge GND Ground
Crankshaft rotating speed fluctua- GPS (Satellite) GPS
CKG
tion
CKP Crankshaft position
H/B Glide back (car body)
CO Carbon monoxide
HC Hydrocarbon
COMP Complete
HID High intensity discharge
CPB Clutch pressure return
HO2S Heated oxygen sensor
CPC Clutch pressure control
1-38
IAB Intake air bypass M/T Manual transmission

IAC Idle air control
IACV Idle air control valve N Neutral
IAR Intake air resonator NOX Oxynitride
IAT Intake air temperature
ICM Ignition control module OBD On-board diagnostic
ID Identification O2S Oxygen sensor
ID or I.D. Inside diameter OD or O.D. Outside diameter
IG or IGN Ignition
IMA Idle mixture concentration control P Parking
Integrated engine auxiliary system PAIR Pulse auxiliary air injection
IMMOBI. Anti-start unit PCM Power control module
IN Intake air PCV Positive crankcase ventilation
INJ Injection air Proportional control valve
INT Intermittence PDU Power drive unit
PGM-FI Programmed fuel injection
KS Knock sensor PGM-IG Programmed ignition
PH Pressure high
L Left side PL Pressure low, indicator light
L/C Locking clutch PMR Pump motor relay
LCD LCD P/N Part number
LED LED PRI Primary
LEV Low emission vehicle P/S Power steering
LF Front left PSF Power steering fluid
LH Left-hand drive (LHD) PSP Power steering pressure
LHD LHD PSW Pressure switch
LR Left rear
LSD Limited slip differential Qty Qty.
L-4 Inline four-cylinder engine R Right side
REF Reference
MAP Manifold absolute pressure RH Right-hand drive (RHD)
MAX. Maximum value RHD RHD
MBS Main shaft brake system RL Left rear
MCK Motor inspection RON Theoretical octane number
MCU Moment control unit RR Right Rear
MIL Fault indicator light
MIN. Minimum value SAE Society of Automotive Engineers
MPI Multi-point fuel injection SCS Signal of maintenance inspection
M/S Manual steering SEC Second
1-39
Secondary Automatic four gears (1st gear to

4th gear)
SOHC Single overhead camshaft Automatic three gears (1st gear to
SOL Solenoid valve 3rd gear)
2nd gear
SPEC Specification
1st gear
S/R Sunroof
Automatic gear
SRS Supplemental restraint system
2nd gear
STD Standard
Low speed gear
SW Switch
O/D Overdrive gear
1st 1st gear
T Torque:
2nd 2nd gear
TB Throttle body
3rd 3rd gear
T/B Timing belt
4th 4th gear
TC Torque converter
5th 5th gear
TCM Transmission control module
TCS Traction control system 52 Color symbols of electric wires
TDC Top dead center
TFT Thin film transistor B Black
T/N Tool number L Blue
TP Throttle position Br Brown
TWC Three-way catalytic converter G Green

Gr Grey
VC Viscous coupling Lg Tender green
VIN Vehicle identification number O Orange
VSC Volume (net) P Pink
VSS Vehicle speed ??sensor R Red
Variable valve timing and valve lift V Purple

VTEC
ECU W White
VVIS Variable volume intake system
Y Yellow
W Equipped
W/O Unequipped
WOT Wide-open throttle
2WD Two-wheel drive
4AT 4-speed automatic transmission
5MT 5-speed automatic transmission
6MT 6-speed automatic transmission
Parking
Reverse
Neutral
1-40
Foreword
Thanks for purchasing the BYD483QA or BYD483QB EFI Gasoline Engine (hereinafter referred
to as BYD483QA/QB Gasoline Engine or the Gasoline Engine) manufactured by BYD Auto Indus-
try Company Limited. Please read this manual carefully before using.
BYD483QA/QB Gasoline Engine adopts the electronic fuel injection system independently devel-
oped by BYD, featuring advanced self-diagnosis, high power per liter, low fuel consumption, low
noise, low pollution and compact size. The key components are made by world-renowned auto-
motive electronics manufacturers. BYD483QA/QB Gasoline Engine can achieve the best state
under various conditions, and ensures the reliable security, comfortable driving, the best economy
and perfect environmental performance of the automobile.
This manual outlines the main performance, technical parameters, and use, maintenance and
repair methods of BYD483QA/QB Gasoline Engine. 3lease read this manual carefully before
using BYD4A/4B Gasoline Engine, to keep the power system of your automobile in good
condition, having better function and bringing greater economic benefits. If you find that the
maintenance methods for gasoline engine in other materials are different from or conflict
with this manual, please follow this manual
In order to continuously improve the performance and quality of the products and provide better
services, any suggestion and improvement opinions about the problems found in the process of
using the EFI gasoline engine are appreciated. Thanks for your supervision.
It is your best choice to buy the passenger cars powered by BYD EFI Gasoline Engine.
Explanation of Symbols
“ ƾ ƾ ƾ ” relates to the personal safety of drivers and passenger; please pay special attention
and strictly abide;
“ ƾƾ ” relates to the security and maintenance of the gasoline engine, and must be strictly imple-
mented;
“ ƾ ” will make maintenance simpler and more convenient.
1
II BYD4B Engine Maintenance Manual
Contents
Section 1 3erformance, Main Technical 3arameters and Structure of Gasoline Engine 2-1
1.1 Performance and main technical parameters...................................................2-1
1.2. External characteristic curve of BYD483QB Gasoline Engine .........................2-2
1.3. Use of Gasoline Engine ...................................................................................2-4
Section 2 Gasoline Engine Maintenance 2-
2.1 Maintenance of gasoline engine lubricating system.........................................2-8
2.2 Maintenance of gasoline engine cooling system ...........................................2-10
2.3 Maintenance of ribbed belts .......................................................................... 2-11
2.4 Maintenance of the ignition system ...............................................................2-12
2.5 Checking and adjusting the valve gear .........................................................2-12
2.6 Maintenance of positive crankcase ventilation valve (PCV valve) .................2-13
2.7 Checking and maintenance of electrical system ...........................................2-13
0DLQWHQDQFHRIDLU¿OWHU .................................................................................2-14
0DLQWHQDQFHRIIXHO¿OWHU ...............................................................................2-14
2.10 Maintenance of fuel vapor recovery system ..............................................2-14
2.11Maintenance of catalytic converter ................................................................2-15
Section Regular Inspection of Gasoline Engine 2-16
3.1 Maintenance cycle and content of gasoline engine ......................................2-16
3.2 Main tightening torque of the gasoline engine ..............................................2-17
Section Gasoline Engine Troubleshooting 2-1
4.1 Considerations for gasoline engine use and maintenance ...........................2-18
4.2 Gasoline engine troubleshooting ...................................................................2-19
4.3 Emission troubleshooting ...............................................................................2-25
Section 5 Gasoline Engine Sealing and Unsealing 2-26
5.1 Gasoline engine sealing .................................................................................2-26
5.2 Gasoline engine unsealing .............................................................................2-26
2-I
Section 1 3erformance, Main Technical 3arameters and Structure

of Gasoline Engine
11 3erformance and main technical parameters
Model BYD4B
Electronically controlled multi-point sequential fuel injection, inline,
Type four-stroke, water cooling, roof combustion chamber, dual overhead
camshafts, 16 valves, electronic ignition system
Number of cylinders 4
Cylinder diameter (mm) 83
Piston stroke (mm) 92
Total displacement (L) 1.991
Compression ratio 9.6:1
Ignition sequence 1-3-4-2
Rated power (kW) / speed (r/min) 103/6000
186
Maximum torque (N m)
(4000r/min~4500r/min)
Minimum fuel consumption rate
275
(g/kWh)
Engine oil pressure (kPa) 300~490 (3000r/min±50r/min)
Minimum steady speed (idle) (r/min) 750±50
Gasoline engine lubricant capacity (L) 3.5
Engine oil fuel ratio (%) 0.25
Dimensions (excluding transmission)
600 × 610 × 640
(mm) (L × W × H)
Net weight (excluding transmission)
130
(kg)
CO 0.15% HC 40 × (750r/min±50r/min)
Emission
CO 0.15% HC 40 × (2000r/min±50r/min)
Fuel 93 grade or higher unleaded gasoline (GB17930)
SG grade, 10W-30 (for all seasons in the South and summer in the
Gasoline engine oil north)
SG grade, 5W-30 (for winter in the north)
Coolant Glycol coolant
Type Dry-type, single disc, diaphragm spring, atmospheric style
Dimensions Clutch plate assembly ¶215 × 7.8 (free state)
Clutch
(mm) Clutch cover assembly ¶257.5 × 44
Weight Clutch assembly: 4.8kg
2-1
12 External characteristic curve of BYD4B Gasoline Engine

([WHUQDOFKDUDFWHULVWLFFXUYHRI%<'4$*DVROLQH(QJLQH
Effective torque of calibration Meo

N·m
160
150
140
Effective power of calibration

130
kW
90
70
50
(Fuel consumption)
30 g/kW·
410
10 390
370
350
330
310
290
270
250
(Speed) 2000 2500 3000 3500 4000 4500 5000 5500 6000 r/min
2-2
([WHUQDOFKDUDFWHULVWLFFXUYHRI%<'4%*DVROLQH(QJLQH
Effective torque of calibration Meo N·m
190
180
170
160
Effective power of
calibration Peo kW
100
80
60
40
Fuel consumption
Gf kg/h
20 35
30
25
20
15
10
Fuel consumption rate

geg/kW·h
410
390
370
350
330
310
290
270
250
2-3
1 Use of Gasoline Engine

&RQVLGHUDWLRQVRIXVLQJJDVROLQHHQJLQH
1 Manual
Read this manual carefully before use, and strictly follow the provisions recommended in this
manual for use and maintenance.
2 Coolant
Check the coolant of the gasoline engine, and add coolant according to the method in Chapter 3,
Section 2 if necessary.
ƾƾ
:KHQWKHJDVROLQHLVUXQQLQJWKHFRROLQJV\VWHPPXVWKDYHVXI¿FLHQWFRRODQWWRHQVXUH
that the gasoline engine works normally, or else “boiling”ZLOORFFXULQWKHJDVROLQHHQJLQH
The service life of the gasoline engine will be affected if it is overheated, and even cause
F\OLQGHUVFRULQJDQGRWKHUVLJQL¿FDQWIDLOXUHV
3 Gasoline engine oil
Check the level of gasoline engine oil in the gasoline engine, and refill in time. See Chapter 3
Section 1 for the method to check and fill gasoline engine oil.
ƾƾ
If the gasoline engine oil isn’WVXI¿FLHQWWKHHQJLQHRLOSUHVVXUHZLOOEHWRRORZUHVXOWLQJ

in poor lubrication, increased wear of gasoline engine and poor cooling, which will easily
FDXVHIDLOXUHDQGDIIHFWWKHOLIHRIWKHJDVROLQHHQJLQH
4 Fuel
Grade 93 or higher unleaded gasoline is recommended.
ƾƾ
The automobile must use high quality unleaded conforming gasoline, or else it will result
in fatal damage to EFI system of the engine, catalytic converter and oxygen sensor, and re-
GXFHWKHHQYLURQPHQWDOSHUIRUPDQFHDQGSRZHUSHUIRUPDQFHRIWKHDXWRPRELOH
5 Starting gasoline engine
To start the gasoline engine, turn the ignition switch key of the automobile to “START” and start
the gasoline engine with the starter. Once the gasoline engine is ignited, release the key and cut
off the power supply of the starter immediately.
ƾƾ
Since the gasoline engine management system will provide the appropriate gas mixture
and engine spark advance in any condition, it is unnecessary to depress the accelerator
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ƾƾ
If the gasoline engine isn’t started for several times, the gasoline engine may have spark
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press the accelerator to the bottom and then start the gasoline engine, and the high speed
2-4
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UHVWDUWWKHJDVROLQHHQJLQH
If the automobile is started for the first time (new gasoline engine or the fuel supply system of the
gasoline engine has been repaired), it may take longer time to start, so that the fuel supply line
will be filled with oil and establish a normal working pressure, supply gasoline and appropriate
fuel gas mixture to ensure normal work of the gasoline engine.
ƾƾ
The starter shouldn’WZRUNIRUPRUHWKDQ¿YHVHFRQGVHYHU\WLPH,IWKHJDVROLQHHQJLQH

isn’WVWDUWHGZDLWIRUWHQVHFRQGVDQGVWDUWDJDLQRUHOVHWKHVWDUWHUPD\EHGDPDJHG,I
the engine still can’t be started after several times, please ask our authorized service cen-
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6 Idle
After started, the gasoline engine should run for 3~5 minutes at idle, no-load condition to warm up
the gasoline engine.
ƾƾ
The idle speed of our gasoline engine is 750r/min±UPLQ 7KH LGOH PHFKDQLVP RI WKH
JDVROLQHHQJLQHKDVEHHQDGMXVWHGDWWKHIDFWRU\)RUDGMXVWPHQWSOHDVHFRQWDFWRXUDX-
WKRUL]HGPDLQWHQDQFHFHQWHUIRUKHOS
While measuring emission, the gasoline engine should be in warming up state, that is, the
FRRODQWWHPSHUDWXUHLV°C±5°C
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perature tolerance is 970°C7KHUHIRUHWKHJDVROLQHHQJLQHVKRXOGEHLQZDUPLQJXSVWDWH
while measuring emission and the exhaust temperature shouldn’WEHORZHUWKDQ°C
7 Driving
While driving, the coolant temperature should be kept at 85°C±5°C. At medium speed, the pres-
sure of gasoline engine oil shouldn’t be lower than 300kPa.
8 Parking
After working, especially high speed heavy load running, the gasoline engine shouldn’t be shut
down immediately; please wait for 3~5 minutes in idle state and then shut down the engine.
9. Warming up in winter
The temperature in winter is low, the viscosity of the gasoline engine oil increases, and the lubri-
cation effect of the gasoline engine is worse than in summer. Therefore, do not drive the auto-
mobile immediately after the gasoline engine is started, especially at high speed or under heavy
load. Please warm up the engine at idle for ten minutes to rise the temperature of the gasoline
engine oil and coolant and fully lubricate the gasoline engine before driving.
ƾƾ
If the automobile is driven before the gasoline engine is fully lubricated in winter, it may
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10 Rainy days or wading
If you drive on the road accumulating water after raining or wade through a river, make sure that
2-5
the air filter is well sealed, or else water may enter into the cylinder of the gasoline engine, and
damage the connecting and other moving parts.
ƾƾ
If water enters into the cylinder, the connecting rod will withstand tens times of normal op-
erating pressure due to the inertia effect of the automobile, resulting bending or breaking
RIWKHFRQQHFWLQJURG
11. Fuel supply system
ƾƾ
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up the oil; replace immediately if there is any problem such as rubber aging, connector
FUDFNLQJGDPDJHDQGORRVLQJ
While checking the fuel line, do not start the gasoline engine if the oil high-pressure hose
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5XQQLQJLQRIQHZJDVROLQHHQJLQH
The life of the gasoline engine depends on the early state of use to a great extent. The new gaso-
line engine should be run in strictly in accordance with the specification.
The running in of gasoline engine on the automobile shall be implemented in accordance with the
automobile instructions; check and maintain the gasoline engine according to the following re-
quirements during running in:
1 Checking
Check whether the gasoline engine oil, coolant, gasoline, and battery electrolyte are sufficient; if
there is insufficiency or leakage, please refill and eliminate immediately.
2 Road surface
The automobile should drive on cement or asphalt road and avoid driving on muddy or sand road.
3 Maintenance
Carry out maintenance for the gasoline engine of the new automobile in accordance with the
items in the table below after strict running in.
Maintenance Items of New Gasoline Engine after Running-in
No Item Content

1 Ribbed belt As required in Chapter 3 Section 3
Cylinder head bolt, intake and exhaust mani-
2 fold bolt As required in Chapter 4 Section 2
Nut and bracket connecting bolt
3 Oil filter Replace
4 Gasoline engine oil Replace
5 Spark plug gap 0.80~0.90mm
ƾƾƾ
'RQRWVWHSRQWKHDFFHOHUDWRUWRRKDUG7KHJDVROLQHHQJLQHVKRXOGQ’t run at high speed,
2-6
ORZRLOSUHVVXUHRULIWKHUHLVDEQRUPDOVRXQG:KHQWKHJDVROLQHHQJLQHLVUXQQLQJRU
just shuts down, do not touch the exhaust manifold or other heat radiating parts; when the
engine is warming up, do not open the radiator cover; the new gasoline engine shouldn’t
EHSXWLQWRQRUPDOXVHEHIRUHUXQQLQJLQ
2-7
Section 2 Gasoline Engine Maintenance

21 Maintenance of gasoline engine lubricating system
1. Lubricant for gasoline engine
Use the gasoline engine oil as required in Chapter 1 Section 1.
ƾƾ
After running in of the new gasoline engine, replace the gasoline engine oil after normally
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XVH:JDVROLQHHQJLQHRLOXQGHUFROGFRQGLWLRQV'RQRWXVHJDVROLQHHQJLQHRLODQWLZHDU
DGGLWLYHVRIGLIIHUHQWJUDGH,IWKHJDVROLQHHQJLQHRLOLVQ’WVXI¿FLHQWWKHHQJLQHRLOSUHVVXUH
will be too low, resulting in poor lubrication, increased wear of gasoline engine and poor cool-
LQJZKLFKZLOOHDVLO\FDXVHIDLOXUHDQGDIIHFWWKHOLIHRIWKHJDVROLQHHQJLQH
2. Measurement of gasoline engine oil level
Use oil gauge to measure the gasoline engine oil level in the oil pan. Measure in three minutes
after the gasoline engine has stopped, take out the oil gauge, wipe the gasoline engine oil with
clean cloth, and then insert into the oil pan to measure the level of the gasoline engine oil. The
level of the gasoline engine oil should be between “F” and “L” of the oil gauge; if the oil level is
at or below the lower limit, refill the gasoline engine oil to the upper limit. Before driving and after
driving 300km~500km every time, check the level of the gasoline engine oil.
3. Filling and replacing gasoline engine oil
Replace the gasoline engine oil once after driving 8,000km on the asphalt or cement road; if driv-
ing on sand road or under other poor conditions, check regularly and replace according to the oil
quality; however, replace at least once every 5,000km.
When replace the gasoline engine oil, warm up the gasoline engine for ten minutes, shut down
and open the fill inlet cap, loosen the oil drain plug in the bottom of the oil pan, drain the oil and
tighten the oil drain plug. Fill in 3.0L new gasoline engine oil through the fill inlet, and tighten the
fill inlet cap (see Fig.2-1).
Start the gasoline engine and run for five minutes; check whether the oil drain plug leaks, then
stop the engine and check the oil level after five minutes; refill to the upper limit of the oil gauge if
the oil level is too low.
Filler inlet cap Oil drain plug
Fig.2-1
2-8
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4. Cleaning the lubricating system
If excessive amount of impurities are accumulated in the oil pan, please clean the gasoline engine
lubricating system with light spindle oil.
When clean the interior of the gasoline engine, fill 2.5L light spindle oil into the gasoline engine
through the filler inlet, start the gasoline with the starter and run for 2~3 times at idle, one minute
each time, then quickly drain the cleaning spindle oil, and refill the gasoline engine oil into the
gasoline engine as specified.
After replacing with new gasoline engine oil every time, run the gasoline engine at no-load state
for 3~5 minutes to ensure that the lubricating system and all oil supply parts are fully lubricated.
ƾƾ
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ƾƾ
The reasonable use of gasoline engine oil is the important factor to ensure its good work-
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engine oil of different grades, places of origin and standards to prevent chemical reaction
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5. Replacing engine oil filter
Replace the engine oil filter every 8,000km. The tightening torque is 25 N·m~30Nm.
6. Checking engine oil pressure indicating system
Under normal condition, when the power switch (key) is turned to “ON”, the engine oil pressure
indicator is lit, indicating that there is no engine oil pressure; continue to turn the switch to “START”,
the gasoline engine starts and enters idle state, and the engine oil pressure indicator automati-
cally turns off, indicating that the engine oil pressure is normal. If the engine oil pressure indicator
doesn’t turn off, which indicates that the engine oil pressure in the lubricating system is abnormal,
please stop immediately and check whether the gasoline engine oil in the engine is sufficient.
2-9
22 Maintenance of gasoline engine cooling system

Cooling system is one of the prerequisites to ensure normal working of the gasoline engine oil; it
is required to keep sufficient coolant in the gasoline engine, check before driving every time, and
refill if necessary.
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that the gasoline engine works normally, or else “boiling”ZLOORFFXULQWKHJDVROLQHHQJLQH
The service life of the gasoline engine will be affected if it is overheated, and even cause
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1 Coolant
The gasoline engine uses ethylene glycol coolant, the freezing point of which should be 5°C lower
than the minimum ambient temperature. Do not mix different grades of coolant or use counterfeit
coolant and avoid using river water, well water and other hard water.
ƾƾ
After frozen, the water will expand and burst the sealed radiator, water pump, cylinder
KHDGDQGF\OLQGHUEORFN
2 Filling coolant
Fill the coolant in the following steps:
(1) Unscrew the radiator cover and fill in coolant, until the level in the water reservoir reaches
“FULL” mark. Do not let the level exceed “FULL” mark.
(2) Put on and tighten the radiator cap.
(3) Start the gasoline engine and run 3~5 minutes at idle; if the coolant level drops, open the
cap of the water reservoir, and fill the coolant to “FULL” mark.
(4) Put on and tighten the cap of the water reservoir, and then the gasoline engine can work normally.
ƾƾƾ
:KHQWKHJDVROLQHHQJLQHLVKRWGRQRWRSHQWKHUDGLDWRUFDSWRDYRLGEHLQJVFDOGHG
3 Filling coolant
After long time of use, if the coolant level in the water reservoir is below the “LOW” mark, fill the
coolant in the water reservoir to “FULL”.
If the coolant reduces too much in short period of time, check whether the cooling system leaks.
After long time of use, if the coolant should be replaced due to coolant deterioration or repair,
please follow the steps below.
(1) Unscrew the radiator cap, and open the water drain valve in the bottom of the radiator to
discharge the coolant.
(2) Remove the water reservoir and drain the coolant.
(3) Install the water reservoir and water drain valve of the radiator as original, and fill in coolant
as described in Chapter 3 Section 2 Item 2.
2-10
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4. Remember to install the temperature regulator assembly.
ƾƾ
If the temperature regulator assembly isn’t installed, the warming up time of the gasoline
engine will be extended; if the gasoline engine works under low temperature for a long
WLPHWKHZHDURIWKHPHFKDQLFDOSDUWVZLOOEHZRUVHQHGWKXVDIIHFWLQJWKHVHUYLFHOLIH
2 Maintenance of ribbed belts

The two ribbed belts are used for driving generator and water pump, power steering pump and air
conditioning compressor respectively. Please check and adjust the two ribbed belts regularly.
ƾƾ
If the ribbed belt doesn’t have sufficient tension or is damaged, it may cause problems
such as gasoline engine overheating, reduced generating capacity, no steering power and
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1 Adjustment method
Stop the gasoline engine, and tighten the adjusting bolts on the position adjusting block of the
generator and the power steering pump.
2 Measuring the tension
As shown in Fig.2-2, apply 98N force to the ribbed belt, the press amount of which should be
6mm~9mm.
Power steering pump

Measuring point
Generator
Water pump
Damping pulley
Air conditioner
compressor
Damping pulley Measuring point
Fig.2-2
3 Appearance
Check the ribbed belt for cracks, wear and fiber cloth aliquation, and replace if necessary.
2-11
2 Maintenance of the ignition system

1. Maintenance of the spark plug
Replace the spark plug every 30,000km. Replace immediately in case of any damage found in
daily check. Please replace with K6RTC or 3923-8 spark plug.
Both polar surfaces of the spark plug should be clean and smooth; regularly clean the carbon de-
posit between the two poles, and use fine sandpaper if necessary. The spark plug gap should be
0.80mm~0.90mm, and the gap should be uniform on the whole electrode plane.
2. Maintenance of the ignition system
The gasoline engine management system integrated in the gasoline engine adopts advanced
ignition system. During normal use, except timely replacement of spark plug and checking high
pressure damping line, it doesn’t require additional maintenance.
ƾƾ
When the ignition system has fault and causes gasoline engine stalling, do not forcibly run
WKHJDVROLQHHQJLQHRUHOVHLWPD\GDPDJHWKHFDWDO\WLFFRQYHUWHU
When the gasoline is running, do not remove the high voltage line of the spark plug to do
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25 Checking and adjusting the valve gear

The valve gear requires regular check and maintenance. Once the timing belt has failures such
as break and sliding gear, it may cause damage to valve, piston and camshaft. Therefore, check
the timing belt and replace immediately if there is any damage such as crack, wear and fiber cloth
aliquation; it is also required to replace every 100,000km.
1. Checking and adjusting installation position of timing gear
Remove the front cover of the engine, rotate the crankshaft clockwise, so that the grooves in the
crankshaft timing pulley aligns to the bar at the boss of the engine oil pump (see Fig.2-3); at this
time, the two horizontal line marks on the two camshaft pulleys should be aligned, and maintain
level; please note that the camshaft pulley mark I on the intake side is inward, and the camshaft
pulley mark E on the exhaust side is also inward (see Fig.2-3). Otherwise, adjust till they are
aligned. At this moment, the primary piston of the gasoline engine (on the side of crankshaft tim-
ing pulley) should be on the top dead center of the compression stroke.
2-12
Intake sid e
Exhaust side
Engine oil pump
Fig.2-3
2 Timing belt
Check the timing belt, eliminate the fault, and replace the belt if necessary.
3 Checking and adjusting valve clearance
The clearance between intake and exhaust valves is 0.23~0.29mm in cold state; when measuring
the clearance, the surface of the adjusting pad should be close to the cam base circle.
ƾƾ
If the valve clearance is too small, it will affect the power performance of the gasoline en-
JLQHDQGVKRUWHQWKHOLIHRIR[\JHQVHQVRUDQGFDWDO\WLFFRQYHUWHUGXHWRYDOYHOHDNDJH
ƾƾ
The maintenance described in this section should be carried out in our authorized mainte-
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26 Maintenance of positive crankcase ventilation valve (3CV valve)

PCV valve consists of valve body, valve, valve cover and spring, and can’t be decomposed. Its
main role is to import the air from crankcase to intake manifold through PCV valve. Remove the
valve every 50,000km, and ask service personnel to clean and check. Replace with new valve if
the valve is stuck or doesn’t ventilate.
27 Checking and maintenance of electrical system

The electrical system of the EFI gasoline engine uses electronic control unit (ECU) as the control
center. Measure the operating parameters of the gasoline engine with the sensors installed on
different positions of the gasoline engine, and control the fuel injection and engine spark advance
precisely according to the control programs set by the gasoline engine ECU, to ensure that the
gasoline engine can always maintain the optimal state in different conditions.
ƾƾ
If the gasoline engine has any fault, do not cut off the power supply of ECU, or else the
IDLOXUHLQIRUPDWLRQZLOOEHORVW'RQRWUXQWKHIDLOVDIHV\VWHPRIWKHJDVROLQHHQJLQHFRQ-
WLQXRXVO\IRUDORQJWLPHWRDYRLGJUHDWHUORVVHV
2-13
2 Maintenance of air filter

The air filter is used to filter air entering the cylinder; if the air filter is poor in filtration, it will ac-
celerate the wear of gasoline engine and shorten the service life. Dirty air filter will affect the air
intake of the gasoline engine, resulting in inadequate air intake and reduced power.
Take out and clean the element of the air filter regularly. Clean the element once every 10,000km
and replace every 40,000km on asphalt road; clean once every 2,500km and replace every
40,000km on sand road; in dusty environment, replace the element more often.
29 Maintenance of fuel filter

Under normal circumstances, the fuel filter should be replaced every 8,000km. If the fuel is dirty,
replace the filter timely to avoid affecting fuel supply or causing fuel injector blockage.
ƾƾ
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210 Maintenance of fuel vapor recovery system

The fuel vapor recovery system is used to collect the fuel vapor discharged when the fuel tank
ventilates, in order to avoid discharging into the atmosphere and protecting the environment.
Please regularly check whether the line and vent of the fuel vapor recovery system are smooth,
and all lines shouldn’t leak, in order to ensure normal working of the system.
ƾƾƾ
Follow the precautions below before any maintenance of the fuel system:
1. Disconnect the cathode wire of the battery.
2. Smoking is prohibited. Set up a “No Smoking” sign near the operation area.
3. Easy-to-use CO2 fire extinguisher is required.
4. Keep in well-ventilated place, and stay away from open flame.
5. To relieve the pressure of the fuel vapor in the fuel tank, remove the filler inlet cap and then
reinstall the cap.
6. Even when the gasoline engine stops running, the fuel line is still under high pressure; if the
fuel line is loosened or disconnected immediately, it may cause fuel injection at the opening.
Therefore, make sure that the pressure has been relieved before loosening or disconnect-
ing the fuel line.
7. When the fuel line is removed, there will be a small amount of fuel spillage. Therefore,
place the empty fuel container under the fuel filter or enwrap the fuel filter with waste cloth,
to let the fuel flow into the empty container or absorbed by the waste cloth. Put the waste
cloth after oil absorption into specified container.
8. The fuel line should be connected and fastened properly.
9. If the fuel line has any crack, damage or excessive bending, please replace immediately.
10. The clamp of the fuel line is disposable. Reuse is prohibited.
11. Take out the fuel pump from the fuel tank. Do not connect the power of the fuel tank when it
is exposed to air, to avoid sparks and resulting in fire.
2-14
211 Maintenance of catalytic converter

The exhaust system of the gasoline engine is equipped with catalytic converter, which is used to
process the exhaust of the gasoline engine and effectively catalyze the harmful gases in the ex-
haust. Good gasoline engine management system can not only maintain the normal operation of
gasoline engine, but also ensure the efficient working of catalytic converter, and extend the ser-
vice life of the catalytic converter.
ƾƾƾ
The catalytic converter is easily damaged due to overheating when the gasoline engine is work-
ing. Pay attention to the following to protect the catalytic converter:
1. Only use grade 93 or higher unleaded gasoline.
2. Ensure good resistance to pressure ( 0.3MPa) and anti-leak characteristics of the fuel
supply system lines.
3. Prevent combustion under the condition of cylinder fuel shortage.
4. Avoid burning engine oil.
5. Do not drive when the fuel is insufficient, or else it may damage the electric fuel pump when
the fuel is run out.
6. Prevent the exhaust system leaking, and ensure particularly that the connection between
exhaust manifold in front of the catalytic and the muffle shouldn’t leak.
7. Do not start the gasoline engine by pushing or trailing the automobile forcibly; if the battery
voltage is low, start the gasoline engine with the secondary battery.
8. Do not perform system ignition function diagnosis by removing any spark plug or high volt-
age damper wire when the gasoline engine is running.
9. If the gasoline engine is unstable at idle or can’t start the gasoline engine after a long time,
do not run the gasoline engine forcibly.
10. If the performance of the gasoline engine drops significantly or the gasoline engine doesn’t
operate properly, e.g. fuel supply system or ignition system doesn’t work normally, shut
down the engine immediately. If the engine can’t be shut down immediately, slow down and
ask qualified maintenance center or our After-service Department for inspection.
2-15
Section Regular Inspection of Gasoline Engine

1 Maintenance cycle and content of gasoline engine
By mileage or km ×
2 10 20 0 0 50 60 70 0
No month, whichever 1000
expires first Month 1 6 12 1 2 0 6 2
Ribbed belt
1ƹ J.T J.T.G G J.T.G G
(Tension and wear)
Timing belt
2ƹ Replace every 100,000km
(Wear or damage)
3ƹ Intake/exhaust valve clearance J.T J.T J.T J.T J.T
Tightening torque of gasoline en-
4ƹ gine bolts, intake/exhaust manifold N N N N N
fixing nuts
5 Engine oil filter G Replace every 8,000km
6 Gasoline engine oil G Replace every 8,000km
7 Gasoline engine coolant G G
Gasoline engine line and fitting
8 J.T.G J.T.G J.T.G
(leak)
9 Fuel filter Replace every 8,000km
10 ƹ Idle J.T J.T J.T J.T J.T
Transmission lubricant
11 ƹ G J.T.G J.T.G J.T.G G J.T.G J.T.G J.T.G G
(Oil level and leaking)
Crankcase ventilation valve Remove to check and clean every 50,000km, and replace if neces-
12 ƹ
(PCV valve) sary
Fuel evaporation control system
14 ƹ J.T.G J.T.G J.T.G J.T.G
hose and connection
Cooling system hose and fittings
15 J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G
(Leaking and wear)
16 Emission and purifying device J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G
High voltage damper wire (deterio-
17 J.G J.G J.G J.G J.G J.G J.G J.G J.G
ration or damage)
18 Spark plug J.T.G Replace every 30,000km
19 Various types of sensors J.G J.G J.G J.G J.G J.G J.G J.G
20 Fuel injector J.T.G J.T.G J.T.G J.T.G
21 Throttle control cable Every 10,000km, J.T.G.R
Asphalt
Clean once every 10,000km, and replace every 40,000km
road
23 Air filter
Clean once every 2,500km and replace every 40,000km; in dusty
Sand road
environment, replace the element more often.
Note: (1) Meaning of symbols
J: Check R: Lubricate T: Adjust G: Replace N: Torque as required
J.T: Check and adjust J.T.G.: Check and adjust, and replace if necessary
(2) The replacing time of engine oil filter can be shortened according to the dirty degree of the
gasoline engine.
2-16
ƾƾ
It is recommended to ask our authorized maintenance center to perform the maintenance

for the items marked with ƹ
2 Main tightening torque of the gasoline engine
Tightening torque
No 3art (component) name
(Nm)
First time: 18~22
1 Cylinder head bolt Second time: +85°~95°
Third time: +85°~95°
2 Spark plug 25~30
3 Intake pipe bolt 21~25
4 Exhaust pipe bolt 25~30 (twice)
5 Camshaft pulley bolt 45~55
6 Crankshaft pulley bolt 122~149
First time: 22~27
7 Connecting rod bolt
Second time: +85°~95°
First time: 18~22
8 Main bearing bolt
Second time: +85°~95°
9 Flywheel belt 86~103
10 Oil drain plug 35~40
11 Cylinder head cover bolt 9~11 (twice)
12 Oil pan bolt 21~25
13 Tensioner pulley bolt 45~55
14 Engine oil pump mounting bolt 21~25
15 Throttle mounting bolt 21~25
17 Knock sensor mounting bolt 21~25
18 Engine oil filter 25~30
19 Clutch pressure plate screw 21~25
20 Engine oil pressure alarm 15~20
21 Water temperature sensor 25~30
2-17
Section Gasoline Engine Troubleshooting

1 Considerations for gasoline engine use and maintenance
1. Use 12V battery only; do not use AC power supply.
2. Connect the anode and cathode of the battery properly to avoid damaging the electronic
components.
3. Do not remove the battery, connecting cable and connector when the gasoline engine is running.
4. The ambient temperature of ECU shouldn’t exceed 80°C.
5. Remove the battery from the body before welding operation.
6. Take out the fuel pump from the fuel tank. Do not connect the power of the electric fuel tank
when it is exposed to air, to avoid sparks and resulting in fire.
7. Connect the positive pole and negative pole of the electric fuel pump properly.
8. Do not install devices that may cause radio interference (e.g. radio antenna) near the ECU
to avoid interference.
9. Do not let water enter into the gasoline engine or spill on the electronic circuit when repair
or clean the gasoline engine in rainy days.
10. It is prohibited to carry out the test by discharging the mixed gas from the cylinder into the
exhaust pipe without burning.
11. The fuel pressure is high. Relieve the pressure before repairing the line: remove the insur-
ance device of the fuel pump, start the gasoline engine and run at idle until stall.
12. Before removing any component, remember to turn off the ignition switch and disconnect
the cathode cable of the battery.
13. Since catalytic converter is used, it is required to use unleaded gasoline; if leaded or low-
leaded gasoline is used, it will damage the catalytic converter and weaken the performance
of the purification system.
14. It is not allowed to test the electrical signal by piercing the wire wrapping.
15. The fuel line clamp is disposable. Reuse is prohibited to prevent fuel leakage.
16. Since high voltage ignition coil is used, do not touch with hands directly when the gasoline
engine is working.
17. The idle adjustment of the gasoline engine is finished by the EFI system, and the idle sys-
tem doesn’t require mechanical maintenance.
18. Before the first start after ECU or idle regulator is replaced, turn the ignition switch to ON
and start after 20 seconds, so that the system or idle regulator will adapt.
19. The electronic control unit will provide appropriate air-fuel ratio for the gasoline engine in
any case to make the gasoline engine work normally. Therefore, do not operate any mecha-
nism on the gasoline engine (including the accelerator) when it is started.
20. The system integrates fail-safe function. However, the gasoline engine isn’t suitable for
long-term continuous operation; therefore, it is necessary to eliminate the fault immediately
when the MIL is lit, to avoid more serious damage of the gasoline engine.
2-18
2 Gasoline engine troubleshooting
3roblem Reason Solution

1. Starter doesn’t work
1.1 Fuse has blow Replace
1.2 Battery voltage is low Charge
1.3 Battery terminal is loose Tighten
Gasoline en-
gine doesn’t 1.4 Battery wire is loose Tighten
work (difficult 1.5 Starter switch contact isn’t closed or
to start) Repair or replace
switch open circuit
1.6 Starter electromagnetic switch wears Replace
1.7 Starter brush wears Replace
1.8 Magnetic field or armature circuit of the
Replace or repair
starter disconnects
2. No spark
2.1 Fuse has blown or looses Tighten or replace
2.2 Spark plug fault Adjust the gap or replace
2.3 High voltage line short circuit Repair or replace
2.4 Ignition coil is damaged Replace
2.5 Speed sensor fault Replace
2.6 ECU is damaged or circuit breaks Repair or replace
3. Intake and fuel supply system fault
3.1 Idle regulator is damaged Replace
3.2 Water temperature sensor Replace
Gasoline en- 3.3 Oil pump relay or fuse Check or replace

gine doesn’t 3.4 Inadequate fuel in the tank Refill fuel
work (difficult
to start) 3.5 Electric fuel pump doesn’t work Replace
3.6 Fuel filter is blocked Clean or replace
3.7 Air in the fuel line Repeat starting
3.8 Injector nozzle is blocked Replace or clean
3.9 Fuel pressure is low Check and adjust
3.10 Fuel hose or pipe is blocked Clean or replace
3.11 Oil inlet pipe and return pipe are reverse Check and adjust
3.12 ECU interface is loose Reinstall
3.13 Intake manifold is loose Tighten
4. Internal state of the gasoline engine is
abnormal
4.1 Cylinder head gasket is damaged Replace
2-19

4.2 Valve clearance is improper Adjust
4.3 Valve spring is weak or damaged Replace
4.4 Timing belt is damaged Replace
Gasoline en-
gine doesn’t 4.5 Valve isn’t tight Repair or replace
work (difficult 4.6 Valve is burnt out Replace
to start)
4.7 Valve guide rod is stuck Adjust or replace the valve and conduit
4.8 Piston, piston ring or cylinder wears Replace, and bore the cylinder if necessary
4.9 Fuel grade doesn’t match Replace
1. Compression pressure is low
1.2 Valve isn’t tight Repair
1.3 Valve rod is stuck Replace
Underpower 1.4 Valve spring is weak or damaged Replace
1.5 Piston ring leaks Replace
1.6 Piston, piston ring or cylinder wears Replace, and bore the cylinder if necessary
1.7 Cylinder head pad leaks Replace
1.8 Air mass flow meter is damaged Replace
2. Ignition system fault
2.1 Spark plug fault Adjust the gap or replace
2.2 ECU fault Replace
2.3 High voltage line leaks current, is loose or
Connect, and replace if necessary
disconnected
2.4 Speed sensor fault Check or replace
3. Fuel system fault
3.1 Injector nozzle is blocked Replace or clean
3.2 Electric fuel pump fault Repair or replace
3.3 Gasoline filter is blocked Replace
3.4 Fuel pressure regulator is abnormal Check and replace
Underpower
3.5 Fuel tank outlet is blocked Repair or replace
3.6 Fuel tank inlet is blocked Check and tighten
3.7 Fuel system connector is loose Check and tighten
3.8 Accelerator cable is abnormal Adjust
4. Intake system is abnormal
4.1 Air filter is dirty or blocked Clean or replace
4.2 Idle regulator is damaged Repair, adjust or replace
4.3 Gasoline engine tends to be overheated See “Overheating”
5. Others
5.1 Brake drags Repair or replace
2-20

Underpower 5.2 Clutch slips Adjust or replace
1. Electrical system fault
1.1 Spark plug damaged or spark plug gap
Replace or adjust the gap
disorders
1.2 Ignition coil deterioration or cracks lead to
Replace
current leakage
1.3 High voltage line leaks current Replace
1.5 Throttle fault Check or replace
Gasoline 1.7 Throttle position sensor is damaged Replace
engine pants
(no response 2. Fuel system fault
in short term 2.1 Fuel pump is blocked Clean or replace
when the
accelerator 2.2 Electric fuel pump doesn’t work Replace
pedal is de- 2.3 Fuel pressure regulator failure Replace
pressed)
3. Gasoline engine fault
3.1 Cylinder head gasket is damaged Replace
3.2 Piston and piston ring are seriously worn Replace
3.3 Cylinder bore wears seriously Bore the cylinder if necessary
3.4 Water temperature sensor is damaged Replace
3.5 Water pump performance is poor Replace
3.6 Radiator leaks Repair or replace
3.7 Valve is burnt out Replace
4. Lubrication system fault
4.1 Engine oil filter is blocked Replace
4.2 Engine oil filter screen is blocked Clean
Gasoline
engine pants 4.3 Engine oil pump performance degrades Replace
(no response
4.4 Oil pan or engine oil pump leaks Repair
in short term
when the 4.5 Gasoline engine oil grade doesn’t match Replace
accelerator 4.6 Gasoline engine oil in the oil pan is
pedal is de- Refill
insufficient
pressed)
5. Others
5.2 Clutch slips Adjust or replace
2-21

1. Crankshaft noise
1.1 Main bearing wears or gap is too large Replace
1.2 Connecting rod bearing wears Replace
Gasoline
1.3 Connecting rod deforms Repair or replace
engine noise
(Note: Check 1.4 Crankshaft main journal wears Repair or replace the crankshaft
the following
before me- 1.5 Connecting rod diameter wears Repair or replace the crankshaft
chanical noise 2. Piston, piston ring, piston pin or cylinder is
test: whether abnormal
ignition tim- 2.1 Abnormal wear of cylinder bore Bore the cylinder
ing is correct;
whether use 2.2 Piston, piston ring or piston pin wears Replace
specified 2.3 Piston ring is stuck Replace
spark plug;
whether use 2.4 Piston ring wears Replace
specified fuel)
3. Others
3.1 Crankshaft thrust clearance is too large Adjust as required
3.2 Valve clearance is too large Adjust as required
3.3 Gasoline engine oil is inadequate Refill
1.1 High voltage line leaks current or
Repair or replace
connection is loose
1.2 Spark plug fault Clean, adjust or replace
2.2 Fuel tank pipe leaks Repair or replace
Fuel con- 2.3 Fuel pressure is low Repair or replace

sumption is 2.4 Injector nozzle is blocked Clean or replace
high
2.5 Air filter element is blocked Clean or replace
2.6 Air mass flow meter is damaged Replace
3.1. Compression pressure is low See above
3.2 Valve isn’t tight Repair or replace
3.4 Idle speed is high Check and repair
4. Others
Fuel con-
sumption is 4.2 Clutch slips Adjust or replace
high
4.3 Tire pressure is insufficient Adjust
4.4 ECU is damaged Replace
2-22

1. Engine oil leaks
1.1 Oil drain plug is loose Tighten
1.2 Mounting bolt in the oil pan is loose Tighten
1.3 Oil pan sealing is poor Re-coat and install
1.4 Oil seal leaks Replace
1.5 Cylinder head pad leaks Replace
1.6 Engine oil filter isn’t tightened Tighten
Gasoline
1.7 Oil pressure switch is loose Tighten
engine oil
consumption 2. Lubricating oil carry-over
is high Clear the carbon deposit or replace the piston
2.1 Piston ring is stuck
ring
2.2 Piston ring and ring groove wears Replace the piston and piston ring
2.3 Piston ring opening isn’t in proper position Adjust the opening position
2.4 Piston or cylinder wears Replace the piston, and bore if necessary
3. Valve rod leaks oil
3.1 Valve oil seal wears Replace
3.2 Valve or valve guide wears seriously Replace
1.1 Engine oil filter is blocked Replace
1.2 Fuel pipe is twisted, damaged or leaks Check, and replace if necessary
1.3 Electric oil pump fault Check, and replace if necessary
Surge (gaso-
line engine 1.4 Intake manifold and throttle leak Check, and replace if necessary
power chang-
es when driv- 1.5 Idle regulator is damaged Replace
ing at stable 1.6 Injector nozzle is blocked Clean or replace
speed; auto-
mobile slows 1.7 Air mass flow meter is damaged Replace
down even if 1.8 Fuel pressure regulator failure Replace
the accelera-
tor pedal isn’t 2. Ignition system fault
changed)
2.1 High voltage line leaks current or is loose Repair or replace
2.2 Spark plug fault Check and repair or replace
1.1 Injector nozzle is blocked Clean or replace
Unstable idle 1.3 Air filter element is blocked Clean or replace
speed
1.4 Intake manifold and cylinder head gasket
Replace
leak
1.5 Fuel pressure regulator failure Replace
1.6 Air mass flow meter is damaged Check or replace
2-23

1.7 Throttle position sensor is damaged Replace
1.8 Accelerator cable is abnormal Adjust
2.1 Spark plug fault Adjust or replace
2.2 High voltage line leaks current or is
Connect or replace
disconnected
Unstable idle
speed 3. Others
3.1 Vacuum hose is loose or torn off Re-connect
3.2 Cylinder head sealed gasket leaks Replace
3.3 Compression pressure is low See above
3.4 Intake manifold bolt or nut is loose Tighten
3.5 Intake manifold sealed gasket leaks Replace
3.6 Air conditioner signal line is damaged Check and repair
3.7 Water temperature sensor is damaged Replace
Replace a spark plug of appropriate heat rat-
1.1 Spark plug is overheated
ing
1.2 High voltage or low voltage circuit
Tighten
connection is loose
2.1 Gasoline filter and fuel line blocked Clean or replace
Abnormal 2.3 Fuel pressure regulator failure Replace

combustion 2.4 Electric fuel pump and line fault Replace
2.5 Intake manifold sealed gasket is damaged Replace
3.1 Excessive carbon deposits on the piston
Clean
top or cylinder head
3.2 Cylinder head gasket damage results in
Replace
reduced compression pressure
3.4 Valve is stuck Replace
3.5 Valve spring weakens Replace
Replace a spark plug of appropriate heat rat-
Overheating 1.2 Spark plug heat rating is improper
ing
2.1 Fuel pressure is low Adjust
2-24

2.3 Intake manifold is loose Tighten
3. Cooling system fault
Overheating 3.1 Coolant is inadequate Refill
3.2 Ribbed belt for the water pump is loose or
Adjust or replace
damaged
3.3 Temperature regulator doesn’t work
Replace
normally
Emission troubleshooting

1. Gasoline engine
11. Water temperature of the gasoline engine
Check
isn’t normal
1.2 Air filter is blocked Clean or replace
1.3 Oil leaks Check and adjust
1.4 Cylinder pressure is low Check and repair
1.5 Fuel is substandard Replace the fuel
2. Fuel system
2.1 Fuel evaporation control system failure Check and repair
2.2 Injector is blocked Replace
2.3 Fuel pressure regulator failure Clean or replace
3. Intake/exhaust system
HC, CO, and
NOx emission 3.1 Catalytic converter is damaged Replace
exceed the 3.2 Oxygen sensor is damaged Check and replace
standard
3.3 Throttle position sensor is damaged Check and replace
3.4 Air mass flow meter is damaged Check and replace
3.5 Water temperature sensor is damaged Check and replace
3.6 Temperature regulator is damaged Check and replace
3.7 Vacuum pipe leaks Check and repair
3.8 Exhaust system leaks Check and repair
4.1 Spark plug fault Clean or replace
4.2 Cylinder fuel shortage Check and repair
4.2 High voltage line contact is poor or leaks
Check and repair
current
4.4 ECU fault Check and repair
2-25
Section 5 Gasoline Engine Sealing and Unsealing

51 Gasoline engine sealing
The gasoline engine should be stored in a warehouse, which is clean, dry, ventilated and without
corrosive gas. The period is three months. If it will be stored for longer time, please take the fol-
lowing sealing measures:
1. Fill 2.5L anti-rust lubricant into the gasoline engine, and then unscrew the spark plug of
each cylinder, to keep all the pistons of the gasoline engine between the top dead center
and bottom dead center. Fill 0.006L anti-rust lubricant into each cylinder, and drive the gas-
oline engine with the starter to run for 3~4 times, about 15 seconds each time.
2. Unscrew the oil drain plug in the oil pan to drain the anti-rust lubricant, reinstall the oil drain
plug and spark plug and torque with specified torque.
3. Drain the coolant, remove the injector nozzle, clean and seal with dust cover, and then plug
the exhaust pipe, throttle opening, gasoline engine water inlet/outlet, and injector hole with
wax paper or plastic cover.
4. Put the gasoline engine into the box.
52 Gasoline engine unsealing

1. Clear the oil outside of the gasoline engine.
2. Unseal all sealed holes.
3. Unscrew the spark plug, idle the gasoline engine and drain the anti-rust lubricant in the cyl-
inder.
4. Fill in gasoline engine oil.
5. Fill in coolant.
6. Start the gasoline engine as described in this manual.
2-26
Customer Feedback
Dear Users,
Thanks for purchasing BYD Gasoline Engine. In order to continuously improve the performance
and quality of the products and provide better services, any suggestion and improvement opin-
ions about the problems found in the process of using the EFI gasoline engine are appreciated.
Please contact us through the phone, fax, or e-mail listed in the back cover. Please send letters to
the following address and fill out the Customer Feedback.
3RVWDOFRGH
1R%<'5G1HZ,QGXVWULDO3DUN;L’DQ+LJKWHFK=RQH6KDDQ[L3URYLQFH
To
After-service Department
%<'$XWR6DOHV&R/WG
Name of Sender: __________________
Address: __________________
2-27
Customer Feedback
Year
Gasoline engine No. Date of Manufacture
Month
Using time or mileage Unit
Contact Tel
FAX/E-MAIL
Comments and Suggestions (please fill in details)
2-28
III BYD4B Engine
Contents
Chapter 1 Gasoline Engine -1

Section 1 Engine Overview .....................................................................................................3-1
1.1 Main Parameters ..............................................................................................3-1
1.2 Service Technical Data.....................................................................................3-2
1.3 BYD483QB Gasoline Engine Tightening Torque Chart ....................................3-3
1.4 BYD483QB Gasoline Engine Bearing Optional Chart......................................3-4
1.5 BYD483QB gasoline engine different parts list ................................................3-4
Section 2 Drive Belt.................................................................................................................3-5
2.1 Drive Belt Tension Inspection ...........................................................................3-5
2.2 Drive belt adjustment........................................................................................3-5
Section 3 Valve Clearance ......................................................................................................3-6
3.1 Valve clearance inspection...............................................................................3-6
3.2 Valve clearance adjustment .............................................................................3-7
Section 4 Compression Pressure Inspection ..........................................................................3-8
Section 5 Timing Belt ..............................................................................................................3-9
Section 6 Cylinder Head Gasket Assembly ..........................................................................3-12
Section 7 Crankshaft Front Oil Seal ......................................................................................3-14
7.1 Crankshaft Front Oil Seal Replacement.........................................................3-14
7.2 Crankshaft Front Oil Seal Removal Instructions ............................................3-14
7.3 Crankshaft Front Oil Installation Instructions..................................................3-15
Section 8 Crankshaft Rear Oil Seal.......................................................................................3-15
Chapter 2 Lubrication System -16
Section 1 Gasoline Engine Lubrication Circuit Schematic Drawing ...................................... 3-16
Section 2 Oil Pressure Inspection .........................................................................................3-16
Section 3 Gasoline Engine Oil ..............................................................................................3-17
3.1 Oil Inspection..................................................................................................3-17
3.2 Oil Change .....................................................................................................3-17
Section 4 Oil Filter .................................................................................................................3-18
Section 5 Oil Pan...................................................................................................................3-18
Section 6 Oil Pump................................................................................................................3-19
6.1 Oil Pump Installation and Removal ................................................................3-19
6.2 Oil pump disassembly/assembly ....................................................................3-21
3-I
6.3 Oil pump inspection........................................................................................3-21

Chapter Cooling System -22
Section 1 Gasoline Engine Cooling System Schematic Drawing.......................................... 3-22
Section 2 Thermostat ............................................................................................................3-22
2.1 Thermostat removal and installation ..............................................................3-22
2.2 Thermostat inspection ....................................................................................3-23
Section 3 Water Pump ..........................................................................................................3-23
Chapter Clutch -2
Section 1 Special Tool ...........................................................................................................3-24
Section 2 Parts Location Index .............................................................................................3-24
Section 3 Adjustment of Clutch Pedal and Its Bolts ..............................................................3-24
Section 4 Clutch Pedal Replacement....................................................................................3-25
Section 5 Clutch Master Cylinder Replacement....................................................................3-25
Section 6 Clutch Release Cylinder Replacement .................................................................3-26
Section 7 Clutch Replacement ..............................................................................................3-27
&OXWFKVSHFL¿FDWLRQ ........................................................................................3-27
7.2 Clutch Removal ..............................................................................................3-27
7.3 Clutch installation ...........................................................................................3-28
7.4 Clutch cover assembly inspection ..................................................................3-28
Section 8 Flywheel ................................................................................................................3-29
8.1 Flywheel removal ...........................................................................................3-29
8.2 Flywheel inspection ........................................................................................3-30
3-II
Chapter 1 Gasoline Engine
Section 1 Engine Overview

BYD483QB gasoline engine applies electronic fuel injection system with advanced self-diagnosis
function. This injection system features multi-port sequential injection and achieves high power,
lower fuel consumption, low noise, less emissions and compact construction.
BYD483QB gasoline engine can operate optimally under any condition. This ensures the vehicle
with reliable security, comfortable drivability, best fuel economy and environment-friendly perfor-
mance.
11 Main 3arameters
BYD483QB
4-Cylinder, in line, water-cooled, double overhead camshaft, 16-valve,
Type 4-stroke
Closed loop electronic fuel injection gasoline engine
Rated power 95kW˄5800r/min˅
Max. torque/speed 172N.M/4750r/min
Min. fuel consumption 275 g/kW·h
Bore × stroke 83 mm × 92 mm
Displacement 1.991 L
Compression ratio 9.6
Valve mechanism Synchronized belt drive, 16-valve DOHC
Combustion chamber type Pent roof
Fuel type Octane No. 93 or higher (Research)
Idle speed (750±50)r/min
Cylinder compression pressure 1.2 MPa~1.5 MPa(400 r/min)
Fuel supply Electronic sequential multiport fuel injection
Injection pressure (differential
pressure before and after the in- 350 kPa
jection)
Ignition order 1—3—4—2
Ignition timing BTDC 10°±1 when idling
Lubricating method Forced and splash lubrication
SG 10W-30 (For four seasons in the South and Summer in the North)
Engine oil
SG 5W-30 (For Winter in the North)
Exhaust emission system Two-level three-way catalytic converter
Oil pressure 300 kPa~490 kPa.(3000 r/min)
Gasoline engine mass 130 kg
Dimension (length × width ×
600 mm × 610 mm × 640 mm
height)
Emission regulation China IV
3-1
12 Service Technical Data
Item Standard Limit value

Cylinder diameter Ï83mm 83.024 mm
Cylindricity 0.008 mm 0.012 mm
Cylinder block Top flatness 100˖0.025 0.06 mm

Verticality 100˖0.025 0.06 mm
1.08 MPa/(400 r/
Cylinder compression pressure 1.2 MPa~1.5 MPa/(400 r/min)
min)
Piston skirt diameter ¶83mm
Piston Piston pin hole diameter ¶19mm

Mating clearance of the piston and
0.036 mm~0.056 mm
cylinder
Piston pin diameter Ï19mm
Piston pin Mating clearance of the piston pin and
0.005~0.017 mm
piston
1st Compression ring 0.15 mm~0.30mm 0.70 mm
Piston ring
opening clear- 2nd Compression ring 0.25 mm~0.40 mm 0.70 mm
ance
Oil ring assembly 0.20 mm~0.70 mm 1.00 mm
Piston ring Compression ring (1st, 2nd ) 0.04 mm~0.08 mm 0.12 mm

side clearance Oil ring 0.06 mm~0.18 mm 0.23 mm
Allowable twist limit 0.05 mm (per 100 mm)
Allowable bent limit 0.05 mm (per 100 mm)
Connecting rod Connecting rod small end hole diam-
¶19mm
eter
Piston pin and connecting rod
0.013~0.037 mm
Magnitude of interference fit range
Main journal diameter ¶56 mm
Connecting rod journal diameter ¶48 mm
Journal Cylindricity 0.005 mm
Crankshaft
Crankshaft radial circular run-out 0.03 mm
Connecting rod big end axial clear-
0.160 mm~0.264 mm
ance
Crankshaft thrust clearance 0.06 mm~0.23 mm
Flywheel axial circular run-out 0.06 mm 0.2 mm
Cylinder head lower surface flatness 0.04 mm 0.10 mm
Cylinder head Manifold joint face flatness 0.06 mm 0.10 mm

Cylinder head camshaft bore diam-
¶26mm
eter
Cylinder head bolt length 104.0~104.6 mm 105.5 mm
Camshaft journals diameter ¶26 mm
Camshaft journal Cylindricity 0.004 mm
Camshaft Gap between the camshaft journal
0.028 mm~0.062 mm 0.10 mm
and shaft hole
Camshaft axial clearance 0.072 mm~0.126 mm 0.15 mm
3-2
Intake valve diameter 31.5±0.01 mm

Exhaust valve diameter 27.6±0.01 mm
Intake valve:¶6 mm
Valve stem diameter Exhaust valve: ¶6-0.020
-0.035 mm
Valve system
Valve guide inner diameter ¶6 mm
Gap between the valve stem and
0.025 mm~0.060 mm 0.080 mm
valve guide
Valve spring free length 44 mm
Intake and exhaust valve clearance
0.26±0.03 mm
(cold)
3.04 mm~3.68 mm Adjust the speci-
Adjust the specification of valve clearance gasket (0.02 mm differentials among fication of valve
adjacent groups) clearance gasket
Thermostat initial and full open temperature 82±2°C, full open 95°C Stroke 9±0.5 mm
K6RTC ,0.8 mm~0.9 mm
Spark plug type and gap
3923-8, 0.8 mm~0.9 mm
Generator belt tension deformation 450 N~550 N
Loctite 587
Flat sealant type
Tianshan 1596F
1 BYD4B Gasoline Engine 15

Knock sensor set
21~25
Tightening Torque Chart bolt
16 Oil filter 25~30
Tightening 17 Oil pressure siren 15~20
No 3art name
torque (N·m)
Water temperature
First:18~22 18 25~30
sensor
1 Cylinder head bolt Second: +85°~95°
Generator hanger
Third: +85°~95° 19 45~55
bolt
2 Spark plug 25~30 Generator preten-
20 21~25
3 Intake manifold bolt 21~25 sion bolt
Cam bearing cap
Exhaust manifold 21 12~14
4 25~30 (Twice) bolt
bolt
22 Skirt rack bolt 21~25
5 Camshaft pulley bolt 45~55
Clutch pressure
Crankshaft pulley 21~25
6 122~149 plate screw
bolt
First:22~27 24 M6 bolt 9~11
7 Connecting rod bolt S e c o n d : M8 bolt 21~25
+85°~95°
First:18~22 M10 bolt 45~55
Main bearing cap
8 S e c o n d : M8 nut 21~25
bolt
+85°~95°
9 Flywheel bolt 86~103
10 Drain plug 45~55
Cylinder head cover
11 9~11 (Twice)
bolt
12 Tensioner pulley bolt 45~55
13 Oil pump set bolt 21~25
14 Throttle set bolt 21~25
3-3
1 BYD4B Gasoline Engine 15 BYD4B gasoline engine dif-

Bearing Optional Chart ferent parts list
Main bearing bush: The parts without part no. indicates that they
are only equipped in BYD483QB engine.
Main bear-
Main journal Main bearing
ing hole BYD483QB
(Group no) (Group no)
(Group no)
Cylinder block pro- BYD483QB- 1002100-
1 1 3
cessed part C2
2 1 2 Front head cover com-
BYD483QB- 1002200
ponent (Lower)
3 1 1
Front head cover com-
BYD483QB- 1003600
1 2 4 ponent (Upper)
Cylinder head gasket as-
2 2 3 BYD483QB- 1003300
sembly
3 2 2 Connecting rod mechan-
BYD483QB- 1004200
ical processed part
1 3 5
Crankshaft BYD483QB- 1005014
2 3 4
3 3 3 Intake camshaft BYD483QB- 1006011
Connecting rod bearing optional chart Exhaust camshaft BYD483QB- 1006012

Intake pipe upper and
Crankshaft Connecting BYD483QB- 1008101
lower gasket
Connecting
connecting rod big end Oil dipstick sleeve
rod bearing wielded part
BYD483QB- 1011100
rod journal hole
(Group no) BYD483QB-
(Group no) (Group no) Timing belt
1021013(YU135)
A A 2
Rubber retainer upper
BYD483QB- 1307016
B A 1 RH
A B 3
B B 2
3-4
Section 2 Drive Belt 3. Tighten the bolt A and B (Tightening

torque: 21 N·m~25 N·m)
21 Drive Belt Tension Inspection
NOTICE
Measure the belt tension of drive belt at the If a new belt or the drive belt that
measuring point marked in the diagram be- operates for less than 5 minutes
low. The measured value of the old and new should be replaced, adjust it to the
belt should be within the specification as VWDQGDUGH[WHQWDVDQHZRQH
shown in the table below.
If the drive belt that operates for
Power steering more than 5 minutes should be
MeasuringWater pump
Generator
point
pump replaced, adjust it to the standard
Measuring
point
H[WHQWDVDQROGRQH
Compressor
Crankshaft pulley Crankshaft pulley
During measuring
Drive belt New belt (N) Old belt (N)
Generator +
750~800 450~550
water pump
22 Drive belt adjustment

Dynamo
1. Loosen the bolt A and B as shown in

the above illustration.
2. Adjust the belt tension within the speci-

fication as shown in the above table by
adjusting bolt C.
3-5
Section Valve Clearance 4. Install the cylinder head cover.
Firstly, ensure there is no oil, water or other

1 Valve clearance inspection
foreign materials in the groove of cylinder
1. Confirm that gasoline engine has head cover.
cooled down.
Secondly, check if the cylinder head cover
2. Remove the cylinder head cover. gasket is in good condition, and press it in
place.
Firstly, Remove the engine ignition coil, high-
tension pole and connected wires. Thirdly, remove the sealant in the area shown
in the illustration below, and apply Loctite
Secondly, remove the cylinder head cover bolts 5699 flat sealant to the seal surface again.
in the order shown in the illustration below.
3. Measurte the valve clearance.
Firstly, rotate the crankshaft clockwise to

make the piston up to the 1st cylinder TDC. Fourthly, install the cylinder head cover. Align
the installation of cylinder head stud bolt with
Secondly, measure the valve clearance at the the cylinder head cover, and ensure the head
point A as shown in the illustration. If it ex- cover contact with sealing area over the front
ceeds the clearance specification, replace the head cover component (upper). Then press
adjusting gasket. the cylinder head cover downward lightly to
contact closely with the cylinder head and the
Standard valve clearance (Cold gasoline en-
front head cover component (upper). Tighten
gine)
the cylinder head cover bolts (Tightening
Intake valve (IN): 0.23 mm~0.29 mm torque: 9~11 N·m) in 2 to 3 times in the order
given in the illustration below, and recheck
Exhaust valve (EX): 0.23 mm~0.29 mm the torques of bolts in the following order
shown in the illustration.
Thirdly, rotate the crankshaft 360º clockwise
to make the piston up to the 4th cylinder TDC.
Fourthly, measure the valve clearance at the

point B as shown in the illustration. If it ex-
ceeds the clearance specification, replace the
adjusting gasket.
3-6
2 Valve clearance adjustment New gasket thickness = used gasket thick-
ness + measured valve clearance –
This procedure is for all the valves that need standard valve clearance (0.26 mm)
to adjust the clearance.
6. Put the adjusting gasket into valve tap-
1. Rotate the camshaft clockwise to turn pet.
the peach-tip of the camshaft upward
and hold it at a suitable position for ad- 7. Loosen the bolt A for the favor of valve
justment, then adjust the tappet open- tappet movement.
ing to the inside of the cylinder head.
8. Loosen the bolt securing the special
2. Unscrew 1 bolt on the outside of cam- tool and remove the special tool.
shaft cap.
9. After removing the special tool, retight-
Note: As long as you remove the bolt outside en the cam bearing cap bolt. Tightening
of corresponding camshaft cap, the gasket torque: 12 Nm - 14Nm.
can be replaced accordingly.
10. Check the valve clearance according to
3. Press the valve tappet with the special 1.3 in this section.
tool eject-rod and secure the special
tool on the camshaft cap with bolt which CAUTION
removed recently.
When pressing the valve tappet, it is pos-
VLEOHWRGDPDJHWKHF\OLQGHUKHDG
Bolt A
4. Tighten the bolt A, press the tappet and

remove the original gasket with nipper.
Bolt A
5. Choose an appropriate adjusting gas-

ket.
3-7
Section Compression 3res- If the compression pressure is still low,

the valves may be stuck or the seal
sure Inspection surface has a poor contact. It is nec-
Warning: Oil temperature is very high when essary to overhaul.
the gasoline engine is hot. Be careful not to
be burnt when installing and removing the Item Compression pressure
components. 1.2~1.5 MPa
Standard
(400 r/min)
1. Confirm that the battery has been fully Min. limit 1.08MPa(400r/min)
charged. Differential pressure
max. limit between 200kPa
2. Warm up the engine to the normal op- each cylinder
erating temperature.
11. Remove the compression gauge.
3. Stop and cool the gasoline engine for
10 minutes. 12. Connect the ignition coil.
4. Remove the fuel pump relay according 13. Install the fuel pump relay.
to ”OIL PATH SAFETY INSPECTION
PROCEDURE”. 14. Install the spark plug. Tightening
torque: 25 Nm.
5. Remove the No.1 cylinder spark plug.
6. Disconnect all the ignition coil connec-

tors.
7. Connect a compression gauge into the

No.1 cylinder spark plug hole.
8. Depress the accelerator pedal to the

end and start the gasoline engine.
9. Start the gasoline engine and record

the max. readings of the compression
gauge.
10. Inspect the compression pressure of

No.2, No.3 and No.4 cylinder in suc-
cession according to step 5 to 9. If the
pressure of one or more cylinders are
too low, or the differential pressure be-
tween the cylinders exceeds the speci-
fied value largely, drop some gasoline
engine oil inside and recheck the pres-
sure:
If the compression pressure increas-

es, the piston, piston ring and cylinder
wall may be worn. It is necessary to
overhaul.
If the pressure of the adjacent cylinder

is low, the cylinder gasket was dam-
aged or the cylinder head was de-
formed. It is necessary to overhaul.
3-8
Section 5 Timing Belt 4. Remove each component in the order

Overview of timing belt removal and installation
5. Adjust the belt deformation/tension.
1. Disconnect the battery negative cable.
6. Perform the installation in the reverse
2. Remove the camshaft phase sensor order of the removal.
(CMP).
7. Start the gasoline engine and check the
3. Remove the ignition coil and spark connection of tensioner pulley, guide
plug. pulley and drive belt.
Damping pulley components installation Timing belt removal instruction

instruction
1. Install the crankshaft pulley bolt.
Lock the flywheel with the special tool, then
remove the damping pulley. 2. Turn the crankshaft clockwise and mark
the timing mark as shown in the illustra-
NOTICE tion below.
Do not tap the outer ring of damping pul- 3. Rotate the tensioner pulley clockwise
OH\GXULQJUHPRYLQJ with socket and wrench.
4. Remove the tensioner pulley spring.
NOTICE
It will damage the belt or shorten its ser-
YLFHOLIHE\ZLQGLQJWKHEHOW¿UPO\RULILW
LVDGKHUHGZLWKRLORUJUHDVH
Note: For corresct reinstallation, mark the

rotating direction on the timing belt when re-
Cylinder head cover removal instruction moving.
For the cylinder head cover removal, please
follow the step 1.2 in SECTION ċ .
3-9
NOTICE
Do not strain the tensioner pulley spring,
otherwise it will over tighten the timing
EHOW
Guide Pulley
Tensioner pulley and tensioner pulley
spring installation instruction:
Measure the free length of tensioner pulley

spring, which should be 36.6mm. If the val-
ue is not within the specified range, replace
the tensioner pulley spring.
5. Rotate the tensioner pulley clockwise,

and strain the tensioner pulley spring
properly.
1. Install the tensioner pulley.
2. Rotate the tensioner pulley. If there is

no resistance or it can not rotate, re-
place the pulley.
Timing belt installation instruction
1. Make sure to align the timing belt mark

with the camshaft pulley mark as shown
in the illustration. 6. Rotate the crankshaft twice clockwise
to confirm all the timing marks has
Inlet side aligned (see above illustration), other-
Outlet side
wise, repeat the operations from the
first procedure.
2. Install the timing belt and press it to the

tensioner pulley firmly.
3. Rotate the timing belt clockwise for two

circles and align it with the timing mark.
4. Make sure all of the timing marks are

aligned perfectly. If not, remove the tim-
ing belt and reinstall.
7. Tighten the camshaft pulley bolt, guide pul-
3-10
ley bolt, or recheck the torque of ten-

sioner pulley bolt (torque: 45-55 N·m).
Front head cover (lower) installation in-

struction
Align the location pin sleeve of front head

cover (lower) to the engine location pin hole,
and keep the seal surfaces contact properly,
then tighten the bolt with the torque 8-10 N·m.
F Mark
Front head cover (upper) installation in-
struction
Align the location pin sleeve of front head

cover (upper) to the cylinder head location Cylinder head cover installation instruction
pin hole, and keep the seal surfaces contact
properly with the front head cover (lower), For the cylinder head cover installation,
then tighten the bolt with the torque 8-10 N·m. please follow the step 1.4 in SECTION ċ .
Damping pulley components installation

instruction
Lock the flywheel with the special tool, then

install the damping pulley and crankshaft pul-
ley bolt torque: 122-149 Nm.
Drive belt installation instruction
For the drive belt installation, please follow

the instruction in SECTION II DRIVE BELT.
Water pump pulley installation instruction
Install the water pump pulley with the “F”

mark facing outward.
NOTICE
After installing the drive belt (engine
EHOW WLJKWHQWKHZDWHUSXPSSXOOH\EROW
7RUTXH1ÂP
3-11
Section 6 Cylinder Head Gas-

ket Assembly Camshaft pulley
Cylinder head gasket assembly replacement

Loctite 5699
Warning: Cylinder
Intake and exhaust
camshaft
head
For the fuel vapor is easy to catch fire,
keep away from the spark or flame.
Fuel leakage or splash will result in

skin burn and eye damage. To avoid Cylinder head
gasket assembly Intake manifold
this situation, please follow the fuel support
safety inspection procedure for fuel

and emission control system.
1. Remove the timing belt.
2. Remove the front exhaust pipe. Camshaft pulley removal instruction

3. Remove the air filter. For the removal, lock the hexagon strut on
the camshaft with wrench as shown in the il-
4. Remove the power steering oil pump
lustration.
and bracket; Do not release the oil
pipe.
5. Remove the accelerator cable.
6. Remove the fuel hose.
7. Drain the gasoline engine coolant.
8. Perform the removal in the order indi-

cated in the illustration below.

Camshaft removal instruction
order of the removal.
Loosen the camshaft bearing seat bolt in 2
10. Check the gasoline engine oil level.
or 3 times in the order given in the illustration
11. Check the cylinder compression pres- below.
sure.
12. Start the gasoline engine.
(1) Check the run-out and contact condi-

tion of pulley and drive belt.
(2) Check the gasoline engine oil and cool-

ant for leak.
(3) Check the idling speed.
Cylinder head removal instruction
Loosen the cylinder head bolt in 2 or 3 times

in the order given in the illustration below.
3-12
Camshaft installation instruction
CAUTION
For the camshaft installation clearance
is so small, ensure its levelness when
LQVWDOOLQJ2WKHUZLVHWKHFRQWDFWVXUIDFH
between shaft and bearing will generate
QRLVH IRU WKH UHDVRQ RI KLJK SUHVVXUH
3OHDVHREVHUYHWKHSURFHGXUHVEHORZWR
Cylinder head insvtallation instruction DYRLGWKHVLWXDWLRQVRFFXU
1. Measure the bolt length of each cyl- 1. Install the camshaft into the cylinder
inder head. If it exceeds the standard head.
value, please replace it.
2. Install the camshaft bearing cap.
Standard length: 104.2 mm-104.8 mm
3. Apply the sealant on the areas shown
Max. length: 105.5 mm in the illustration. Pay attention to that
the sealant diameter is 1 mm-2
mm, it is even and continuous. Make
sure the camshaft surface is clean to
avoid gasoline engine damage.
Loctite 5699
2. Tighten the cylinder head bolts in the
order given in the illustration below.
First tightening torque: 20±2 N·m. Loctite 5699
Loctite 5699
4. Apply appropriate oil on the camshaft

and bearing seat.
5. Install the rest camshaft bearing caps.
6. Tighten the bolt 1, 2, 11, 12 marked on

3. Mark on each bolt head. the camshaft manually.
4. Tighten the bolt for the second time as 7. Tighten the camshaft bolts in 2 to 3
shown in the illustration and take the times in the order given in the illustra-
marks as a reference. Rotate 90º±5º. tion below.
8. Confirm the camshaft levelness before

tightening the No.3 camshaft bearing
Step 1 cap bolt.
Mark
9. Add the clean oil to the camshaft oil
Step 1 groove.
5. Rotate 90º±5º for the third time.
3-13
Section 7 Crankshaft Front Oil

10. Install the oil seal manually whose lip is Seal
applied with gasoline engine oil.
71 Crankshaft Front Oil Seal Re-
11. Press the oil seal with the special tool
and hammer.
placement
Cylinder head
2. Perform the removal in the order shown
Hammer in the illustration.

Special tool
Camshaft oil seal
Front oil seal
Camshaft pulley installation instruction

Key
1. Install the camshaft pulley. Place the lo-
cation pin on the location shown in the Camshaft timing gear
illustration.
Position pin
72 Crankshaft Front Oil Seal Re-
moval Instructions
1. Cut off the oil seal edge with blade.
2. Remove the oil seal with screwdriver

wrapped with rag.
2. Lock the camshaft and tighten the cam-

shaft pulley bolt with wrench as shown
in the illustration. Torque: 45-55 N·m. Oil seal edge
Rag
3-14
7 Crankshaft Front Oil Installation 2. Install the oil seal manually.
Instructions
1. Apply appropriate clean gasoline en- and hammer.
gine oil on the oil seal lip.
2. Install the oil seal manually.

and hammer.
Rag
Oil pump
Hammer
Gasoline engine disassembly/assembly
1. Disconnect the connection between the

0~0.5mm gasoline engine and transmission case.
Remove the air intake system.
SST
Front oil seal
2. Remove the exhaust system.
3. Remove the oil filter.

Section Crankshaft Rear Oil
Rear oil seal cap
Seal Hammer
Crankshaft rear oil seal replacement
1. Remove the flywheel.
2. Perform the removal as shown in the il-

lustration.
Perform the installation in the reverse order of SST

Rear oil seal
the removal.
4. Remove the thermostat.
5. Remove the ignition coil.
6. Remove the generator.

Rear oil rea 7. Perform the disassembly in the order
8. Perform the assembly in the reverse

Crankshaft rear oil seal removal instruc- order of the disassembly.
tions
1. Cut off the oil seal lip with blade. Heating return pipe
2. Remove the oil seal with screwdriver Generator bracket
wrapped with rag.
Crankshaft rear oil seal installation in-

structions Steering pump bracket
Compression bracket
Thermolator
1. Apply appropriate clean gasoline en- Outlet pipe connector
gine oil on the oil seal lip.
3-15
Chapter 2 Lubrication System
Section 1 Gasoline Engine Lubrication Circuit Schematic Drawing
Section 2 Oil 3ressure Inspection 4. Warm up the gasoline engine to the

normal operating temperature.
WARNING Increase the gasoline engine speed to
The oil temperature of the hot engine is very the specified
KLJK,WLVHDV\WREHVFDOGHG6WDUWWKHZRUN 5. value, and pay attention to the readings
DIWHUVWRSSLQJDQGFRROLQJWKHHQJLQH on the oil pressure gauge.
1. Remove the intake pipe bracket. γ If the pressure is not as specified, find
out the cause and repair or replace as
2. Remove the oil pressure siren. required.
3. Install the special tool to the oil pres-
sure siren installation hole. NOTICE
Oil pressure varies according to
WKHYLVFRVLW\DQGWHPSHUDWXUH
2LO3UHVVXUHN3D>U
min]
6. Stop and cool the gasoline engine.
7. Remove the special tool.

SST 8. Apply sealant to the oil pressure siren
thread evenly as shown in the illustra-
tion below.
3-16
Wash your skin with a soap and

clear water as the old oil will
FDXVHFDQFHU
1. Park the vehicle on a level surface.
2. Remove the oil filler cap and drain plug.

Loctite 5699
3. Drain the oil into a proper container.
4. Install the oil drain plug with a new

9. Install the oil pressure siren. washer.
Tightening torque: 15-20 Nm Tightening torque: 35-45 Nm
10. Install the intake pipe bracket. 5. Add the engine oil with specified type
and volume into the engine again.
11. Start the gasoline engine and check for
the oil leak. 6. Reinstall the oil filler cap.
Section Gasoline Engine Oil 7. Start the gasoline engine and check for
the oil leak.
1 Oil Inspection
8. Check the gasoline engine oil level and
1. Park the vehicle on a level surface. add oil as required.
2. Warm up the engine to the normal op- NOTICE

erating temperature, and then stop.
,QVRPHFDVHVWKHRLOPDVV¿OOHGDFFRUG-
3. Wait for 5 minutes. ing to the oil level differs from the speci-
¿HGDFWXDOPDVV
4. Pull out the oil dipstick and examine the
oil level and oil condition. Check if the Item Capacity (L)
oil level is between FULL and LOW.
Oil change 3.0
5. Add or change the engine oil as re- Oil and oil filter change 3.3
quired.
6. Check if the O-ring on the oil dipstick Gasoline engine oil grade SG or higher:
tip is in good condition.
Oil viscosity choice
Oil grade
7. Reinsert the oil dipstick. standard
Above -25°C SG 10W-30
2 Oil Change
-30°C-37°C SG 5W-30
WARNING
The oil temperature of the hot en-
JLQHLVYHU\KLJK%HFDUHIXOQRWWR
EHVFDOGHG
If the vehicle is not raised to the safe
location, it will drop off and result in
GHDWK7KXVLWLVIRUELGGHQWRZRUN
under or around the vehicle if it is not
VXSSRUWHGSHUIHFWO\
3-17
Section Oil Filter

2LO¿OWHUUHSODFHPHQW
1. Remove the oil filter with the special

tool.
Oil pan removal instructions

SST
1. Remove the oil pan bolt.
2. Wipe off the oil filter surface with a 2. Remove the sealants on the thread.
piece of clean cloth.
3. Screw a bolt in the welded nut, leave a
3. Install the oil filter firmly according to narrow clearance between the oil pan
the instruction procedure on the filter or and floor.
packing case. Torque: 25-30 N·m.
4. Start the gasoline engine and check for

the oil leak.
5. Check the oil level. Add oil if necessary.
NOTICE
When replacing oil filter, make sure the
accumulator cathode is disconnected
DQG UHSODFH LW DV WKH DERYH SURFHGXUH
Avoid damaging electrical parts because
of short circuit in the process of replace- 4. Remove the oil pan with a remover.
PHQW
Section 5 Oil 3an

Oil pan installation and removal
1. Disconnect the battery negative.
2. Drain the oil.
3. Remove the front pipe.

in the illustration below.
Oil pan installation instructions
CAUTION:
6. Start the gasoline engine and check for Remove the sealants on the used
the oil leak. WKUHDG ZKHQ UHXVLQJ 7KH XVHG
VHDODQWVZLOOGDPDJHWKHEROWKROH
3-18
Section 6 Oil 3ump

61 Oil 3ump Installation and Removal
2. Remove the oil pan.
3. Remove the transmission case.

1. Wipe off the sealants on the oil pan and in the illustration below.
bolt. 5. Perform the installation in the reverse
2. Apply continuous sealants around the order of the removal.
inside of the oil pan bolt hole, with the
tip overlapped.Diameter 2.0-3.0
Front oil seal
mm
Oil pan
O-ring
Oil pump
Loctite 5699 Loctite 5699
Loctite 5699
Oil collector washer

Skirt rack
3. Install the oil pump and tighten the bolt

(Torque: 21-25 N·m) in 2 to 3 times in
the order given in the illustration below.
Oil collector
Then recheck the torque value.
Skirt rack removal instructions
Remove 2 bolts behind the cylinder block.
Loosen the skirt rack bolts in 2 to 3 times in

the order given in the illustration below.
Bolt
Remove the skirt rack with remover.
3-19
Loctite 5699
5. Install the oil pump.
Tightening torque: 21-25 N·m

Oil pump removal instructions
Skirt rack installation instructions
Remove the front oil seal with screwdriver
wrapped with clean rag. Apply the sealants to the skirt rack evenly as
Thickness: 2.0-3.0mm
Loctite 5699
Loctite 5699
Loctite 5699
Oil pump installation instructions Tighten the skirt rack bolts (Tightening torque:
21-25 N·m) in 2 to 3 times in the order given
1. Apply the clean oil on the outer oil seal. in the illustration below. Finally tighten the
bolt A: 9-11 N·m.
2. Install the oil seal manually.
3. Press in the oil seal evenly with the

special tool.
Hold-down
Device
SST
Front oil seal Oil pump

Oil collector installation instructions
1. Install the oil collector washer as shown

in the illustration.
4. Apply the sealants to the oil pump edge
evenly as shown in the illustration.
Thickness: 1.0-2.0 mm
3-20
Standard pump clearance: 0.113-0.186 mm

Tighten the bolt as shown in the illustration: Max. pump clearance: 0.226 mm
9-11 N·m.
Standard side clearance: 0.035-0.095 mm
Max. side clearance: 0.14 mm
62 Oil pump disassembly/assembly

1. Remove the oil pump.
2. Perform the disassembly in the order

3. Install in the reverse order of the disas-

sembly.
3UHVVXUHOLPLWHGYDOYHVSULQJLQVSHFWLRQ
Front cover
Apply pressure to the spring and inspect its
Oil pump cover plate height. Replace the spring if necessary.
Outer rotor
Pressure: 97.7-107.4 N·m
Inner rotor
Pressure limited valve element Standard height: 33.50 mm
Pressure limited valve spring
6 Oil pump inspection

1. Measure the clearance below. Replace
the rotor or pump if the value is not as
specified.
Standard teeth end clearance: 0.130-

0.206 mm
Max. teeth end clearance: 0.30 mm
3-21
Chapter Cooling System side flows in left and right line along the water cav-
ity of the cylinder block vertically, one line flows
vertically and the other flows up to the cylinder
Section 1 Gasoline Engine head. The coolant from exhaut side to cylinder
Cooling System Schematic head will cool down the 2 exhaust pipes. Then it
Drawing will be divided into two parts, one part cools down
the cylinder spark plug and the rest conflows to
Gasoline engine cooling system in the whole the vertical lines of spark plug both sides in next
vehicle pipe line system is as follow: cylinder. The coolant from intake side to cylinder
head will cool down the two intake pipes. Then it
The coolant pumped by the water pump flows will be divided into two parts, one part cools down
into the cylinder block from the front side and the cylinder spark plug and the rest conflows to
then into the cylinder head. And it flows out the vertical lines of spark plug both sides in next
from the cylinder head rear end. cylinder. The coolant to the cylinder head will flow
laterally at first. After conflowing into the central
The thermostat (opening temperature is 82°C) path from the intake and exhaust sides, the cool-
is mounted on the water pump inlet. The coolant ant will flow vertically.
refilled from the middle of the cylinder block front
From the engine bottom

Power steering reservoir
Fluid pressure power steering system
Add water Thermostat
Heater Thermolator cap

Warm air outlet water
Expansion
tank
Warm air
Cylinder head
Inlet water
Water
Cylinder pipe
A/C
A/C
Power steering pump Water Thermostat

pump Steel tube
Hose
Compressor
Water tank Vapor pressure relief hose
A/C radiator
Section 2 Thermostat 3. Drain the coolant.

21 Thermostat removal and installa-
in the table.
tion
1. Disconnect the battery negative cable. order of the removal.
2. Remove the breather tube.
3-22
Warm up and open the valve
Item Gasoline engine

Open temperature (°C) 80-84
Full open temperature (°C) 95
Full open stroke (mm) 8.5-9.5
Thermostat cover
Thermostat Section Water 3ump

Water tank sewer pipe Water pump removal and installation
Thermostat installation instructions
1. Make sure the locking notches on the

movable pin and gasket are aligned as
2. Align the locking notch on the gasket, Water pump

install the thermostat on its seat.
Power steering
pump regulator
2. Drain the gasoline engine coolant.

Thermostat installation precautions in the table above.
Align it with the new grommet on the thermo- 4. Perform the installation in the reverse
stat seat installing annular sealing convex. order of the removal. Tightening torque:
21-25 N·m.
Annular sealing convex
Water pump installation precautions
Install a new grommet, pay attention to keep

the grommet with annular sealing convex face
the water pump.
Annular sealing convex

Thermostat seat side
22 Thermostat inspection

Inspect the thermostat as follow. If it is not as
Water pump side
specified, replace the thermostat.
Close the valve under room tempera-

ture
3-23
Chapter Clutch
Section 1 Special Tool
No. Name Quantity

1 Gear ring support 1
2 Clutch location set tool 1
Section 2 3arts Location Index
Reservoir Reservoir hose
O-ring Replace
Lock pin
Clutch pedal
Adjustment
Replace
Pedal pin
Retaining
clamp Clutch master cylinder
Replace
Clutch hose clip
Clutch hose
Section Adjustment of Clutch til it cannot contact with the clutch pedal
(C).
3edal and Its Bolts
NOTICE
Remove the driver side floor mat
EHIRUHDGMXVWLQJWKHFOXWFKSHGDO
The clutch will make self-adjust-
PHQWWRFRPSHQVDWHWKHZRUQ
If there is no clearance between
the master pump piston and push
rod, the releasing bearing will
contact with diaphragm spring
WLJKWO\,QWKLVVLWXDWLRQWKHFOXWFK
1. Loosen the lock nut (D) of clutch push
will slip or some other problems
rod, then screw in and out the push rod
ZLOORFFXU
(E) to reach the specified pedal height
(F), stroke (G), free play (H) and sepa-
1. Loosen the lock nut (A) and unscrew
the clutch pedal adjustment bolt (B) un- ration height (I).
3-24
Clutch pedal stroke: 130-140 mm (B) and master cylinder installation nut
(C).
Clutch pedal free play: 10-18 mm
2. Apply grease on the pedal pin (D).
Clutch pedal height: 187 mm Then, install the pedal pin and new lock
Clutch pedal separation height: 91 pin (E) on the clutch release fork.
mm
Section 5 Clutch Master Cylin-
1. Tighten the clutch push rod lock nut (D). der Replacement
2. Release the clutch pedal. Screw in the
clutch pedal adjustment bolt (B) until it NOTICE
contacts with the clutch pedal (C). Never spill the brake fluid on the vehicle,
RWKHUZLVHLWZLOOGDPDJHWKHSDLQW,ILWKDS-
3. Then, screw in the clutch pedal adjust- SHQVSOHDVHULQVHZLWKZDWHULPPHGLDWHO\
ment bolt (B) for 3/4 to 1 circle.
4. Tighten the clutch pedal adjustment 1. Drain the brake fluid in the clutch mas-
bolt lock nut (A). ter cylinder reservoir with sucker.
2. Remove the air filter case.

Section Clutch 3edal Replace-
ment 3. Remove the battery tray.
1. Pry out the lock pin (A). Then, pull out the 4. Pry out the lock pin (A). Then, pull out
pedal pin (B) from clutch release fork. the pedal pin (B) from clutch release
fork. Remove the master cylinder lock
nut (C).
1. Remove the master cylinder installation

nut (C) and clutch pedal installation nut
(D).
2. Remove the clutch pedal (E).

5. Remove the reservoir installation bolt (A).
3. Install the clutch pedal (A).
1. Install the clutch pedal installation nut
3-25
6. Remove the clutch pipe bracket (B). 12. Pry off the clamping ring end (B) with a
screwdriver to avoid clamping ring (A)
7. Remove the clutch master cylinder (C). dropping down.
8. Disconnect the reservoir hose (A),
remove the retaining clamp (B) and
remove the clutch pipe (C) from clutch
master cylinder (D). Seal the reservoir
hose and clutch pipe ends with cloth for
service to avoid the brake overflow.
13. Bleed the clutch mater hydraulic sys-

tem.
NOTICE
The reservoir refilling is included in the
EOHHGLQJSURFHGXUH
Section 6 Clutch Release Cyl-

9. Remove the O-ring (E) and clutch mas- inder Replacement
ter cylinder seal packing (F) from the
Note:
clutch master cylinder.
Use mudguard cover to protect the
10. Install the clutch master cylinder in the SDLQWHGVXUIDFH
reverse order of the removal and pay 1HYHUVSODVKEUDNHÀXLGRQWRERG\
attention to the precautions below: otherwise the painted surface may
Apply brake system lubricant on the EH GDPDJHG ,I EUDNH IOXLG ZDV
clutch pipe. Then, install a new O-ring. splashed onto any painted surface,
clean and wash it off completely
Tighten the master cylinder lock nut to ZLWKZDWHU
24 N·m.
1 Remove assembling bolt and clutch re-
Install the air filter case (See section lease cylinder.
ċ in this chapter).
11. Make sure the hose clip (A) is locked

on the master cylinder (B) and reservoir
(C) as shown in the illustration. Clutch pipe line
Pipe union bolt
Gasket
Pipe
Clutch release cylinder
3-26
2. Disconnect the clutch pipe and plug the Section 7 Clutch Replacement
end of clutch pipe line with service cloth
to avoid brake fluid spilling out. 71 Clutch specification
3. Install the clutch release cylinder in the Basic specification
reverse order of the removal.
Item Specification
4. Pull the protecting cover (A) out, apply
grease for brake assembly to the cover Clutch operation type Hydraulic romote control
and the clutch release cylinder rod (B), Clutch plate type Dry and single plate
and reinstall the cover. Clutch plate size
Outer dia. × Inner dia. 215x154
Diameter
Clutch cover type Diaphragm spring
Item Specification (Limit)

Rivet depth in clutch
0.3
surface
Height differential of
0.5
diaphragm spring ends
Clearance between
Grease for brake assembly release cylinder inner
0.15
circle and piston exter-
nal circle
5. Apply grease to the contact surface be-
tween the clutch release cylinder rod (B) Item Specification
and the release fork, tighten the clutch
Clutch pipe union nut 15 (1.5)
release cylinder assembling bolt (torque
22 N·m), and drain the clutch hydraulic Clutch hydraulic line
18(1.9)
carrier
system.
22 (2.3)
Install a hose on the drain screw (A), pipe union
and hang another hose in the brake 11(1.1)
air drain plug
fluid tank. Clutch release cylinder
18 (1.9)
assembling bolt
Ensure there is enough brake fluid in
clutch master cylinder, and raise the Supporting pin 35 (3.6)
pressure to clutch pedal slowly until
no air bubble in the drain hose. 72 Clutch Removal
If necessary, use a wood stopper to 1. Install the special tool (as shown in the
limit the movement of release fork (B) illustration).
in order to drain the air.
2. Loosen the bolt crossly, until the spring
Tighten the drain screw to the torque pressure was released.
of 8N·m(0.8kgf·m, 5.8lbf·ft), but do not
over tighten it. 3. Remove the clutch cover assembly and
clutch driven plate assembly.
Refill brake fluid into the clutch master
cylinder after above operations.
Make sure to refill DOT3 or DOT4

brake fluid.
3-27
1.1 Inspect if the ends of diaphragm spring

are worn and differ in height. If there is
obvious worn or the height differential is
over the limit, replace the clutch cover.
Limit value: 0.6mm
7 Clutch installation

1. Use special tool (shown in the illustration)
to keep the positions of clutch linings.
1.2 Inspect if there is any worn, crack and

discoloring at the surface of pressure
plate.
1.3 Inspect if the rivets in the cover plate

are loose. If so, replace the clutch cov-
er.
1.4 Inspect the flatness of pressure plate

with a straightedge and feeler gauge. If
it is not as specified, replace the clutch
assembly.
2. Apply special tool (As per the following
figure). Max. clearance: 0.5mm.
3. tighten the bolts in cross sequence

evenly in several steps.
1.5 Rotate the flywheel to check diaphragm

axial circular run-out. If it is not as spec-
ified, replace the clutch pressure plate.
Axial circular run-out 0.6mm

7 Clutch cover assembly inspec-
tion
1. Clutch
(1) Clutch cover
3-28
specified, replace the clutch linings.
Axial circular run-out 0.7mm
(2) Clutch driven plate

(3) Clutch release bearing
NOTICE
'RQRWZDVKWKHFOXWFKGLVFZLWKJDVROLQH NOTICE
For the release bearing is filled with
2.1 Inspect if the plate surface is deterio- grease, never clean it with oil or similar
rated or attached oil for loose rivets, PDWHULDOV
poor single surface contact or burn. If
so, replace the clutch disc. 3.1 Check if the bearing is burnt, damaged
or abnormal noise and uneven rotation
2.2 Measure the rivet depth in clutch sur- occur.
face. If it is over the limit, replace the
clutch disc. 3.2 Check if the diaphragm spring contact
surface of release bearing is worn.
Limit value: 0.3mm
If the abnormal worn occurs, please re-
place.
(4) Release fork
If the abnormal worn occurs, please replace.
2. Clutch release cylinder
Release cylinder:
(1) Check if the release cylinder inner sur-

face is rusted or damaged.
(2) Measure the release cylinder inner

diameter for three locations (bottom,
middle and top) with cylinder gauge. If
the clearance with piston external circle
2.3 Inspect if the torsion spring is loose or
exceeds the limit value, replace the re-
broken. If so, replace the clutch disc.
lease cylinder assembly.
2.4 Install the clutch disc to the input shaft,
Limit value: 0.15 mm
and check the sliding status and loose-
ness in rotating direction. If it can not
Section Flywheel
slide smoothly, you should clean it or
replace it. If there is serious looseness, 1 Flywheel removal
replace clutch disc or input shaft or both.
1. Lock the flywheel with the special tool
2.5 Use dial indicator to check clutch lin-
(shown in the illustration).
ings axial circular run-out. If it is not as
3-29
2. Remove the installation bolt evenly in

the cross sequence. Flywheel
Pilot bearing
3. Remove the flywheel.
0~0.4mm
2 Flywheel inspection

1. Install dial gauge on the cylinder body.
2. Measure the flywheel axial circular run-

out. If it is not as specified, please re-
Flywheel installation instructions place the flywheel.
1. Install the flywheel on the crankshaft. Axial circular run-out: 0.2 mm
2. Clean the thread and hole and apply

the sealant on its thread before install-
ing the bolt.
3. Pre-tighten the flywheel lock bolt manu-

ally.
4. Install the special tool on the flywheel

(shown in the illustration).
5. Tighten the lock bolt gradually in the

cross sequence. Torque: 86-103 N·m.
3LORWEHDULQJLQVWDOODWLRQLQVWUXFWLRQV
NOTICE
Install the pilot bearing according to the
LQVWUXFWLRQVEHORZ
Installation depth of pilot bearing: 0-0.4 mm
3-30
Foreword
Welcome to use BYD488QA EFI engine (hereinafter referred to as BYD488QA engine) manu-
factured by BYD Auto Industry Company Limited. Before operating, please read this Operation
Manual carefully.
BYD488QA engine adopts electronic control fuel injection system developed by our company,
is provided with advanced self-diagnosis function. Key components are from world-famous auto
electronic companies. It has characteristics of high power, low fuel consumption, low noise, low
pollution and compact structure. Under various working conditions, BYD488QA engine can work
at the optimum state. It can ensure reliable safety, comfortable driving, optimum economy and
perfect environment protection performance.
This manual describes main performance, technical parameters, operation and maintenance and
maintenance methods of BYD488QA engine. Before you operate BYD488QA engine, please read
this manual carefully to ensure power system of your vehicle is in a good state to play a more im-
portant role and produce higher economic benefit. When you read this manual, if you find any
difference from the same maintenance method of the engine in other documents or mutual
contradiction, please follow the maintenance method in this manual
In order to improve product performance and quality, serve the customers better, our company
hopes you will inform us of problems that you find during the course of using electronic injection
engine and suggestions at any time.
It is your best choice to buy passenger vehicles with BYD electronic ejection engines.
Symbol description
“ ƾƾƾ ” is involved in personal safety of driver and passenger. Please pay special attention and
follow it;
“ ƾƾ ” is involved in safety and maintenance of the engine. Please follow it;
“ ƾ ” maintenance is simple and easy.
1
IV BYD4A Engine Maintenance Instruction
Contents
Chapter 1 3erformance, main technical parameters and structure of the engine -1
Section 1 Performance and main technical parameters of the engine.................................... 4-1
Section 2 External characteristic curve for BYD488QA engine............................................... 4-2
Chapter 2 Engine operation -
Section 1 Notes for engine operation ......................................................................................4-3
Section 2 New engine running-in ............................................................................................4-5
Chapter Engine maintenance -6
Section 1 Engine lubrication system maintenance..................................................................4-6
Section 2 engine cooling system maintenance .......................................................................4-7
Section 3 V-ribbed belt maintenance ......................................................................................4-9
Section 4 Ignition system maintenance...................................................................................4-9
Section 5 Check and adjustment for valve timing mechanism ................................................ 4-9
Section 6 Crankcase forced ventilation valve (PCV) maintenance ....................................... 4-10
Section 7 Electrical system check and maintenance ............................................................4-10
Section 8 Air filter maintenance............................................................................................. 4-11
Section 9 Gasoline filter maintenance................................................................................... 4-11
Section 10 Fuel vapour collecting system maintenance ......................................................... 4-11
Section 11 Three-way catalytic converter maintenance..........................................................4-12
Chapter Regular check of the engine -1
Section 1 Engine maintenance period and items..................................................................4-13
Section 2 Main tightening torque of the engine.....................................................................4-14
Chapter 5 Main fault and troubleshooting method of the engine -15
Section 1 Notes for engine operation and maintenance ....................................................... 4-15
Section 2 Main fault and troubleshooting method of the engine ........................................... 4-16
Section 3 Abnormal emission and troubleshooting ...............................................................4-23
Chapter 6 Engine sealing and unsealing-2
Section 1 Engine sealing and storage...................................................................................4-24
Section 2 Unseal the engine .................................................................................................4-24
4-I
Chapter 1 3erformance, main technical parameters and struc-

ture of the engine
Section 1 3erformance and main technical parameters of the engine

Item
3arameter BYD4A
Model
In-line four cylinder, forced cycle water cooling, double overhead camshafts
Type
and four strokes
Maximum torque/speed 229N.M˄4000r/min˅
The lowest fuel consumption 250+10 g/kW·h
Cylinder bore × stroke 88.5 mm × 96 mm
Gasoline engine displacement 2.362 L
Compression ratio 9.8:1
Variable valve timing mechanism (VVT), double overhead camshafts
Valve mechanism
(DOHC), chain drive, 16 valves
Fuel types 92# lead-free gasoline or above (GB 17930-1999)
Stable idle speed ˄700±50˅r/min
Compression pressure of cylinder 0.98MPa ~ 1.46 MPa
Fuel supply type Electronic control multipoint sequence fuel injection
Ignition sequence 1—3—4—2
Lubrication type Pressure and splashing combined type
Exhaust emission system Three-way catalytic converter
Oil Pressure: 170kPa ~ 550kPa ˄3000 r/min±50 r/min˅˄TBD˅
Engine quality 131 kg (transmission excluded)
Outline dimension (L × W × H) 600 mm × 640mm × 680 mm (excluding transmission)
Working conditions and emission State IV
4-1
Section 2 External characteristic curve for BYD4A engine
4-2
Chapter 2 Engine operation
Section 1 Notes for engine operation

1 Operation Manual
Before operating, please read Operation Manual, operate and maintain the machine in strict ac-
cordance with regulations in this manual.
2 Coolant
Check engine coolant. If necessary, please fill coolant according to Section 2 in Chapter 3.
ƾƾ
When the engine is running, cooling system shall have enough coolant to ensure the
HQJLQHZRUNVQRUPDOO\2WKHUZLVHWKHHQJLQHZLOOEHFRPH“boiling”,IWKHHQJLQHLVRYHU-
KHDWHGVHUYLFHOLIHRIWKHHQJLQHZLOOEHDIIHFWHG6HULRXVO\VFXI¿QJRIF\OLQGHUERUHPD\
RFFXU
3 Engine oil
Check engine oil level. If engine oil is not enough, please refill it immediately. Please check and
refill engine oil according to Section 1 in Chapter 3.
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IHFWVVHUYLFHOLIHRIWKHHQJLQH
4 Fuel
It is suggested to use 92# lead-free gasoline and above.
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injection system, three-way catalytic converter and oxygen sensor of the engine will be
damaged heavily to degrade environmental protection performance and dynamic perfor-
PDQFH
5 Start the engine
When starting the engine, turn ignition switch key to “Start” position, and start the engine by the
starter. Once the engine starts, release the key to shut off starter power.
ƾƾ
Because the engine management system can provide appropriate gas mixture and ignition
advance angle, it is not necessary to step on accelerator pedal before starting under any
FOLPDWH
ƾƾ
If the engine cannot start several times, spark plug has short circuit because the engine
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EORZRIIRYHUÀRZLQJRLOZLWKLQV1RZUHOHDVHDFFHOHUDWRUSHGDODQGUHVWDUWWKHHQJLQH
4-3
If a vehicle starts initially (new engine or engine with fuel supply system repaired), starting time may be
longer so as to fill fuel supply system pipe and build up normal working pressure, supply gasoline and
appropriate fuel gas mixture to ensure the engine works normally.
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SOHDVHJRWRVSHFLDOVHUYLFHVWDWLRQRIRXUFRPSDQ\IRUUHSDLULQJ&KHFNIXHOV\VWHPDQG
HOHFWULFDOV\VWHP
6 Idle speed
After the engine starts, it shall run idly for 3~5 minutes without load to warm it up.
ƾƾ
The idle speed of our engine is 700 r/min±UPLQ,GOHPHFKDQLVPRIWKHHQJLQHKDVEHHQ

VHWEHIRUHGHOLYHU\7KHFXVWRPHUVKDOOQRWPRGLI\LWZLWKRXWSHUPLVVLRQ,IDGMXVWPHQWLV
UHTXLUHGSOHDVHDVNVSHFL¿HGVHUYLFHVWDWLRQIRUKHOS
When measuring the emission, the engine shall be in heating state, i.e., the coolant shall be
85°C±5°C.
Optimum temperature of three-way catalytic converter: 375°C~850°C, tolerable temperature in

a short time is 970°C. Therefore, when measuring the emission, the engine shall be in heating
state. Exhaust gas temperature shall not be less than 375°C.
7 Driving
During the course of driving, keep the coolant temperature between 85°C±5°C. At medium speed,
engine oil pressure shall not be less than 300kPa.
8 Stop
After the engine runs, especially after it runs at high speed with high load, it cannot stop immedi-
ately. It shall run idly for 3~5 and then stop.
9. Warming up in winter
In winter, because the temperature is very low, engine oil viscosity increases. Now, the engine
lubrication is worse than that in summer. Therefore, after the engine starts, the vehicle cannot
drive immediately and the engine cannot run at high speed with high load. It shall run idly for 10
minutes for warming up to increase engine oil temperature and coolant temperature. The engine
is enough lubricated and then the vehicle drives.
ƾƾ
In winter, if the vehicle drives when the engine is not lubricated enough, moving parts may
EHH[FHVVLYHO\ZRUQWRVKRUWHQVHUYLFHOLIHRIWKHHQJLQH
10 On rainy day or in the water
On a rainy day, if the vehicle drives in water or wades, air filter shall be sealed well. Otherwise,
rain water may go into the engine cylinder, which damages moving parts, such as connecting rod.
ƾƾ
4-4
After water goes into one cylinder, connection rod may be applied by dozens of times of
normal working pressure due to inertial effect of the vehicle, which bends or breaks up the
FRQQHFWLQJURG
11. Fuel supply system
ƾƾ
In order to prevent gasoline from leaking, it is necessary to check gasoline pipe, clean oil
FRQWDPLQDWLRQLIUXEEHULVDJLQJMRLQWLVEURNHQGDPDJHGRUORRVHUHSODFHLWLPPHGLDWHO\
When checking fuel pipe, it is forbidden to start the engine after removing fuel inlet/return
KRVHV2WKHUZLVHJDVROLQHPD\OHDNZKLFKFDXVHV¿UH
Section 2 New engine running-in

Service life of the engine is greatly related to the operation at initial stage. New engine shall run in
according to running-in specifications.
The engine on the vehicle shall run in according to Operator Manual of the vehicle. Please check
and maintain the engine according to the following requirements during the course of running-in:
1 Check
Check if engine oil, coolant, gasoline and battery electrolyte is sufficient. If it is insufficient, refill it
in time.
2 Road
It would be best to drive on cement or asphalt roads. Try to avoid driving on a muddy or sandy
road.
3 Maintenance
After running-in, the engine shall be maintained as follows.

Maintenance items after a new engine runs in
S/N Item Working content

1 V-ribbed belt According to Section 3 in Chapter 3
Cylinder head bolt and intake/exhaust manifold bolt
2 According to Section 2 in Chapter 4
Nuts and connecting bolts for each bracket
3 Engine oil filter Replace
4 Engine oil Replace
5 Spark plug clearance 1.0 ~ 1.1mm
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4-5
Chapter Engine maintenance
Section 1 Engine lubrication system maintenance

1. Engine lubrication oil
SJ grade and above 10W-30 (in spring, summer and autumn in the north and in each season in
the south)
SJ grade and above 5W-30 (in winter in the north).
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2. Engine oil level measurement
Measure engine oil on oil pan with an oil level gauge. After the engine runs for 3 minutes, mea-
sure it and take out the oil level gauge, wipe off engine oil on it with a cleaning cloth, then insert it
on oil pan to measure engine oil level. Engine oil level shall be between two points of the oil level
gauge. If oil level is close or lower than lower limit, please refill engine oil to upper limit. Before
driving and every 300km~500 km, check engine oil level.
3. Fill and replace engine oil
Replace engine oil every 8000km on asphalt or cement road; it is necessary to check frequently
on extremely sandy soil roads. Replace it more frequently. But, replace it every 5000km.
When replacing engine oil, warm up the engine for 10 minutes, open filler cap after stopping, un-
screw drain plug on the bottom of oil pan to discharge oil and then tighten drain plug. Fill new en-
gine oil 5.0L through oil filler cap and tighten oil filler cap. (See figure 4-1)
Start the engine and run for 5 minutes. Check if drain plug leaks. Then shut down and wait for 5
minutes, check oil level. If oil is insufficient, refill oil to upper limit of oil level gauge.
Drain plug
Filler-cap flap
Figure 4-1
ƾƾƾ
4-6
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4. Lubrication system washing
If there are excessive impurities on oil pan, clean engine lubrication system with light spindle oil.
When washing inside the engine, fill 2.5L light spindle oil into the engine, start the engine by
starter to run idly 2~3 times. Run idly for one minute every time. Then discharge light spindle oil
immediately. Fill engine oil into the engine according to the specification.
After replacing engine oil every time, run the engine idly without load for 3~5 minutes to ensure
lubrication system and lubricating positions are lubricated sufficiently.
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areas and standards to avoid oil from chemical reaction, which affects normal work of the
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5. Engine oil filter replacement
Every 8000km, replace engine oil filter once. When installing, tightening torque is 13 N·m.
6. Engine oil pressure indication system check
Normally, when power switch (key) is turned to “ON” position, engine oil pressure indicator lamp
is lit, which means no engine oil pressure; turn the switch to “START” position, and then the en-
gine goes into idling state. Now, engine oil pressure indicator lamp goes out automatically, which
means engine oil pressure is normal. If engine oil pressure indicator lamp does not go out, it
means engine oil pressure in engine lubrication system is abnormal. It is necessary to stop the
engine to check if engine oil is sufficient.
Section 2 engine cooling system maintenance

Cooling system is one of essential conditions that ensure the engine works normally. Therefore,
the engine shall have enough coolant. Every time, check coolant before driving. If it is insufficient,
refill it immediately.
ƾƾ
When the engine is running, cooling system shall have enough coolant to ensure the en-
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1 Coolant
Engine coolant adopts glycol coolant. Freezing point is 5°C lower than the lowest temperature in
application area. Different brands of coolant cannot be mixed. It is forbidden to use fake and poor
quality coolant. River water or well water is forbidden.
ƾƾ
After water is frozen, the volume will be expanded to burst sealed radiator, water pump,
4-7
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2 Fill coolant
Fill coolant according to the following procedure:
(1) Unscrew radiator cover and fill coolant, keep water level of the pot at “FULL” scale. Do not
exceed “FULL” scale.
(2) Place the radiator cover and tighten it.
(3) Start the engine and run idly for 3~5 minutes; if coolant level reduces, open water pot cover
and fill coolant to “FULL” position.
(4) Place water pot cover and tighten it. Then the engine can work normally.
ƾƾƾ
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3 Fill the coolant
After a long time, if the coolant level in water pot is lower than “LOW”, fill coolant into water pot to
“FULL” position.
If a lot of coolant reduces in a short time, cooling system may leak. Please check it carefully.
After a long time, if it is necessary to replace the coolant due to deterioration or repair, replace it
according to the following procedures.
(1) Unscrew radiator cover, open water drain valve on the bottom of radiator to discharge the
coolant.
(2) Remove water pot and empty the coolant.
(3) Reinstall water pot and water drain valve of the radiator in original positions. Fill coolant ac-
cording to Item 2 of section 2 in Chapter 3.
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4. Thermosistor assembly shall be reinstalled.
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IHFWVLWVVHUYLFHOLIH
4-8
Section V-ribbed belt maintenance

Two V-ribbed belts are used to drive generator and water pump, power-assisted steering pump
and A/C compressor, respectively. Check and adjust two V-ribbed belts frequently.
ƾƾ
If V-ribbed belt tension is not enough or damaged, the engine will be overheated, generat-
ing capacity will be reduced; steering has no power assistance and A/C refrigeration is in-
VXI¿FLHQW
1 Adjustment method
Stop the engine, tighten adjusting bolt on position adjusting block of the generator and adjusting
bolt on power-assisted steering pump.
2 Measure tension
Apply 98N pressure on V-ribbed belt. The sagging shall be mm~9mm.
3 Appearance
Check if V-ribbed is cracking and worn, if fibre cloth is flaking. Replace it if necessary.
Section Ignition system maintenance

1. spark plug maintenance
Every 30000km, replace spark plug. If necessary, replace it immediately.
The surfaces of two electrodes for spark plug shall be clean and smooth. Remove carbon deposi-
tion on two electrodes with fine sand paper. Spark plug clearance shall be 1.0mm ~1.1mm. The
clearance shall be smooth on electrode surface.
2. Ignition system maintenance
Engine management system adopts an advanvced ignition system. During the course of normal
operation, only replace spark plug and check high voltage damper. No other maintenance is re-
quired.
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When the engine is running, do not dismantle spark plug high voltage line to make spark-
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Section 5 Check and adjustment for valve timing mechanism

Valve timing mechanism shall be checked and maintained frequently. Once timing chain is broken
or slipping, the valve, piston and cam shaft may be damaged.
1 Timing gear installation position check and adjustment
Remove ignition coil, PCV vent pipe assembly and cylinder head assembly.
Adjust cylinder #1 to compression TDC: rotate crankshaft vibration damping pulley until white
mark groove on the pulley aligns with timing mark “0” on timing cover. Check if intake/exhaust
4-9
cam shaft timing sprocket wheel aligns with timing mark on corresponding cam bearing cap. As
shown in Fig.4-2, if they do not align, rotate crankshaft by one turn (360°), and align timing marks
according to the procedure above.
Timing marks
Timing marks
Slot
Figure 4-2
2 Valve clearance check and adjustment
Intake valve clearance is 0.19mm~0.29mm in cold state; exhaust valve clearance is

0.38mm~0.48mm in cold state. When measuring the clearance, make the tappet surface close to
base circle of the cam.
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oxygen sensor and three-way catalytic converter will be shortened greatly due to valve
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Section 6 Crankcase forced ventilation valve (3CV) maintenance

PCV consists of valve body, valve, valve bonnet and spring, which are not disassembled. Main
function is to introduce gas in crankcase into intake manifold through PCV. Every 50000km, dis-
mantle it, and then a maintainer washes and checks it. If the valve is stuck or not ventilated, it
shall be replaced with a new valve.
Section 7 Electrical system check and maintenance

Electrical system of electronic injection engine centers on electronic controller unit (ECU). Sen-
sors installed on different positions are used to measure various working parameters of the en-
gine. It control fuel injection quantity accurately and ignition advance angle according to control
program set in electronic controller unit of the engine to ensure the engine works in the optimum
state under various working conditions.
4-10
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Section Air filter maintenance

Air filter is used to filter air going into the cylinder. If air filter function is not good, it will speed up
the engine wear and shorten its service life. If air filter is too dirty, it will affect engine intake and
lead to insufficient air intake and low power.
Air filter element shall be dismantled for cleaning frequently. On asphalt road, clean it once every
10000km, replace it once every 40000km; on sandy soil road, clean it once every 2500km, re-
place it once every 40000km; it is required to replace it more frequently in dusty environment.
Section 9 Gasoline filter maintenance

Normally, replace gasoline filter once every 8000km. If fuel is too dirty, replace gasoline filter im-
mediately to avoid fuel supply or block fuel injector.
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Section 10 Fuel vapour collecting system maintenance

Fuel vapour collecting system is used to collect fuel vapour discharged when fuel tank ventilates
to avoid it from going into atmosphere and protect the environment. Please check if fuel vapour
collecting system pipe and air hole are smooth periodically. No leakage is allowed to ensure nor-
mal working of the system.
ƾƾƾ
Before maintaining fuel system, the following regulations shall be observed:
1. Dismantle negative cable of the battery.
2. Smoking is prohibited. “No Smoking” nameplate is placed near the operation area.
3. CO2 fire extinguisher shall be accessible.
4. Operation shall be in a place with good ventilation and keep away from open flame.
5. In order to release fuel vapour pressure in fuel tank, remove fuel filler cap and then install it.
6. Even if the engine stops, fuel pipe is still in high pressure state. If fuel pipe is released or
dismantled immediately, fuel injection may occur. Dangerous ʽ Therefore, before releasing
or dismantling fuel pipe, first confirm if the pressure is released.
7. When dismantling fuel pipe, a small amount of fuel overflows. Therefore, place empty fuel
container under gasoline filter or wrap gasoline filter with to make fuel return to the empty
container or be absorbed by waste cloth. Place waste cloth with fuel into specified contain-
er.
8. Connect and tighten fuel pipe correctly.
9. If fuel pipe is cracked, damaged or bent excessively, please replace it immediately.
4-11
10. Fuel pipe clamp is disposable. It is forbidden to be reused.
11. Take out fuel pump from fuel tank and expose it in the air. Do not energize fuel pump to
avoid spark and fire.
Section 11 Three-way catalytic converter maintenance

Exhaust system of the engine is provided with three-way catalytic converter. The function is to
post-process engine exhaust. Three-way catalytic converter can catalyze harmful gas in the
exhaust. Good engine management system can keep the engine running normally and endure
three-way catalytic converter works efficiently, and prevent three-way catalytic converter from
overheating to prolong service life of three-way catalytic converter.
ƾƾƾ
Three-way catalytic converter is easily damaged due to overheating when the engine
ZRUNV,QRUGHUWRSURWHFWWKUHHZD\FDWDO\WLFFRQYHUWHUWKHGULYHUVKDOOREVHUYHWKHIROORZ-
ing items:
1 Only use 92# lead-free gasoline or above
2 Good resistance to pressure of fuel supply system (not less than 0M3a) and leak-
proof characteristic
Avoid misfiring in the cylinder
3revent engine oil from burning
5 When fuel is insufficient, do not drive a vehicle Otherwise, electric fuel pump may be
damaged after the fuel is used up
6 3revent exhaust system from leaking, especially, ensure the connection between ex-
haust manifold before three-way catalytic converter and the muffler is airproof
7 Do not push or tow the vehicle to start the engine If the battery power is low, please
use auxiliary battery to start the engine
When the engine is running, do not dismantle any spark plug or high voltage damper
to make system ignition function diagnosis
9 When the engine runs idly unstably or cannot start in a long time, do not operate the
engine forcedly
10 If the engine performance reduces greatly or the engine runs abnormally, for ex-
ample, fuel supply system or ignition system works abnormally, please stop the en-
gine immediately If it is impossible to stop the engine immediately, slowdown and go
to professional maintenance department or specified service station for check and
maintenance
4-12
Chapter Regular check of the engine
Section 1 Engine maintenance period and items

Determine it km × 1000 2 10 20 30 40 50 60 70 80
according to
S/N travel distance or
Month 1 6 12 18 24 30 36 42 48
months, which-
ever comes first.
V-ribbed belt
1ƹ J.T J.T.G G J.T.G G
(Tension and wear)
Timing chain
2ƹ Every 100000km, replace it
(Worn or damaged)
3ƹ Intake/exhaust valve clearance J.T J.T J.T J.T J.T
Engine bolt and tightening torque
4ƹ for fastening intake/exhaust mani- N N N N N
fold nut
5 Engine oil filter G Every 8000km, replace it
6 Engine oil G Every 8000km, replace it
7 Engine coolant G G
8 Engine pipe and joint (leakage) J.T.G J.T.G J.T.G
9 Gasoline filter Every 8000km, replace it
10 ƹ Idle speed J.T J.T J.T J.T J.T
Transmission lubricating oil
11 ƹ G J.T.G J.T.G J.T.G G J.T.G J.T.G J.T.G G
(Oil level and leakage)
Crankcase vent valve
12 ƹ Dismantle to check and wash it every 50000km. If necessary, replace it.
PCV valve
Fuel evaporation control
14 ƹ J.T.G J.T.G J.T.G J.T.G
System hose and connection
Cooling system hose and joint
15 J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G
(leakage and wear)
16 Emission and purification plant J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G J.T.G
High voltage damper (deterio-
17 J.G J.G J.G J.G J.G J.G J.G J.G J.G
rated or damaged)
18 Spark plug J.T.G Every 30000km, replace it
19 Various sensors J. G J.G J.G J. G J.G J. G J. G J. G
20 Fuel injector J.T.G J.T.G J.T.G J.T.G
Asphalt road Wash it every 10000km; replace it every 40000km
Air
21 Wash it every 2500km; replace it every 40000km. Replace it more fre-
filter Sandy soil road
quently in dusty environment
Note: (1) symbol meanings in the table
J: check R: lubrication T: adjustment G: replacement N: tightened according to specified

torque J.T: check and adjust J.T.G: check and adjust, replace it if necessary
(2) Shorten replacement period of engine oil filter according to dirt degree of the engine.
ƾƾ
It is suggested that maintenance items with ƹ shall be made by special service station of
RXUFRPSDQ\
4-13
Section 2 Main tightening torque of the engine

S/N 3art name Tightening torque (Nm)
1st time: 30, 2nd time: 70
1 Cylinder head bolt
3rd time: turn by 90°
2 Spark plug 25
3 Intake manifold bolt 30
4 Exhaust manifold bolt 37
5 Camshaft sprocket bolt subassembly 54
6 Crankshaft pulley bolt assembly 170
7 Connecting rod bolt 1st time: 25, 2nd time: turn by 90°
1st time: 20 2nd time: 40
8 Main bearing bolt
3rd time: turn by 90°
9 Flywheel bolt 98
10 Drain plug 40
M6 × 30 enlarging series: 11
M6 × 60 enlarging series: 14
11 Cylinder head cover bolt
M6 nut: 11
Cylinder head cover bolt: 9
12 Oil pan bolt 9
Bolt 60
13 Tension mechanism assembly bolt and nut
Nut: 30
M6 nut: 11
M6 × 30˖9
14 Timing cover bolt and nut
M8 × 30˖25
M10 × 1.25 × 40˖55
15 Throttle valve bolt 9
17 Fixing nut of knock sensor 20
18 Engine oil filter 13
19 Socket head cap screw for clutch 40
20 Engine oil pressure switch 15
21 Coolant Temp Sensor 15
4-14
Chapter 5 Main fault and troubleshooting method of the engine

Section 1 Notes for engine operation and maintenance
1. Only 12V battery can be used. AC power supply is forbidden.
2. Positive and negative electrodes of the battery shall not be reversed to avoid electronic ele-
ments.
3. When the engine is running, do not dismantle the battery, connect wire and a connector.
4. Operating ambient temperature of ECU shall not exceed 80°C.
5. Before welding on the vehicle, the battery shall be taken away from the body.
6. Take out electric fuel pump from fuel tank and expose it in the air. Do not energize electric
fuel pump to avoid spark and fire.
7. Positive and negative electrodes of electric fuel pump shall not be reversed.
8. Equipment that may generate radio interference, like radio antenna shall not be installed
near ECU to avoid mutual interference.
9. On a rainy day, when maintaining and washing the engine, do not let water go into the en-
gine or splash water onto electronic circuit.
10. Prohibit the use of detection method that gas mixture in the cylinder does not burn and then
go into exhaust pipe.
11. If fuel pressure is high, first release the pressure before maintaining the pipe. The method:
dismantle fuel pump fuse, start the engine, run it idly unit it flames out.
12. Before removing any part, first switch off ignition switch and remove negative cable of
the battery.
13. Because three-way catalytic converter will be installed, lead-free gasoline shall be used. If
lead gasoline or low-lead gasoline is used, three-way catalytic converter will be damaged
and purifying result of purification system will be reduced.
14. Do not pierce wire shield to detect electric signal.
15. Fuel pipe clamp is disposable. It is forbidden to reuse to avoid fuel leakage.
16. Because high voltage ignition coil is used, do not contact it by hand when the engine works.
17. Idling adjustment of the engine is completely made by electronic fuel injection system. There is
no need to make mechanical maintenance for idling adjustment and idling system.
18. After replacing ECU or idle speed regulator, before first start, turn ignition switch to ON for
20s and then start it to make the system or idle speed regulator complete self-adaption.
19. Electronic control system can provide appropriate air-fuel ratio to the engine in any case to
make the engine work normally. Therefore, when starting the engine, do not operate any
mechanism of the engine (including accelerator).
20. The system has fault safety function. Note: although the engine system has fault safety
function, it is not appropriate to run for a long time. Therefore, when MIL is lit, it is required
to make troubleshooting immediately to avoid serious damage of the engine.
4-15
Section 2 Main fault and troubleshooting method of the engine

3roblems Fault cause Troubleshooting
1. The starter does not run
1.1 Fuse blown out Replace
1.2 Battery is dead Charge
1.3 Battery terminal connection loose Tighten
The engine does
not work (difficult 1.4 Battery wire connection loose Tighten
to start)
1.5 Start switch contact is not closed or switch circuit is open Repair or replace
1.6 Starter electromagnetic switch worn Replace
1.7 Starter brush worn Replace
1.8 Starter magnetic field or armature circuit off Replace or repair
2. No spark
2.1 Fuse blown or loose Tighten or replace
Adjust clearance or re-
2.2 spark plug fault
place
2.3 High voltage line is short Repair or replace
2.4 Ignition coil damaged Replace
2.6 ECU damaged or open circuit Repair or replace
3. Intake and oil supply system fault
3.1 idle speed regulator damaged Replace
3.2 Water temperature sensor Replace
3.3 Fuel pump relay or fuse Check or replace
3.4 Fuel in fuel tank is insufficient Refill
The engine does 3.5 Electric fuel pump does not work Replace
not work (difficult 3.6 Fuel filter clogged Clean or replace it
to start)
3.7 Air in fuel pipe Repeated starting
3.8 Fuel nozzle blocked Replace or wash
3.9 Insufficient fuel pressure Check and adjust
3.10 Fuel hose or fuel pipe blockage Clean or replace it
3.11 Inlet/return oil reversed Check and adjust
3.12 ECU interface loose Reinstall
3.13 Intake manifold loose Tighten
4. Internal state of the engine is abnormal
4.1 Cylinder head gasket damaged Replace
4.2 Valve clearance incorrect Adjust it
4.3 Valve spring weakened or damaged Replace
4.4 Timing chain damaged Replace
4.5 Valve gaping Repair or replace
4-16

4.6 Valve burnt Replace
Adjust or replace valve
The engine does 4.7 Valve stem stuck
and guide pipe
not work (difficult
Replace it, if necessary,
to start) 4.8 Piston, piston ring or cylinder worn
bore the cylinder
4.9 Fuel brand inconsistence Replace
1. Compression pressure insufficient
1.2 Valve gaping Repair
1.3 Valve stem stuck Replace
P o w e r i n s u ff i - 1.4 Valve spring weakened or damaged Replace
cient
1.5 Piston ring leakage Replace
Replace it, if necessary,
1.6 Piston, piston ring or cylinder worn
bore the cylinder
1.7 Cylinder head and lining leakage Replace
1.8 Intake pressure temperature sensor Replace
Adjust clearance or re-
place
Reconnect, replace it if
2.3 High voltage line connection leaks, is loose or broken.
necessary.
2.4 Speed sensor fault Repair or replace it
3.1 Fuel nozzle blocked Replace or wash
3.2 electric fuel pump fault Repair or replace
3.3 Gasoline filter clogged Replace
3.4 Fuel pressure regulator is abnormal Check and replace
P o w e r i n s u ff i -
cient 3.5 Fuel tank outlet pipe blockage Repair or replace
3.6 Fuel tank inlet pipe blockage Check and tighten
3.7 Fuel system joint loose Check and tighten
3.8 Electronic throttle valve fault Replace
4. Intake system abnormal
4.1 Air filter dirty or clogged Clean or replace it
4.2 idle speed regulator damaged Repair, adjust or replace
4.3 Engine has a tendency of overheating See “Overheating”
5. Others
5.1 Brake seizing Repair or replace
5.2 Clutch slipping Adjust or replace it
4-17

1. Electric system fault
Replace or adjust clear-
1.1 Spark plug damaged or spark plug clearance imbalance
ance
1.2 Ignition coil is degraded or cracked which leads to leak-
Replace
age
1.3 High voltage line leakage Replace
1.5 Throttle body fault Repair or replace it
1.7 Throttle position sensor damaged Replace
Engine slipping
(when stepping 2. Fuel system fault
on accelerator 2.1 Fuel pump blocked Clean or replace it
pedal, no re-
sponse occurs in 2.2 Electric fuel pump does not work Replace
a short time) 2.3 Fuel pressure regulator inoperative Replace
3. Engine fault
3.1 Cylinder head gasket damaged Replace
3.2 Piston and piston ring worn seriously Replace
3.3 Cylinder hole worn seriously Bore a hole if necessary
3.4 Water temperature sensor damaged Replace
3.5 Water pump performance poor Replace
3.6 Radiator leakage Repair or replace
3.7 Valve burnt Replace
4. Lubrication system fault
4.1 Engine oil filter clogged Replace
4.2 Engine oil screen clogged Clean it
Engine slipping 4.3 Engine oil pump performance degraded Replace
(when stepping
on accelerator 4.4 Oil pan or engine oil pump leakage Repair
pedal, no re- 4.5 Engine oil brand inconsistence Replace
sponse occurs in
a short time) 4.6 Engine oil on oil pan is insufficient Refill
5. Others
4-18

1. Crankshaft noise
1.1 Main shaft bushing worn or clearance enlarged Replace
1.2 Connecting rod bearing shell worn Replace
1.3 Connecting rod deformed Repair or replace
Grind, repair or replace
1.4 Crankshaft main journal worn
Engine noise crankshaft
(Note: Before Grind, repair or replace
testing mechani- 1.5 Connecting rod shaft diameter worn
crankshaft
cal noise, it is
2. Piston, piston ring, piston pin or cylinder abnormal
necessary to
check if ignition 2.1 Bore hole is worn abnormally Bore hole
timing is correct;
2.2 Piston, piston ring and piston pin are worn Replace
if specified spark
plug is used; if 2.3 Piston ring stuck Replace
specified fuel is
used) 2.4 Piston ring worn Replace
3. Others
Adjust it according to the
3.1 Crankshaft thrust clearance too large
specification
Adjust it according to the
3.2 Valve clearance too large
specification
3.3 Engine oil insufficient Refill
1.1 High voltage line connection leaks or is loose Repair or replace
1.2 spark plug fault Wash, adjust or replace
2.2 Fuel tank fuel pipe leakage Repair or replace
2.3 Insufficient fuel pressure Repair or replace
Fuel consump- 2.4 Fuel nozzle blocked Clean or replace it
tion high
2.5 Air filter clogged Clean or replace it
2.6 Intake pressure temperature sensor Replace
3. Engine fault
See the above-mentioned
3.1. Compression pressure insufficient
content
3.2 Valve gaping Repair or replace
3.4 High idle speed Check and repair
4. Others
Fuel consump-
tion high
4.3 Tyre pressure insufficient Adjust it
4.4 ECU damaged Replace
4-19

1 Engine oil leakage
1.1 Drain plug loose Tighten
1.2 Fixed bolt of oil pan is loose Tighten
1.3 Oil pan sealing poor Reapply glue and install
1.4 Oil seal leakage Replace
1.5 Cylinder head and lining leakage Replace
1.6 Engine oil filter is not tightened Tighten
1.7 Oil pressure switch loose Tighten
Engine oil con-
2. Engine oil jumping
sumption high
Remove carbon deposi-
2.1 Piston ring stuck
tion or replace piston ring
Replace piston and piston
2.2 Piston ring and ring slot worn
ring
2.3 Piston ring opening position incorrect Adjust opening position
Replace the piston, if nec-
2.4 Piston or cylinder worn
essary, bore the cylinder
3. Valve stem leakage
3.1 Valve oil seal worn Replace
3.2 Valve or valve guide pipe worn seriously Replace
1.1 Engine oil filter clogged Replace
Check it; if necessary, re-
1.2 Fuel pipe twisted, leaking or damaged
place it.
Check it; if necessary, re-
1.3 Electric oil pump fault
place it.
Surging (when Check it; if necessary, re-
1.4 Intake manifold and throttle leakage
driving at stable place it.
speed, the 1.5 idle speed regulator damaged Replace
engine power
changes; the 1.6 Fuel nozzle blocked Clean or replace it
vehicle seems to 1.7 Intake pressure temperature sensor Replace
decelerate with-
out accelerator 1.8 Fuel pressure regulator inoperative Replace
pedal changing)
2.1 High voltage line connection leaks or is loose Repair or replace
Check and repair or re-
place
4-20

1.1 Fuel nozzle blocked Clean or replace it
Unstable idling 1.3 Air filter clogged Clean or replace it
1.4 Intake manifold cylinder head gasket leakage Replace
1.5 Fuel pressure regulator inoperative Replace
1.6 Air quality flowmeter damaged Check or replace
1.7 Throttle position sensor damaged Replace
1.8 Electronic throttle valve fault Adjust it
2.1 Spark plug has a fault Adjust or replace it
2.2 High voltage line connection leaks or is disconnected Connect or replace
Unstable idling 3. Others

3.1 Vacuum hose connection is loose or disconnected Reconnect
3.2 Cylinder head gasket leakage Replace
See the above-mentioned
3.3 Compression pressure low
content
3.4 Intake manifold bolt or nut loose Tighten
3.5 Intake manifold gasket leakage Replace
3.6 Air conditioner signal wire damaged Check and repair
3.7 Water temperature sensor damaged Replace
Replace it with spark plug
1.1 Spark plug overheated with an appropriate heat
value
1.2 High voltage or low voltage circuit connection loose Tighten
2.1 Gasoline filter and fuel pipe blocked Clean or replace it
Abnormal com- 2.2 Fuel nozzle blocked Clean or replace it
bustion
2.3 Fuel pressure regulator inoperative Replace
2.4 Electric fuel pump and circuit fault Replace
2.5 Intake manifold gasket damaged Replace
3. Engine fault
3.1 Carbon deposition on piston top or cylinder head is too
Clean it
much
3.2 Cylinder head gasket damaged, which reduces compres-
Replace
sion pressure
4-21

Abnormal com- 3.4 Valve stuck Replace
bustion 3.5 Valve spring weakened Replace
Replace it with spark plug
1.2 Spark plug heat value incorrect with an appropriate heat
value
2.1 Insufficient fuel pressure Adjust it
Overheating
2.2 Fuel nozzle blocked Clean or replace it
2.3 Intake manifold loose Tighten
3. Cooling system fault
3.1 Coolant insufficient Refill
3.2 V-ribbed belt for water pump is loose or damaged Adjust or replace it
3.3 Thermosistor works abnormally Replace
4-22
Section Abnormal emission and troubleshooting

3roblems Reasons Handling method
1. Engine
1.1 Engine water temperature does not reach normal tem-
Check
perature
1.2 Air filter clogged Clean or replace it
1.3 Fuel leakage Check and adjust
1.4 Cylinder pressure low Check and repair
1.5 Fuel disqualified Replace fuel
2 Fuel system
2.1 Fuel evaporation control system ineffective Check and repair
2.2 Fuel injector blocked Replace
2.3 Fuel pressure regulator inoperative Clean or replace it
3. Intake/exhaust system
HC, CO, NOX
3.1 Three-way catalytic converter damaged Replace
emission exceed
the standards 3.2 Oxygen sensor fault Check and replace
3.3 Throttle position sensor damaged Check and replace
3.4 Intake pressure temperature sensor Check and replace
3.5 Water temperature sensor damaged Check and replace
3.6 Thermostat damaged Check and replace
3.7 Vacuum pipe leakage Check and repair
3.8 Exhaust air system leakage Check and repair
4.1 spark plug fault Clean or replace it
4.2 Engine misfiring Check and repair
4.3 High voltage line is in poor contact or leaking Check and repair
4.4 ECU fault Check and repair
4-23
Chapter 6 Engine sealing and unsealing
Section 1 Engine sealing and storage

The engine shall be stored in a clean, dry, ventilated warehouse without corrosive gas. Storage
period is three months. If it is stored for a long time, it shall be sealed by the following methods:
1. Fill 2.5L anti-rust lubricating oil into the engine to be sealed, then remove each spark plug,
keep the piston for each cylinder of the engine between TDC and BDC. Fill 0.006L anti-rust
lubricating oil into each cylinder, drive the engine by start motor to run 3~4 times and run for
15s every time.
2. Unscrew oil pan drain plug, discharge anti-rust lubricating oil, reinstall drain plug and spark
plug, and tighten with specified torque.
3. Discharge the coolant, remove engine cooling nozzle, clean it, and seal it with dust cover.
Then cover exhaust pipe, throttle opening, engine water inlet/outlet, fuel injector hole with
wax paper or rubber cover.
4. Clean external surface of the engine with washing fluid.
5. Put the engine into a packaging box
Section 2 Unseal the engine

1. Remove grease outside the engine.
2. Unseal each hole.
3. Remove spark plug, run the engine idly and discharge anti-rust oil in the cylinder.
4. Fill engine oil.
5. Fill coolant.
6. Start the engine according to this Operation Manual.
4-24
3aper of User Opinion

Dear customers:
Thank you for choosing BYD engine! In order to improve product performance and quality, serve
the customers better, our company hopes you will inform us of problems that you find during the
course of using the engine and suggestions at any time.
Please contact us by phone, fax or E-mail listed on the back cover of this Operation Manual. The
mail address is as following. Please fill Paper of User Opinion in detail.
Zip code: 518118
3009, BYD road, Pingshan New District, Shenzhen
BYD Auto Sales Company
To after-sale service department
Sender name: ___________
Sender address:___________
4-25
3aper of User Opinion

Engine number Ex-factory date Date
Service time or mileage User
Contact person Contact number
Fax/E-MAIL
Suggestions and advice (please fill it in detail)
4-26
V BYD4A Engine
Contents
Section 1 Overview of Engine 5-1

1.1 General Information..........................................................................................5-1
1.2 Main Technical Parameters ..............................................................................5-1
Section 2 Engine 5-9
2.1 Inspection of engine .........................................................................................5-9
2.3 Inspection and adjustment of valve clearancev ...............................................5-9
2.4 Timing chain ...................................................................................................5-14
2.5 Inspection of spark plugs................................................................................5-21
2.6 Removal and inspection of alternator assembly.............................................5-23
2.7 Installation of engine assembly ......................................................................5-46
Section Lubricativng system 5-61
3.1 Checking engine oil level................................................................................5-61
3.2 Checking engine oil quality.............................................................................5-61
3.3 Replacement of the engine oil........................................................................5-61
3.4 Checking engine oil pressure .........................................................................5-62
3.5 Removal, inspection and installation of oil pump ...........................................5-62
Section Cooling System 5-67
4.1 Inspection of cooling system ..........................................................................5-67
5HSODFHPHQWDQGUH¿OOLQJRIFRRODQW ..............................................................5-68
4.3 Thermostat .....................................................................................................5-68
4.4 Water pump....................................................................................................5-70
5-I
Section 1 Overview of Engine

11 General Information
The BYD488QA is a type of naturally aspirated all-aluminum engine, with a displacement of 2.4L,
using a variable valve timing mechanism (VVT), and characterized by strong power, light weight
and low pollution. Under various operating conditions, the BYD488QA engine is capable of work-
ing at its best state to ensure the whole vehicle to be provided with reliable safety, strong power,
comfortable driving, optimal economy and perfect environmental protection performance.
12 Main Technical 3arameters

1.2.1 Main technical parameters of BYD488QA Engine
Model
3arameter BYD4A
Item
In-line four cylinder, forced cycle water cooling, double overhead camshafts
Type
and four strokes
Maximum torque/speed 229N.M(4000r/min)
The lowest fuel consumption 250+10 g/kW·h
Cylinder bore × stroke 88.5 mm × 96 mm
Gasoline engine displacement 2.362 L
Compression ratio 9.8: 1
Variable valve timing mechanism (VVT), double overhead camshafts
Valve mechanism
(DOHC), chain drive, 16 valves
Fuel types 92# lead-free gasoline or above
Stable idle speed ˄700±50˅r/min
Compression pressure of cylinder 0.98MPa~1.46 MPa˄400 r/min±10 r/min˅
Fuel supply type Electronic control multipoint sequence fuel injection
Ignition sequence 1—3—4—2
Lubrication type Pressure and splashing combined type
Exhaust emission system Three-way catalytic converter
Oil Pressure: 170kPa~550kPa ˄3000 r/min±50 r/min˅
Engine quality 131 kg (transmission excluded)
Outline dimension (L × W × H) 600mm × 640mm × 680mm (excluding transmission)
Working conditions and emission State IV
5-1
1.2.2 Technical data for maintenance of BYD488QA Engine
Item Standard
Cylinder diameter mm
Cylinder cylindricity 0.008 mm
0.05mm
Cylinder block Flatness of cylinder deck
100: 0.03
Cylinder verticality 0.04
Compression pressure of cylinder 0.98MPa~1.46MPa˄400 r/min˅
Diameter of piston skirt mm
Piston Diameter of piston pin hole mm
Fit clearance between piston and cylinder 0.021~0.041 mm
Piston pin diameter mm
Piston pin
Fit clearance between piston pin and piston pin hole 0.001~0.007 mm
Piston ring end gap:
Piston ring 1st compression ring
0.20~0.35 mm˗
Piston ring gap/
Piston ring end gap:
side clearance 2nd compression ring
0.3~0.45 mm˗
Diameter of connecting-rod small end mm
Connecting rod Fit clearance between piston pin and connecting-rod
0.005~0.011 mm
small end
Main shaft journal diameter mm
Connecting rod journal diameter mm
Journal cylindricity 0.0065mm
Crankshaft
Crankshaft radial circle run-out 0.04mm
Connecting-rod big-end axial clearance 0.16~0.362 mm
Crankshaft thrust clearance 0.04~0.24 mm
Flywheel axial circle run-out 0.06mm
Temperature when thermostat beginning to open and fully opening 82 ± 2 °C, 95 °C fully open
Spark plug clearance 1.0~1.1mm
0.04 mm
Cylinder-head lower face flatness
100/0.02
Manifold joint surface flatness 0.05 mm
Cylinder-head intake camshaft first-bearing hole
mm
diameter
Cylinder-head intake camshaft second~fifth-bearing
Cylinder head mm
hole diameter
Cylinder-head exhaust camshaft first-bearing hole
mm
diameter
Cylinder-head exhaust camshaft second~fifth-bearing
mm
hole diameter
Cylinder-head bolt length 142±0.8mm
5-2
Item Standard
Intake camshaft first-journal diameter mm
Intake camshaft second~fifth-journal diameter mm
Exhaust camshaft first-journal diameter mm
Exhaust camshaft second~fifth-journal diameter mm
Camshaft journal cylindricity 0.005mm
Radial clearance between intake camshaft first jour-
0.007~0.038mm
Camshaft nal and bearing hole
Radial clearance between intake camshaft
0.025~0.062mm
second~fifth-journal and bearing hole
Radial clearance between exhaust camshaft first
0.015~0.056mm
journal and bearing hole
Radial clearance between exhaust camshaft
0.025~0.062mm
second~fifth-journal and bearing hole
Intake camshaft axial clearance 0.129~0.2mm
Exhaust camshaft axial clearance 0.129~0.2mm
Diameter of intake valve 34±0.1mm
Diameter of exhaust valve 29.5±0.1mm
Intake valve: mm
Valve stem diameter
Exhaust valve: mm
Valve system Valve guide diameter mm
Intake valve: 0.030 ~ 0.065 mm;
Clearance between valve stem and valve guide
Exhaust valve: 0.040 ~ 0.075 mm
Free length of valve spring 47.43±0.5mm
Intake valve 0.19 ~ 0.29mm;
Intake/exhaust valve clearance (cold)
Exhaust valve 0.38 ~ 0.48mm
1.2.3 Dimensional choice
B.1 Key dimensions and group table of crankshaft main journals, main bearing bores and main
bearing shells
Group number for main Group number for main

Group number for bearing
journal - Crankshaft main bearing cap hole- Main Oil clearance
shell Main bearing
journal bearing cap hole
1-¶55(-0.063,-0.057) 1-¶59(0,+0.008) 3-2(+0.007,+0.011) 0.035~0.057
2-¶55(-0.057,-0.051) 1-¶59(0,+0.008) 2-2(+0.003,+0.007) 0.037~0.059
3-¶55(-0.051,-0.045) 1-¶59(0,+0.008) 1-2(-0.001,+0.003) 0.039~0.061
1-¶55(-0.063,-0.057) 2-¶59(+0.008,+0.016) 4-2(+0.011,+0.015) 0.035~0.057
2-¶55(-0.057,-0.051) 2-¶59(+0.008,+0.016) 3-2(+0.007,+0.011) 0.037~0.059
3-¶55(-0.051,-0.045) 2-¶59(+0.008,+0.016) 2-2(+0.003,+0.007) 0.039~0.061
1-¶55(-0.063,-0.057) 3-¶59(+0.016,+0.024) 5-2(+0.015,+0.019) 0.035~0.057
2-¶55(-0.057,-0.051) 3-¶59(+0.016,+0.024) 4-2(+0.011,+0.015) 0.037~0.059
3-¶55(-0.051,-0.045) 3-¶59(+0.016,+0.024) 3-2(+0.007,+0.011) 0.039~0.061
Bearing shell group number=3-Main journal group number+Main bearing cap hole group number
5-3
B.2 Key dimensions and group table of crankshaft connecting-rod journal, connecting-rod big-end
hole and connecting-rod bearing shells
Group number for crank-

Group number for con- Group number for con-
shaft connecting-rod Oil clearance
necting-rod big-end hole necting-rod bearing shell
journal
1-¶48(-0.06,-0.053) 1-¶51(0,+0.007) 2-1.5(+0.008,+0.012) 0.029~0.051
2-¶48(-0.053,-0.045) 1-¶51(0,+0.007) 1-1.5(+0.004,+0.008) 0.029~0.052
1-¶48(-0.06,-0.053) 2-¶51(+0.007,+0.015) 3-1.5(+0.012,+0.016) 0.028~0.051
2-¶48(-0.053,-0.045) 2-¶51(+0.007,+0.015) 2-1.5(+0.008,+0.012) 0.028~0.052
Group number for connecting-rod bearing shell=2-Group number for crankshaft connecting-rod
journal+Group number for connecting-rod big-end hole
B.3 Key dimensions and group table of intake camshaft Ibearing hole, camshaft bearing shell and
camshaft Ijournal
Intake camshaft Camshaft bearing

Group number Camshaft journal Oil clearance
Ibearing hole shell
A ¶40(0,+0.008) 2(0,+0.004) ¶36(-0.029,-0.015) 0.007~0.037
B ¶40(+0.008,+0.017) 2(+0.004,+0.008) ¶36(-0.029,-0.015) 0.007~0.038
C ¶40(+0.017,+0.025) 2(0.008,+0.012) ¶36(-0.029,-0.015) 0.008~0.038
1.2.4 Table of Limited Torques
Fastening Number of
Torque
S/N parts or Bolt specification 3art number pieces for Note
(N·m)
components each unit
A Key torque
1ST:30
2ND:70
1 Cylinder head Cylinder head bolt BYD488QA-1003401 10
Rotating
by 90°
1ST: 20
Main bearing
2 Main bearing cap bolt BYD488QA-1002101 10 2ND: 40
cap
turn 90°
25
Connecting
3 Connecting rod bolt BYD488QA-1004101 8 Rotating
rod cap
by 90°
4 Flywheel Flywheel bolt BYD488QA-1005011 8 98
5 Spark plug M14 × 1.25 BYD488QA-3707100 4 25
Crankshaft pulley bolt as-
6 Crankshaft BYD488QA-1025200 1 170
sembly
Camshaft
7 Camshaft bearing cap (I) bolt BYD488QA-1003118 4 30
bearing cap (I)
Cylinder-head Cylinder-head screw plug
8 BYD488QA-1003500 2 86
screw plug cluster
B Main torque
9 Oil filter cluster Screw plug BYD371QA-1003032 1 30
Hexagon flange bolts M6 x
10 Oil pan cluster Q1840612T1F6 14 9
12
5-4
Fastening Number of
Torque
(N·m)
Q1860616T1F6 1 9
Heater water- 16
11 return pipe Stud M6 BYDQ120F0615T1F6 2 5
cluster
Hexagon flange nut M6 Q32006T2F6C 2 9
Oil-cooling Hexagon socket cap head
12 Q218B0612TF2 4 7
nozzle screw screw M6 x 12
Chain guide Hexagon flange bolts M6 x
13 Q1840612T1F6 2 9
plate 12
Chain tension-
14 Chain tensioner plate bolt BYD371QA-1021014 19
er plate
Chain tension- Stud M6 BYDQ120G0615T1F6 2 5
15
er Hexagon flange nut M6 Q32006T2F6C 2 9
Small washers M6 + hexa-
Engine oil col- Q40006T16F6 +
16 gon socket cap head screw 2 9
lector Q218B0625T1F6
M6 x 25
17 OCV valve Q1840612T1F6 1 9
12
Hexagon socket cap head
18 Clutch screw screw Q218B0825TF6 6 40
M8 × 25
19 Dipstick tube Q1860616T1F6 1 9
16
Hexagon bolt and spring-
20 Starter washer assemblies M10 × Q1421040T1F6P1.25 2 39
1.25 × 40
Q1860620T1F6Q 4 9
20
21 Water pump Stud M6 BYDQ120F0620T1F6 2 5
Water pump
22 Hexagon flange bolt M8 x 16 Q1840816T1F6 4 26
pulley
Hexagon flange bolts M6 x 30 Q1840630T1F6Q 1 9
Hexagon flange bolt M8 x 30 Q1840830T1F6Q 8 25
Hexagon flange bolt M10 ×
23 Timing cover Q1841040T1F6P1.25 3 55
1.25 × 40
Stud M6 BYDQ120F0620T1F6 2 5
Q1841065T1F6P1.25 2 54
1.25 × 65
24 Front bracket
Q1841040T1F6P1.25 1 54
1.25 × 40
5-5
Fastening Number of
Torque
(N·m)
Hexagon flange bolt - En-
Q1860630T1F6 7 11
larged series M6 × 30
Hexagon flange bolts - En-
Q1860660T1F6 2 14
larged series M6 × 60
BY-
Stud M6 2 5
DQ120G0630T1F6
Hexagon flange nut M6 (for
Cylinder head
25 studs used to install cylinder- Q32006T2F6C 2 11
hood
head cover)
Hexagon flange nut M6 (for
studs used to install cylinder- Q32006T2F6C 2 9
head cover)
Cylinder-head cover bolt BYD488QA-1003015 4 9
Hexagon flange bolt M8 x 35 Q1860835T1F6 5 30
Intake mani-
26 Stud M8 BYDQ120F0833T1F6 2 9.5
fold
27 Throttle valve Q1840655T1F6 4 9
55
Oil drain plug
28 Oil drain plug cluster BYD488QA-1009200 1 40
seat
Vacuum-
Vacuum-booster-pipe
29 booster-pipe 1 7
bracket bolt
bracket
Q1841085T1F6P1.25 1 52
30 Generator 1.25 × 85
31 Ignition coil Q1860625T1F6Q 4 9
25
Cylinder block
32 Hexagon flange bolt M8 x 120 Q18408120T1F6 5 24
frame
Hexagon tapered bolt NPT3 / 8 Q619B03F6 1 25
Exhaust mani- Stud M8 BYDQ120F0820T1F6 5 9.5

33
fold Hexagon flange nut M8 Q32008T2F6C 5 37
Q1841025T1F6P1.25 2 44
Exhaust mani- 1.25 × 25
34 fold cluster Stud M10 × 1.25 BYDQ120E1020T1F6 2 9.5
bracket
Hexagon flange nut M10 x 1.25 Q32010T2F6CP1.25 2 44
Exhaust mani-
35 fold heat shield Hexagon flange bolt M8 x 20 Q1840820T1F6 4 25
I
Exhaust mani-
fold heat shield 2
II
36 Hexagon flange bolt M8 x 12 Q1840812T1F6 15
Three-way cat-
alytic converter 4
heat shield
37 Idle pulley bolt Q1841050T1F6P1.25 1 54
1.25 × 50
5-6
Fastening Number of
Torque
(N·m)
Idler bracket Hexagon flange bolt M8 ×
38 Q18408100T1F6 2 24
bolt 1.25 × 100
Q1841085T1F6P1.25 1 60
1.25 × 85
Tensioner clus- BY-
39 Stud M8 1 9.5
ter DQ120G08645T1F6
40 Thermostat
Nut M6 Q32006T2F6C 2 9
Camshaft
Camshaft bearing cap bolt
41 bearing cap Q1400635TF2 16 9
cluster
bolt cluster
Exhaust cam-
Camshaft sprocket bolt sub-
42 shaft compo- BYD488QA-1021300 1 54
assembly
nent
Intake cam-
43 shaft compo- Hex flange bolt Q1841040TF2P1.25 1 54
nent
Oil filter connecting thread-
44 BYD488QA-1017011 1 30
Engine oil filter ed-pipe
45 Oil filter assembly BYD473QA-1017010 1 13
Fuel distributor
46 Fuel distributor bolt BYD488QA-1003013 2 20
assembly
Knock Sensor stud BYD488QA-3611011 1 9.5
47 Knock sensor
Cross recessed countersunk
head screw Q2540609T1F6P0.75 2 7
M6 × 0.75 × 9
Q1860625T1F6Q 1 7
25
48 Oil pump
Q1840816T1F6P0.75 3 9
0.75 × 16
Q1840820T1F6P0.75 2 9
0.75 × 20
Pressure-limiting valve
BYD488QA-1011107 1 45
spring seat
Hexagonal head bolt and
spring washer cluster M12 × Q1421265T1F6P1.25 1 54
Transmission 1.25 × 65
connecting Hexagonal head bolt and
49
bolt(reverse spring washer cluster M12 × Q1421270T1F6P1.25 2 54
direction) 1.25 × 70
Q1841065T1F6 2 54
1.25 × 65
Q1841065T1F6P1.25 1 54
Transmission 1.25 × 65
connecting Hexagon flange bolt M10 ×
50 Q1841020T1F6P1.25 1 54
bolt( forward 1.25 × 20
direction) Hexagon flange bolt M10 × Q1841040T-
3 54
1.25 × 40 1F6QP1.25
5-7
Fastening Number of
Torque
(N·m)
Engine oil
51 pressure Engine oil pressure switch BYD483QA-3611030 1 15
switch
Front
52 Front oxygen sensor 371QA-3611600 1 44
oxygen sensor
Canister
53 control valve Q1840612T1F6 1 9
12
bracket bolt
Intake pres-
54 sure tempera- Q1840616T1F6 1 9
16
ture sensor
Camshaft Hexagon flange bolts M6 x
55 Q1840612T1F6 1 9
phase sensor 12
Crankshaft Hexagon flange bolts M6 x Q1840614T1F6 (all-
56 1 9
position sensor 14 threaded)
Coolant Temp
57 Coolant Temp Sensor 0999CN0020 1 15
Sensor
5-8
Section 2 Engine Recommendation: Some cracks on the side

of belt teeth are allowed. If the belt teeth
21 Inspection of engine would be shattered in a massive manner, re-
place the belt. A new multi-wedge belt revfers
2.1.1 Inspection of engine coolant (see to one which has been used for less than 5
Chapter IV) minutes when the engine running. A used
multi-wedge belt refers to one which has
2.1.2 Inspection of engine oil (see Chapter
been used for 5 or more minutes when the
III)
engine running.
2.1.3 Inspection of spark plugs (see Section
2.2.3 Installation of multi-wedge belt
2.5 of ChapterII)
Put the socket onto the hexagon head of the
2.2 Removal, inspection and installation of
tensioner cluster. Using the wrench, press the
multi-wedge belt
tensionver cluster clockwise. Circle the multi-
2.2.1 Removal of multi-wedge belt wedge belt as shown in the figure and make
sure to install the belt into the ribbed grooves
Put the socket onto the hexagon head of the properly, and then release the tensioner clus-
tensioner cluster. Using the wrench, press ter slowly.
the tensioner cluster clockwise. Remove the
multi-wedge belt, and then release the ten-
sioner cluster slowly.
Hex head of
Tension
mechanism
assembly
Note: After completion of installation,

FKHFNWKHEHOWIRUVWDJJHUHGWHHWK
Note: When pressing the tensioner clus-
WHUURWDWHLWFORFNZLVHVORZO\'RQ’t apply
DVXGGHQIRUFHWRLW$IWHUFRPSOHWHUHWUHDW
of the tension wheel, do not continue to
press it in order to avoid any damage to
WKHWHQVLRQHUFOXVWHU
Correct Wrong
2.2.2 Inspection of multi-wedge belt
Check the multi-wedge belt visually for bad wear.

If any defect, replace the multi-wedge belt.
2 Inspection and adjustment of
Replace valve clearancev
2.3.1 Removing ignition coil, PVC breather
pipe fittings and cylinder-head cover
cluster
2.3.2 Adjusting piston in No.1cylinder to

top dead center (TDC)of compression
stroke
5-9
1) Rotate the vibration-damping pulley on

the crankshaft until the pulley’s white
marked groove is in alignment with the
timing mark “0” on the timing cover.
2) Check if intake/exhaust cam shaft tim-

ing sprocket wheel aligns with timing
mark on corresponding cam bearing
cap. Otherwise, as shown in the figure,
rotate the crankshaft by a turn ˄360°˅
again, and make sure to align the tim- Standard valve clearance (cold)
ing marks as mentioned above.
Item Standard state
Timing marks Intake 0.19-0.29mm
Exhaust 0.38-0.48mm
Note: When measuring, insert the feeler

between cam and tappet from the middle
LHRQWKHVLGHRIVSDUNSOXJ
Timing marks
Slot
Note: The timing mark on the intake VVT

cluster refers to the one with which the
intake camshaft positioning pin is in align-
PHQW$QGWKHWLPLQJPDUNRQWKHVSURFNHW
of the exhaust camshaft refers to the one
with which the exhaust camshaft position-
ing pin is in alignment, that is, the timing
mark with which the gap is in alignment
DIWHUVFUHZLQJWKHEROW
2) If disqualified, record the measured
Timing valve clearance in order to calculate
Positioning pin marks Positioning pin
hole of rear hole of exhaust and replace the valve tappet.
camshaft camshaft
3) Rotate the vibration-damping pulley by

a turn (360°), and be sure to make the
timing mark on the pulley be aligned.
4) Measure the valve clearance as shown

in the figure. If failed, record the mea-
sured valve clearance.
2.3.3 Inspection of valve clearance
1) Check the valve clearance of the 8

tappets as shown in the figure with a
feeler.
5-10
Intake
5) If there would be any valve clearance

beyond the specified range, adjust the
valve clearance.
2.3.4 Adjust valve clearance.
1) Remove the intake/exhaust camshaft.
(1) Adjust piston in No.1cylinder to top Exhaust

dead center (TDC)of compression
stroke and make sure that the timing
mark on the timing vibration-damping (3) Fix the chain with a rope or other tools
pulley is in alignment with that on the to prevent it from falling off from the
sprocket of the camshaft. crankshaft sprocket.
(2) Mark the timing mark positions on the Note: In the whole process of the removal,
timing chain and camshaft sprocket be sure to prevent the chain from falling
with a marker. RIIIURPWKHFUDQNVKDIWVSURFNHW
2) Measure the thickness of the tappet

with a micrometer.
7 sections
Painting
marks Painting
marks
Timing marks Timing

marks
Slot
(3) Remove the chain tensioner. 3) To make the valve clearance be within
the specified range, calculate the thick-
(4) Remove the bolts of exhaust camshaft
ness of the new tappet through the fol-
sprocket and the exhaust camshaft
lowing methods:
sprocket. Meanwhile, tighten the chain
upwards to prevent it from falling off Intake: A=B+˄C-0.24mm˅˗
from the crankshaft sprocket.
Exhaust: A=B+˄C-0.43mm˅˗
(5) Remove the intake/exhaust camshaft
bearing cap bolts in the order as shown A: Thickness of new tappet
in the figure.
B: Thickness of used tappet
5-11
C: Measured valve clearance 1) Coat a thin layer of engine oil onto the
journal of intake camshaft.
Examples:
2) Mount the timing chain onto the sprocket
Measured valve clearance on the intake side: of the intake VVT cluster and make the
0.40mm˗ chain piece with paint mark align to the
0.40mm-0.24mm=0.16mm (measured clear- timing mark on the sprocket of the intake
ance-standard clearance=clearance deviation VVT cluster, as shown in the figure.
value)
Painting marks
Thickness of used tappet: 5.35mm
5.35mm+0.16mm=5.51mm
(Thickness of used tappet+clearance devia-

tion value=thickness of new tappet to be re-
placed) Timing marks
Choose the tappet closest to 5.51mm to use.

Select the tappet of 5.52mm, i.e., No.52 tappet. 3) Check the camshaft bearing cap, for-
ward mark and number, and assemble
Note: Choose the tappet closet to the cal-
the intake camshaft bearing cap as
FXODWHGYDOXHDVPXFKDVSRVVLEOH
shown in the figure.
The tappet thickness ranging from 5.05 mm
to 5.75 mm is divided into 35 groups, with a Intake
difference of 0.02mm between two adjacent
groups.
For the grouping of tappet thickness, see the

table below:
Group Thick- Group Thick- Group Thick-

num- ness num- ness num- ness
ber (mm) ber (mm) ber (mm)
06 5.06 30 5.30 54 5.54
4) Coat a thin layer of engine oil onto the
bolts of camshaft bearing cap.
08 5.08 32 5.32 56 5.56
5) Tighten the ten bolts to the specified
10 5.10 34 5.34 58 5.58
torque by several steps in the order as
12 5.12 36 5.36 60 5.60 shown in the figure.
14 5.14 38 5.38 62 5.62
Torque
16 5.16 40 5.40 64 5.64
No.1 camshaft bearing cap bolts: 30N·m˗
18 5.18 42 5.42 66 5.66
20 5.20 44 5.44 68 5.68 No.2-5 camshaft bearing cap bolts: 9N·m˗
22 5.22 46 5.46 70 5.70
Intake
24 5.24 48 5.48 72 5.72
26 5.26 50 5.50 74 5.74
28 5.28 52 5.52
2.3.5 Assembly of new tappet
2.3.6 Assembly of intake/exhaust camshaft
5-12
6) Make sure that the timing mark on the bearing cap bolts.
sprocket of the intake camshaft is in
alignment with that on the camshaft 12) As shown in the figure, tighten the ten
bearing cap. bolts in sequence.
7) Coat a thin layer of engine oil onto the Torque

journal of the exhaust camshaft. No. 1 bearing cap: 30N·m˗
8) Make sure that the timing mark on the No. 2-5 bearing caps:9 N·m.
sprocket of the intake camshaft is in
alignment with the paint mark on the
sprocket.
Painting marks
Exhaust
Timing marks 13) Stabilize the exhaust camshaft by

hand, and tighten the camshaft-chain-
9) Stabilize the exhaust camshaft by wheel bolt cluster. Torque: 54N·m.
hand, and temporarily pre-tighten the
camshaft-chain-wheel bolt cluster.
Tighten
Fix
14) Install the chain tensioner and allow the

its plunger to pop up.
10) Check the forward mark and number of 15) Check whether the timing mark on the
the exhaust camshaft bearing cap, and camshaft sprocket is in alignment with
check their sequences as shown in the that on the crankshaft vibration-damp-
figure. ing pulley. Rotate the crankshaft vibra-
tion-damping pulley by 2 turns, and
then check whether the timing mark on
the camshaft sprocket is in alignment
with that on the crankshaft vibration-
damping pulley again.
11) Coat a thin layer of engine oil onto the

threads and below the heads of the
5-13
7 seg.
Painting marks Painting marks
Timing marks Timing marks
Slot
16) During the procedures above-men-

tioned, make sure that the crankshaft
sprocket can always mesh with the (2) Remove the bolt cluster of crankshaft
chain. If not, remove the timing chain to vibration-damping pulley and the crank-
replace the tappet through the methods shaft vibration-damping pulley.
defined in Section 2.4.
17) Measure the valve clearance again.
2.3.7 Install the cylinder-head cover cluster,

ignition coil and PCV breather pipe fit-
tings.
2 Timing chain

2.4.1 Removal of timing chain
1) Drain the engine oil.
2) Remove the V-shaped multi-wedge Recommendation: If necessary, remove

belt. WKHSXOOH\DQGLWVEROWVZLWKWKHWRRO$
3) Remove the alternator assembly. 7) Removal of oil pan fittings
4) Remove the ignition coil assembly. (1) Remove the 14 bolts.
5) Remove the cylinder-head cover.
Remove the 13 bolts, 2 nuts and
cylinder-head cover.
6) Remove the crankshaft vibration-damp-

ing pulley.
(1) Fix the crankshaft vibration-damping

pulley with the tool A, and loosen its
bolt cluster.
5-14
(2) Insert the blade between cylinder block

frame and oil pan. Cut through the seal-
ant and remove the oil pan.
Note: Be sure to avoid any damage to the 10) Remove the tensioner cluster.
contact surfaces between cylinder block Remove the bolts and nuts, and then take out
IUDPHDQGRLOSDQ the tensioner cluster.
8) Remove the chain tensioner.
Remove the 2 nuts, the chain tensioner and

its shim.
11) Remove the front bracket cluster.

9) Remove the idler fitting and the idler Remove the 3 bolts, and then take out the
bracket. front bracket cluster.
Remove the 3 bolts, the idler bracket bolts
and the idler fitting.
5-15
12) Remove the engine oil pump. (4) Remove the plane sealant thoroughly
from the joint surfaces between the tim-
(1) Remove the studs of the drive-tension- ing cover and the cylinder head or cyl-
er cluster from the cylinder block with inder block with a blade.
the E6 ring wrench.
Note: Be sure to avoid any scratch to the
(2) Remove the bolt(M6), 8 bolts(M8), 3 joint surfaces of the cylinder block, cylin-
bolts(M10) and 2 nuts (M6) in the order GHUKHDGRUWLPLQJFRYHU%HVXUHWRZUDS
from outside to inside as well as from the screwdriver with adhesive tape before
both sides to the middle. XVLQJLW
(5) Remove the seal ring from the cylinder

block frame.
13) Remove the chain tensioner plate and

the chain guide plate.
(1) Remove the bolts of the chain tensioner

plate and the chain tensioner plate.
Stud
(3) Pry up the timing cover carefully by

applying a screwdriver to the reserved
action points on the joint surfaces be-
tween the timing cover and the cylinder
head or cylinder block. (2) Remove the chain guide plate.
Remove the 2 bolts and the chain guide plate.
(3) Remove the timing chain.
14) Remove the crankshaft sprocket and

take out the half-round key.
2.4.2 Installation of timing chain
5-16
1) Install the half-round key and the crank- key is upward. Mount the chain onto the
shaft sprocket. crankshaft sprocket, and make sure that
the coloured chain piece on the chain is
2) Install the chain guide plate. in alignment with the timing mark on the
(1) Install the chain guide plate with the exhaust camshaft sprocket.
2 bolts. Coat thread sealant onto the
bolt A mounted on the cylinder block.
Half-roun
Torque: 9.0 N·mǄ d key
Timing marks
Coloured chain piece
(4) Align the coloured chain piece on the

timing chain with the timing marks on
the intake VVT cluster and the exhaust
camshaft sprocket, and then install the
chain.
3) Install the timing chain.
Coloured
(1) Rotate the crankshaft to allow the half- chain piece
round key to be at its horizontal posi-

tion. When rotating the crankshaft, be
sure not to allow the piston to touch the
valve.
Timing marks Timing marks
(2) Rotate the camshaft with the hexagon
top of a wrench to make sure that each
timing mark on the camshaft timing
gear is in alignment with that on the
intake/exhaust first camshaft bearing 4) Install the chain tensioner plate.
cap, as shown in the figure.
Install the chain tensioner plate with its bolts.
Torque: 19 N·m
Timing marks
Timing marks
(3) Using the crankshaft pulley bolt cluster, 5) Install the oil pump.
rotate the crankshaft until the half-round
5-17
(1) Remove all used sealing materials. Seal

material
Seal material
Wipe off the joint surfaces between the

timing cover and the cylinder head or
cylinder block. Make sure there is no
residual oil dirt or impurity.
(2) Install the two positioning cylindrical

pins on the cylinder block, and make
Seal material
sure to assemble the seal ring P15 Seal material
of the oil hole on the cylinder block in
place. (5) Tighten the ten bolts in the order as
Cylindrical
location pin
Torque
8 bolts B (M8): 25 N·m ˗
1 bolt A (M6): 9N·m˗
3 bolts C(M10): 55 N·m˗
2 bolts (M6): 11N·m.

Oil hole seal
ring
Nut Nut
(3) When installing the oil pump assembly,

coat plane sealant around the mount-
ing surfaces, as shown in the figure. Be
sure to coat the sealant in a successive
manner. No breakpoint is permitted. Be
sure to install the oil pump assembly
within 3 minutes after coating the seal-
ant.
Seal diameter
Seal diameter
Seal
diameter
Seal diameter
(6) Mount the studs onto the cylinder block

Seal diameter
with the E6 ring wrench.
Seal
diameter Seal diameter
Note:
Be sure to install the oil pump assembly in

Seal
diameter Seal diameter
SODFHZLWKLQPLQXWHVDIWHUFRDWLQJVHDO-
Seal diameter
DQW2WKHUZLVHUHPRYHWKHVHDODQWRQWKH
unit
RLOSXPSWKRURXJKO\DQGUHFRDWVHDODQW
After installing the oil pump assembly, be

(4) Coat sealant onto the joint surfaces sure to tighten its mounting bolts within
between the cylinder block and cylinder PLQXWHV
head, as well as between the cylinder
block and cylinder block frame, with a Don’t start the engine within 2 hours after
diameter of 4.0~4.5 mm, as shown in FRDWLQJVHDODQW
the figure.
5-18
6) Install the chain tensioner assembly. chain tensioner while checking whether
the chain tensioner’s plunger is moving.
(1) Be sure to ensure that the 2 studs on Make sure that the chain tensioner has
the timing cover have been installed been installed in place.
in place before installing the chain
tensioner. Lubricate the plunger of the 7) Install the front bracket cluster.
chain tensioner before installation.
Install the front bracket cluster with the 3
(2) Loosen the limit stop, and push into the bolts.
plunger completely and use the hasp
to hook the hanger pin to enable the Torque: 54N·m.
plunger to stay at the position as shown
in the figure.
Lift
Clipper
Hook
Pin
(3) Install the chain tensioner and new

shim with the 2 nuts. Pay attention to
the direction of the shim. Be sure to
8) Install the tensioner cluster.
make its sharp angle towards the rear
end of the engine. Install the tensioner cluster with the bolts and
nuts.
Torque
Nut: 30 N·m.
Bolt: 60 N.m
Front part
of engine
(4) Insert the flat-tip screwdriver into the

middle of the timing cover from the upper
end of the cylinder head. Use the tip of
the flat-tip screwdriver to press the chain
tensioner plate to release the hasp of the
chain tensioner and allow the chain ten-
sioner’s plunger to pop up. 9) Install the idler fitting and idler bracket.
(5) Use the flat-tip screwdriver to press the Install the idler fitting and idler bracket with
5-19
the 3 bolts. clean cloth. Recommendation: Don’t

start the engine until 2 hours after in-
Torque: stalling the oil pan assembly in place.
Idler bracket bolts: 24 N·m Torque:9 N·m.
Idler fitting bolts: 54 N·m
11) Install the crankshaft vibration-damping

pulley.
10) Install the oil pan assembly
(1) Remove the sealant and oil thoroughly
(1) Remove the used sealing materials.
on the crankshaft vibration-damping
Wipe the joint surfaces of the oil pan
pulley and the crankshaft pulley bolt
and the cylinder block frame. Make
cluster.
sure there is no oil dirt or impurity on
the joint surfaces of the cylinder block (2) As shown in the figure, coat plane
frame and oil pan. sealant on the desired positions of the
crankshaft vibration-damping pulley,
(2) As shown in the figure, coat sealant
and then align the key groove on the
within the continuous coating line onto
crankshaft vibration-damping pulley
the oil pan fitting, with a diameter of
with the position of the half-round key
2.5~3.0 mm. No breakpoint is permit-
at the front end of the crankshaft so as
ted. Install the oil pan fitting within 3
to install the crankshaft vibration-damp-
minutes after coating sealant.
ing pulley.
Plane sealant Plane sealant wire
(3) Install the oil pan onto the cylinder

block frame.
(4) Tighten the 14 bolts in the order as (3) As shown in the figure, coat sealant
shown in the figure. Wipe off the sur- onto the roots of the crankshaft pulley
plus sealing materials extruded with a bolts, and then install the crankshaft
5-20
pulley bolt cluster to the front end of the (4) As shown in the figure, install the cylin-
crankshaft. Torque:170 N·m der-head cover bolts in the order.
Torque:
Paint a round of plane sealant on the
back and front of gasket
Bolt 1,2: 14 N.m
Nut 9, 12: 9 N.m
Nut 4, 6, 8, 10: 9 N.m
Other bolts: 11 N.m
Crankshaft pulley bolt assembly
12) Install the cylinder-head cover assem-

bly.
(1) Remove any sealing material on the

contact surfaces. Make sure there is no 13) Install the ignition coil assembly.
oil or impurity on the contact surfaces
of the cylinder head and the timing cov- Install the ignition coil assembly with the 4
er. bolts.
(2) Coat sealant onto the joint surfaces Torque: 9.0 N·m
between the cylinder head and the tim-
14) Install the alternator assembly.
ing cover, with a colloid diameter of
4.0~4.5 mm, i.e., the 2 positions as 15) Install the V-shaped multi-wedge belt.
16) Add oil to the engine.
Note: Be sure to remove any oil on the
FRQWDFWVXUIDFHV$IWHUFRDWLQJSODQHVHDO- 17) Check the engine oil for leakage.
ant, make sure to install the cylinder-head
FRYHU ZLWKLQ PLQXWHV 2WKHUZLVH LW LV 25 Inspection of spark plugs
proper to remove the used residue and re- Note: When the engine is hot, its oil tem-
FRDWVHDODQW$IWHULQVWDOOLQJWKHF\OLQGHU SHUDWXUH LV KLJK :KHQ UHPRYLQJ DQG
head cover, don’t add oil to the engine installing the components, be sure to be
XQWLOKRXUVODWHU FDUHIXOQRWWREHEXUQW
2.5.1 Removal of spark plugs
1) Disconnect the cable from the negative

battery terminal.
2) Disconnect the terminal connector from

the ignition coil.
3) Remove the mounting bolts from the ig-

nition coil, and remove the ignition coil.
(3) Align the cylinder-head cover with its
gasket well-installed with its positioning 4) Remove the spark plug with the special
studs, and then install the cylinder-head wrench.
cover in place. 2.5.2 Inspection of spark plugs
5-21
1) As shown in the figure, measure the gap range:1.0~1.1mm.

resistance with an ohmmeter. Check
whether the resistance is more than
10M¡. If it is less than 10M¡, clean
the spark plug as shown in Step 5, and
measure the resistance again .
Grounding
1.0 to 1.1mm
Note: If it is necessary to adjust a new

spark plug gap, be sure to adjust the root
Ground RIWKHRXWVLGHHOHFWURGHRQO\'RQ’t adjust
WKHWRSRIWKHRXWVLGHHOHFWURGH1RDGMXVW-
2) If no ohmmeter is available, simply PHQWRIDQ\XVHGVSDUNSOXJLVSHUPLWWHG
check the spark plug with the following
methods. 5) Clean the spark plugs.
(1) Increase the engine speed to 4000rpm If there would be any deposited carbon on
quickly, and repeat 5 times. the spark plug electrode, be sure to clean it
with the spark plug cleaner. Barometric pres-
(2) Remove the spark plug, and observe sure: 588 kPa; Duration: not more than 20
the spark plug electrode. seconds.
(3) If the spark plug electrode is dry, it is an

indication that the spark plug is func-
tioning properly. Note: The spark plug cleaner can only be
used when there is no grease mark on the
(4) If the spark plug electrode is wet, pro- HOHFWURGH 2WKHUZLVH EH VXUH WR UHPRYH
ceed as the following steps. the grease marks with gasoline before us-
LQJWKHVSDUNSOXJFOHDQHU
3) Check the spark plug thread and insu-
lation for damage. If any, replace the 2.5.3 Inspection of compression pressure
spark plug.
1) Warm up the engine until its working
4) Inspection of spark plug gap: Limit gap temperature, and then let the engine
of a used spark plug: 1.3 mm. If the misfire.
spark plug gap would be oversized,
replace the spark plug. New spark plug 2) Remove the terminal connector from
5-22
the No.1 cylinder ignition coil. If the compression pressure would

increase after adding a few drops
3) Remove the No.1 cylinder ignition coil of engine oil, it is an indication that
and its spark plug. the piston, piston rings or cylinder
4) Check the compression pressure of the ZDOO FRXOG EH ZRUQ ,W LV QHFHVVDU\
No.1 cylinder. WRSHUIRUPRYHUKDXO
If the compression pressure would
5) Connect the pressure gauge into the still be low, it is an indication that
spark plug hole of the No.1 cylinder. the valve could be seized or the
sealing surfaces could contact
SRRUO\ ,W LV QHFHVVDU\ WR SHUIRUP
RYHUKDXO
If all the adjacent cylinder compres-
sion pressures would also be low,
it is an indication that the cylinder
head gasket could be damaged
or the cylinder head could be de-
IRUPHG ,W LV QHFHVVDU\ WR SHUIRUP
RYHUKDXO
9) Remove the pressure gauge. Install the
spark plug, with a tightening torque: 25
6) Press the accelerator pedal all the way Nm.
down to its extreme position and stop
the engine from running. 10) Install the ignition coil, and connect its
terminal connector.
7) Record the maximum reading on the
pressure gauge. 26 Removal and inspection of alter-
nator assembly
Compression pressure
Item
MPa ˄400±10r/min˅ 2.6.1 Disconnection of cable from negative
Standard value 0.98~1.46 MPa battery terminal
Maximum limit of pres-
sure difference between 0.1 MPa 2.6.2 Drain the alternator oil.(see Chapter III)
cylinders
2.6.3 Drain the engine coolant.(see Chapter
Note: Make sure that the battery is fully IV)
charged enough to maintain the engine
2.6.4 Removal of pulley and tensioner as-
VSHHG PRUH WKDQ UPLQ$FFRUGLQJ WR
sembly
6WHSVaLQWXUQPHDVXUHWKHFRPSUHV-
VLRQ SUHVVXUH RI WKH 1R F\OLQGHU 1R 1) Installation and removal of V-shaped
F\OLQGHU DQG 1R F\OLQGHU UHVSHFWLYHO\ multi-wedge belt (see Section 2.2 in
Be sure to complete such measurements Chapter II).
DVVRRQDVSRVVLEOH
2) Remove the alternator assembly.
8) If the cylinder pressure is too low or the
pressure difference between cylinders (1) Disconnect the alternator connector.
exceeds the maximum limit too much,
(2) Remove the nut from the terminal and
try to add a few drops of engine oil into
disconnect the harness.
the cylinder through the spark plug
hole, and then re-measure the cylinder (3) Remove the bolts and the bracket of
compression pressure again. harness clamp.
Note: (4) Remove the harness clamp.
5-23
the idler bracket.
(5) Remove the 2 bolts and the alternator

assembly.
5) Remove the water pump assembly (see

Chapter Č ).
6) Lock the crankshaft vibration-damping

pulley with the special tool. Remove the
crankshaft pulley bolt cluster with the
sleeve of 21mm.
3) Remove one bolt and one nut of the

tensioner, and remove the tensioner
cluster.
2.6.5 Removal and installation of front bracket
1) Remove the 3 bolts(M10), and then re-

move the front bracket.
4) Pry up the idler dust cover with the

screwdriver. Remove the idler bolts and
remove the idler. And then remove the
2 bolts of the idler bracket and remove
5-24
2.6.8 Removal and inspection of exhaust

manifold cluster
2.6.6 Removal of PCV breather pipe fitting
1) Remove the bolts from the exhaust
1) Loosen the wire-type elastic hoop. manifold brackets, and remove the ex-
Remove the PCV breather pipe fitting. haust manifold brackets 1 and 2.
Pull out the PCV valve, and remove the
PCV valve washer.
PCV valve PCV breather pipe

attachment
PCV valve
washer
Steel wire elastic ring
2.6.7 Removal and inspection of intake mani-

fold cluster
1) Remove the 5 bolts and 2 nuts of the

intake manifold in the order as shown in
the figure, and then remove the intake
manifold. Remove the throttle on the
intake manifold and the intake pressure
and temperature sensors, and then re-
move the knock sensor on the cylinder
block. Check the intake manifold for
crack or other damage.
2) Remove the 4 bolts and the exhaust

manifold heat-shield 1.
5-25
2.6.10 Remove the heater water-return pipe

and gasket.
1) Remove the bolt and 2 nuts from the

heater water-return pipe. Remove the
heater water-return pipe and gasket.
3) Remove the 5 bolts, and then remove

the exhaust manifold and its gasket.
2.6.11 Remove the thermostat cover and the

4) Remove the exhaust manifold heat
thermostat.
shield II and the three-way catalytic
converter heat shield. 1) Remove the 2 nuts, and then the ther-
mostat cover and the thermostat.
5) Check the exhaust manifold. Measure
the flatness of the joint surfaces be- 2.6.12 Removal of clutch flywheel cluster
tween the exhaust manifold and the
cylinder-head. No flatness more than 1) Removal of clutch
0.7 is permitted. Otherwise, replace the
(1) Remove the starter.
exhaust manifold.
(2) Remove the transmission.
2.6.9 Remove the dipstick and its tube.
(3) Remove the clutch.
1) Pull out the dipstick, and remove the
dipstick tube bolt. Remove the dipstick Let the centering plunger pass through
tube and its O-ring. the clutch plate assembly, and then in-
sert it into the bearing hole at the rear
end of the crankshaft.
Remove the clutch bolts. Remove the

clutch from the flywheel.
Dipstick
Dipstick tube
Dipstick tube
O-ring
5-26
2) Inspection of clutch 4) Inspection of flywheel
(1) Inspection of clutch plate assembly (1) Measure the run-out of the rear end
of the flywheel with a magnetic frame
Measure the depth of the rivet heads type dial gauge. Allowed maximum run-
on the friction lining with a vernier out:0.1 mm If necessary, replace the
caliper. Minimum depth: 0.3 mm. If flywheel.
necessary, replace the clutch plate as-
sembly. 2.6.13 Disconnect the terminal connector
from the ignition coil. Remove the
Measure the run-out of friction lining mounting bolts of the ignition coil.
with a magnetic frame type dial gauge Remove the ignition coil. Remove the
and a deflection tester. Allowed maxi- spark plug.
mum run-out: 0.8 mm.
(2) Inspection of clutch cover assembly
Measure the wear of the pressure

plate spring strip with a vernier caliper,
with allowed maximum depth: 0.6 mm,
and allowed maximum width: 0.5 mm.
If the measured value exceeds the
allowed maximum value, replace the
clutch cover assembly.
Note: Make sure to prevent oil dirt or other

impurity from falling onto the surfaces of
the driven plate assembly, flywheel and
RWKHU 2.6.14 Removal of cylinder-head cover cluster
3) Removal of flywheel 1) Remove the 13 bolts and 2 nuts from

the cylinder-head cover in the order as
(1) Lock the flywheel starter ring gear with shown in the figure. Remove the cyl-
the special tool. Remove the 8 flywheel inder-head cover. Check the cylinder-
bolts by several steps through the cross- head cover for crack or other damage.
ing method. Remove the flywheel. Check its gasket for fracture or other
damage. If any damage, replace it.
5-27
1) Remove the 2 nuts, chain tensioner

and its gasket.
2.6.15 Removal of oil pan fittings
1) Remove the 14 bolts.
2.6.17 Removal of timing cover
1) Remove the studs of the drive-tension-

er cluster from the cylinder block with
the E6 ring wrench.
2) Remove the bolt(M6), 8 bolts(M8), 3

bolts(M10) and 2 nuts (M6) in the order
from outside to inside as well as from
both sides to the middle.
2) Insert the blade between cylinder block

frame and oil pan. Cut through the seal-
ant and remove the oil pan.
Stud
3) Be careful to pry up the timing cover

Note: When inserting the blade, don’t pry
by applying the screwdriver to the joint
up the cylinder block frame and the joint
surface between the timing cover and
surface of the timing cover in order to
the cylinder-head or cylinder block.
avoid damage to the cylinder block frame
and the joint surface between the timing
FRYHUDQGWKHRLOSDQ
2.6.16 Removal of chain tensioner
5-28
Exhaust
2) Removal of intake camshaft
(1) Remove the 10 bolts of the intake cam-

shaft in the order as shown in the fig-
ure. And remove the intake camshaft.
Intake
4) Remove the plane sealant thoroughly

ing cover and the cylinder head or cyl-
inder block with a blade.
Note: Be sure to avoid any scratch to the joint

surfaces of the cylinder block, cylinder head
RUWLPLQJFRYHU%HVXUHWRZUDSWKHVFUHZ- (2) Removal of camshaft intake VVT cluster
GULYHUZLWKDGKHVLYHWDSHEHIRUHXVLQJLW Clamp the camshaft with a vice, and
5) Check the timing cover for crack, make sure that the camshaft timing
scratch or other damage. If any, replace gear cannot rotate.
the timing cover. Use PVC (poly vinyl chloride) to cover
6) Remove the P15 seal ring from the cyl- all oil interfaces except the interface
inder block frame and the two position- on the advance side.
ing pins from the cylinder block.
2.6.18 Removal of timing chain (see Section Advanced

2.4 in Chapter II) side interface
2.6.19 Removal of camshaft assembly
1) Removal of exhaust camshaft
(1) Stabilize the exhaust camshaft with a

wrench, and then remove the bolts of
its sprocket with a torque wrench. And
remove its sprocket. Apply a pressure of 100kPa to the oil
passages, and then turn the camshaft
(2) Remove the 10 bolts of the exhaust
timing gear by hand in the advance
camshaft in the order as shown in the
direction (i.e., counterclockwise).
figure.
Note: Cover the oil passages with a cloth
WRSUHYHQWRLOIURPVSODVKLQJRXW
5-29
RQ WKH DGYDQFH VLGH $V VKRZQ LQ WKH

¿JXUHVWDEDKROHLQWRWKHDGKHVLYHWDSH
SODFHGRQWKHGHOD\VLGHRQWKHRSSRVLWH
Retard side
path
Advanced
side path
Recommendation: Only turn the camshaft
timing gear to the side of advance angle
ZLWKDLUSUHVVXUH0HDQZKLOHLILWZDVGLI-
ficult to apply a pressure due to air leak-
age at the interface, it would be not easy
Off Open circuit
WRXQORFN
Open Off
Remove the bolts of the camshaft tim-
circuit
ing gear.
Ethylene strap Rubber
Apply a pressure of 200kPa to these

two disconnected passages.
Note: When applying the pressure to stop

the oil from splashing out, be sure to cov-
Note: Don’W UHPRYH RWKHU EROWV ,I WKH HUWKHRLOSDVVDJHVZLWKFORWK
gear is going to be re-used, make sure to
Retard side path Advanced
release the straight locking pin before in-
side path
VWDOODWLRQRIWKHJHDU
(3) Inspection of camshaft intake VVT clus-

ter
Check the camshaft timing gear for

locking. Clamp the camshaft with a
vice, and make sure that the camshaft
timing gear is locked.
When reducing the pressure applied to
1RWH$YRLGGDPDJHWRWKHFDPVKDIW the passages on the delay side, check
whether the camshaft timing gear can
Release of locking pin: As shown in rotate in the advance direction. If the
the figure, cover the oil passages of camshaft timing gear can rotate in the
the 4 camshaft journals with PVC. advance direction, it indicates that the
Recommendation: The 2 passages on the timing gear is functioning properly.
advance side are available in the camshaft Recommendation: The locking pin at the
JURRYH 3OXJ RQH RI WKH SDVVDJHV ZLWK maximum delay position can be loosened
UXEEHU WKURXJKWKLVRSHUDWLRQ
Stab a hole into the adhesive tape placed
5-30
When the camshaft timing gear reach-

es its maximum advance position, re-
move the air guns from the passages
on the delay side and the advance
side in the specified order.
Note: Don’t remove the air guns from the

SDVVDJHV RQ WKH DGYDQFH VLGH DW ILUVW
The timing gear can move suddenly in the
delay direction and cause damage to the
ORFNLQJSLQ
Inspection of smooth rotation Rotate

the camshaft timing gear several
(2) Check the top of the camshaft.
times within its movable range. How-
ever, don’t rotate it to its maximum de- Measure the cam lobe height.
lay position. Check whether the timing
gear can rotate smoothly. If the timing Standard cam lobe height
gear can rotate smoothly, it indicates it
Intake camshaft:47.35±0.08mm
is functioning properly and it can con-
tinue to be used. Exhaust camshaft: 46.11±0.08mm
Note: Don’t use the air gun to check the If the cam lobe height less than the minimum
WLPLQJJHDUIRUVPRRWKURWDWLRQ value, replace the camshaft.
Check the locking at the maximum de-
lay position. Make sure that the cam-
shaft timing gear can be locked at its
maximum delay position.
3) Check the camshaft.
(1) Inspection of camshaft run-out
Put the camshaft on the V-shaped

block.
Measure the round run-out at the in-

termediate journal with a dial indica-
tor. Maximum round run-out:0.03mm (3) Check the camshaft journal.
If the measured value exceeds the
maximum round run-out, replace the Using a dial gauge, measure the intake
camshaft. camshaft’s first-journal: M 360.015
0.029 mm, the
exhaust camshaft’s first journal: M 360.015

0.031
mm, the intake/exhaust camshaft’s

other journals: M 230.025
0.041 mm. If the journal
diameter is beyond the specified value,

check its oil clearance.
5-31
0.129~0.2mm.
Allowed maximum axial clearance:0.3 mm
If the measured axial clearance ex-

ceeds the allowed maximum value,
replace the cylinder head. If the cam-
shaft thrust surface is worn, replace
the camshaft.
2.6.20 Removal of OCV valve
1) Removal of OCV valve
(1) Disconnect the connector from the

OCV valve.
(4) Check the camshaft’s oil clearance.
(2) Remove the bolts and OCV valve.
Clean the camshaft bearing seat and
the camshaft journal.
Be careful to put the camshaft on the

camshaft bearing seat of the cylinder
head.
Put a plastigauge on the camshaft

journal.
After determining that the arrow on the

camshaft bearing cap directs properly
towards the front end of the engine,
put back the camshaft bearing cap Standard range
Item
and screw in the bolts. (mm)
Intake first journal 0.007~0.038
Tightening torque: Camshaft bearing Intake second~fifth
cap I: 30 N · m, camshaft bearing cap 0.025~0.062
journal
II: 9N · m. Exhaust first journal 0.015~0.056
Remove the bolts of the camshaft Exhaust second~fifth
0.025~0.062
journal
bearing cap. And then remove the
camshaft bearing cap.
2) Inspection of OCV valve
Measure the oil clearance at the wid-
(1) Inspection of resistance
est position of the plastigauge.
Measure the resistance between ter-
Note: After completion of measurement,
minals with the ohmmeter.
remove the plastigauge on the camshaft
MRXUQDOFRPSOHWHO\ 6WDQGDUGUHVLVWDQFHaȍDW°&,I
QHFHVVDU\UHSODFHWKH2&9YDOYH
(5) Measure the axial clearance of the
camshaft.
Install the camshaft in place.
Move the camshaft back and forth

slightly, and then measure its axial
clearance with a dial gauge. Stan-
dard camshaft axial clearance:
5-32
cylinder-head bolts and 10 flat washers

by several steps with the ring wrench of
Oil control valve
12mm.
(2) Inspection of operation of OCV valve
Connect the battery positive ˄+˅wire

to the Terminal 1, and connect the bat-
tery negative˄-˅ wire to the Terminal 2.
Note: Wrong sequence of removal of bolts
Check the operating conditions of the can cause warping or cracking to the cyl-
OCV valve. LQGHUKHDG
Note: Make sure that the OCV valve can (2) Insert the screwdriver with its tip
PRYH VPRRWKO\ 1R VWLFNLQJ LV SHUPLWWHG wrapped with adhesive tape between
,IQHFHVVDU\UHSODFHWKH2&9YDOYH the cylinder head and the cylinder block
Recommendation: The accumulated impu- to pry the cylinder head, and remove
ULWLHV FDQ FDXVH VOLJKW SUHVVXUH OHDNDJH the cylinder head.
3UHVVXUH OHDNDJH FDQ FDXVH DGYDQFH RI Note: Be careful not to cause damage to
FDPVKDIWWLPLQJWKHUHE\D'7&ZLOOEHVHW the contact surfaces between the cylinder
2.6.21 Removal of cylinder head KHDGDQGWKHF\OLQGHUEORFN
1) Remove the lower bearing shall of the

intake camshaft.
Pry lightly the bottom of the lower bearing

shell of the intake camshaft from the mount-
ing hole of the cylinder-head bolt with the
screwdriver, and remove the lower bearing
shell.
3) Removal of cylinder-head gasket
Remove the cylinder-head gasket.
2) Remove the cylinder head.
(1) According to the order as shown in

the figure, loosen and remove the 10
5-33
lets with the tool T and wooden block.
Remove the valve-spring retainer (up-

per), valve spring and exhaust valve.
5HFRPPHQGDWLRQ 3ODFH WKH UHPRYHG

FRPSRQHQWVLQWKHRUGHU
4) Disassemble the cylinder head.
(1) Removal of tappet
Remove the tappet. Block
Recommendation: Place the tappets in the

order on the cylinder head. (4) Removal of valve oil seal with needle-
nose pliers
(2) Removal of intake valve
Compress and remove the valve col- (5) Remove the valve-spring retainer (lower)
lets with the tool T and wooden block.
Using compressed air to blow air onto the
valve-spring retainer (lower), remove it
with the magnetic probe.
Block
Remove the valve-spring retainer (up-

per), valve spring and intake valve.
5HFRPPHQGDWLRQ 3ODFH WKH UHPRYHG

(6) Removal of cylinder-head screw plug
FRPSRQHQWVLQWKHRUGHU
Remove the 2 cylinder-head screw plugs and
(3) Removal of exhaust valve
its 2 washers with the hexagon head sleeve.
Compress and remove the valve col-
Note: If any cylinder-head screw plug
5-34
PDNHVZDWHURULVHURGHGUHSODFHLW
5) Inspection of cylinder head
(7) Remove the studs. (1) Check the flatness of the cylinder head.
(8) Removal of intake valve guide (2) Using the precision straightedge and
feeler gauge, check and measure the
Heat the cylinder head up to flatness of the contact surfaces with the
80~100°C. cylinder block and the exhaust mani-
fold.
Put the cylinder head on the wooden
block.
Tap out the intake valve guide with the

tool T and hammer.
Cylinder block side
(9) Removal of exhaust valve guide Intake manifold side
Heat the cylinder head up to

80~100°C.
Put the cylinder head on the wooden

block.
Exhaust manifold side
Tap out the exhaust valve guide with
the tool T and hammer.
5-35
Maximum flatness value valve seat width of 1.0~1.4mm˄intake

side˅.
Item Specified value
4) Check whether the valve seat can
Cylinder block side 0.04mm contact the valve surface center with a
Intake manifold side 0.05mm valve seat width of 1.2~1.6mm˄exhaust
Exhaust manifold side 0.05mm side˅.
If the flatness value exceeds the specified

range, replace the cylinder head.
(3) Check the cylinder-head for cracking.
Using colored penetrant, check intake

and exhaust valve seats and the cyl-
inder block surface for cracks. If any Width
crack, replace the cylinder head.
(5) Repair of valve seat
Note
While checking the valve seat position, re-

SDLUWKHYDOYHVHDW0DNHVXUHWKDWWKHUHLV
QRLPSXULW\RQWKHOLS
Re-grind the surface of the valve seat

with the cutter of 45°to enable the
(4) Inspection of valve seat valve seat width to be more than the
Coat a thin layer of Prussian blue on specified value.
the valve surface. Correct the valve seat with the cutters
Press the valve surface towards the of 30° and 75°to enable the valve to
valve seat slightly. contact the whole circumference of the
valve seat. Make sure that the contact
Note: Don’t rotate the valve point is in the center of the valve seat,
and the width of the whole circumfer-
Check the valve surface and valve ence of the valve seat is maintained
seat according to the following steps: within the specified range.
1) If Prussian blue appears around the
entire valve surface, the valve is con-
centric. If not, replace the valve.
2) If Prussian blue appears around the

entire valve seat, the valve guide and
valve surface are concentric. If not,
grind the valve seat.
3) Check whether the valve seat can

contact the valve surface center with a
5-36
Width of valve seat Plastic

clearance
gauge
Item Width of valve seat
Intake side 1.0~1.4mm
Exhaust side 1.2~1.6mm
Grind the valve and valve seat by

hand with abrasive paste.
Check the position of valve seat.

Standard oil clearance of intake/exhaust cam-
(6) Check the camshaft axial clearance. shaft
Install the camshaft.
Specified condi-
Item
While moving the camshaft back and tions
forth, measure the thrust clearance Group A of intake cam-
with the dial indicator. Standard camshaft bearing hole (first 0.007~0.037mm
journal)
shaft axial clearance:0.129~0.2mm.
Group B of intake cam-
shaft bearing hole (first 0.007~0.038mm
journal)
Group C of intake cam-
shaft bearing hole (first 0.008~0.038mm
journal)
Exhaust camshaft bear-
0.015~0.056mm
ing hole (first journal)
Other journal of camshaft 0.025~0.062mm
Maximum oil clearance of camshaft
Specified condi-
Item
(7) Inspection of camshaft oil clearance tions
Intake camshaft bearing
0.070mm
Clean the bearing cap and the cam- hole (first journal)
shaft journal. Exhaust camshaft bear-
0.100mm
ing hole (first journal)
Put the camshaft on the cylinder head. Other journal of cam-
0.12mm
shaft
Put a plastigauge across each cam-
shaft journal. If the oil clearance exceeds the maxi-
mum value, replace the camshaft. If
Install the camshaft bearing cap. necessary, replace the cylinder head.
Note If the oil clearance of the first journal
Don’WURWDWHWKHFDPVKDIW of the camshaft exceeds the maxi-
mum value, select and install a new
Remove the bearing cap. camshaft bearing shell.
Measure the widest point of oil clear-
ance with the plastigauge.
5-37
Grouping of intake camshaft bearing hole (first (9) Check the intake valve.
journal)
Scrape off the deposited carbon on
Specified condi- the top of the intake valve with the
Item gasket scraper.
tions
Group A of intake cam-
40.000~40.008mm
shaft bearing hole
Group B of intake cam-
40.008~40.017mm
shaft bearing hole
Group C of intake cam-
40.017~40.025mm
shaft bearing hole
Grouping of camshaft bearing shell
Specified condi-
Item
tions
Group A 2.000~2.004mm
Group B 2.004~2.008mm Measure the full length of intake valve
Group C 2.008~2.012mm with the vernier caliper.
Standard full-length:101.7mm.
(8) Check the internal compression spring.
Minimum full-length:101.2mm.
Measure the free length of valve
spring with the vernier caliper. Free If the full-length is less than the minimum
length:47.43mm. If the free length is value, replace the intake valve.
inconsistent with the specified value,
replace the valve spring.
Overall
length
Measure the deviation of valve spring

with the steel square. Maximum
deviation:1.6mm. If the measured
deviation is more than the maximum
value, replace the valve spring.
Deviation
Measure the intake valve stem
diameter with the micrometer
screw gauge. Intake valve stem
diameter:5.465~5.480mm. If the in-
take valve diameter is inconsistent
with the specified value, check the oil
clearance.
5-38
Measure the exhaust valve stem

diameter with the micrometer
screw gauge. Exhaust valve stem
diameter:5.455~5.470mm. If the ex-
haust valve diameter is inconsistent
with the specified value, check the oil
clearance.
(11) Check the intake valve guide.
Measure the inner diameter of the

intake valve guide with the calli-
pers. Inner diameter of intake valve
(10) Check the exhaust valve.
guide:5.510~5.530mm.
Scrape off the deposited carbon on
the top of the exhaust valve with the
gasket scraper.
Subtract the measured diameter of the

intake valve stem from the measured
inner diameter of the intake valve
Measure the full length of exhaust valve with guide.
the vernier caliper.
Standard oil clearance: 0.03~ 0.065mm.
Standard full-length:101.15 mm.
Maximum oil clearance:0.080mm.
Minimum full-length:100.70 mm.
If the clearance is more than the maximum
If the full-length is less than the minimum value, replace the intake valve and the intake
value, replace the exhaust valve. valve guide.
(12) Check the exhaust valve guide.
Measure the inner diameter of the

exhaust valve guide with the calli-
pers. Inner diameter of exhaust valve
guide:5.510~5.530mm.
Overall
length
5-39
Subtract the measured diameter of If the oil clearance is more than the maximum
the exhaust valve stem from the mea- value, replace the tappet. If necessary, re-
sured inner diameter of the exhaust place the cylinder head.
valve guide.
(14) Check the cylinder-head bolts.
Standard oil clearance:0.04~0.075mm.
Measure the length from the bolt seat
Maximum oil clearance: 0.100mm. to the bolt end of the cylinder-head
bolt with the vernier caliper.
If the clearance is more than the maximum
value, replace the exhaust valve and the ex-
haust valve guide.
Length
(13) Check the tappet.
Measure the tappet with the microm-

eter screw gauge. Tappet diameter:
30.959~30.975mm.
Standard bolt length:141.2~142.8mm.
Maximum bolt length:144.2mm
If the bolt length is more than the maximum

value, replace the cylinder-head bolts.
2.6.22 Removal of cylinder block frame
1) Remove the oil filter with the special

Measure the diameter of the tappet tool.
hole of the cylinder-head with the cal-
2) Remove the connecting threaded-pipe
lipers.
of the oil filter. Remove the NPT 3/8
Standard diameter of tappet hole: plug.
31.000~31.025mm.
3) Remove the O-ring from the cylinder
block frame.
4) Remove the 11 bolts from the cylinder

block frame. Pry up the cylinder block
frame carefully by applying the screw-
driver with its tip wrapped with adhesive
tape to the reserved action points on
the joint surfaces between the cylinder
block frame and the cylinder block, and
remove the cylinder block frame.
Subtract the measured tappet diam-

eter from the measured tappet hole
diameter.
Maximum oil clearance:0.080mm.
5-40
ing-rod bolts, and then put back the

connecting-rod cap and screw in the
bolts. Tightening torque: 25 N · m, Turn-
ing by 90°.
(4) Remove the 2 connecting-rod bolts and

remove the connecting-rod cap and
connecting-rod bearing shell.
(5) Measure the oil clearance at the widest

position of the plastigauge.
Note: After completion of measurement,

remove the plastigauge on the journal
FRPSOHWHO\
5) Remove the rear oil seal of the crank-

(6) If the measured value is more than the
shaft.
allowed maximum clearance, replace
6) Remove the plane sealant thoroughly the connecting-rod bearing shell of the
on the cylinder block frame and cylinder same group. If after replacement of
block with a blade. connecting-rod bearing shell, the mea-
sured value is still more than the al-
Note: Be sure to avoid scratch to the joint lowed maximum clearance, replace the
surfaces of the cylinder block and the crankshaft.
F\OLQGHUEORFNIUDPH%HVXUHWRZUDSWKH
screwdriver with adhesive tape before us- Group number for connecting-rod bear-
LQJLW ing shell=2-Group number for crankshaft
connecting-rod journal+Group number for
7) Check the cylinder block frame for connecting-rod big-end hole
crack or other damage. Check the oil
passage for impurities or clogging. For key dimensions and grouping of crank-
shaft connecting-rod journal, connecting-rod
2.6.23 Removal and inspection of piston and hole and connecting-rod bearing shell, see
connecting-rod assembly the attached Table B.2.
1) Check the axial clearance of con- 3) Check the inner diameter of connect-
necting-rod big end. Standard axial ing-rod big-end hole and the thickness
clearance:0.16~0.362mm. of connecting-rod bearing shell.
2) Check the oil clearance of connecting- (1) Check the inner diameter of connect-
rod big end. ing-rod big-end hole in the direction as
Note: Don’WURWDWHWKHFUDQNVKDIW
Standard inner diameter: ¶51.000~¶
(1) Remove the 2 connecting-rod bolts and
remove the connecting-rod cap and 51.015mm. If the measured value is beyond
connecting-rod bearing shell, and then this range, replace the connecting-rod.
clean them.
(2) Put a plastigauge on the connecting-

rod journal.
(3) Coat oil onto the thread of the connect-
5-41
the cylinder sequence and put them in place.
7) Remove the round wire snap rings for

hole.
Pry up the 2 round wire snap rings for hole

with the screwdriver.
(2) Measure the thickness of connecting-

rod bearing shell with a micrometer.
Standard thickness:1.504~1.516mm. If
the measured value is inconsistent with
the above-mentioned value, replace the
connecting-rod bearing shell.
Note: Be sure to avoid scratch to the pis-

WRQSLQKROH
8) Remove the piston pin hole.
(1) Heat the piston up to 80~90°C gradu-

ally.
(2) Push the piston pin out of the piston pin

hole, and remove the connecting rod.
4) Check the connecting-rod bolts. Note: Because the piston and piston pin
are in pairs, be sure to put the piston, pis-
Measure the diameter of the connecting-rod ton pin, piston rings, connecting rod and
bolt shank with a vernier caliper. There are EHDULQJVKHOOVLQDSURSHURUGHU
two types of bolts, with a minimum diameter
of ¶8.3mm or ¶7.5mm, respectively. 9) Check the piston.
5) Remove the connecting rod. (1) Clean up the deposited carbon on the
piston with a used piston ring or other
Push the piston and connecting-rod assembly similar tool.
as well as the connecting-rod bearing shell
(upper) to allow it to pass through the cylin- (2) Remove the residual deposited carbon
der bore. Take out the piston and connecting- on the piston with special solvent.
rod assembly from the upper end face of the Note: When operating, be sure to wear a
cylinder block. In turn, take out the four piston SDLURISURWHFWLYHJODVVHV0HDQZKLOHPDNH
and connecting-rod assemblies. VXUHWRDYRLGVFUDWFKWRWKHSLVWRQVXUIDFH
Note: Install the removed connecting rod (3) Measurement of piston skirt.
DQGFRQQHFWLQJURGEHDULQJVKHOOLQSODFH
Mark the piston and connecting-rod as- As shown in the figure, perpendicular to the
semblies based on the cylinder sequence, piston pin, at a distance 12mm from the pis-
DQGSXWWKHPLQSODFH ton bottom, measure the size of piston skirt.
Piston skirt diameter:¶88.469~88.489mm.
6) Remove the piston ring kit.
After removal, mark the components based on
5-42
Group number 3iston-pin hole

A ¶22˄+0.001, +0.004˅
B ¶22˄+0.004, +0.007˅
C ¶22˄+0.007, +0.010˅
If the piston-pin hole diameter is inconsistent

with the specified value, replace the piston.
(4) Check the piston ring play. Measure the piston-pin diameter with a mi-
crometer. Standard piston-pin diameter:
Insert a new piston ring into the piston ring
groove and check the clearance in the piston ¶21.997~¶22.006Ǆ
ring groove with a feeler.
Group number 3iston pin
Standard clearance A ¶22˄-0.003, 0˅
Item
(mm)
1st compression ring 0.03 ~ 0.07 B ¶22˄0, +0.003˅
2nd compression ring 0.02 ~ 0.06 C ¶22˄+0.003, +0.006˅
Oil ring 0.05 ~ 0.17

If the piston-pin diameter is inconsistent with
the specified value, replace the piston pin.
If the measured clearance is more than the
maximum valve, replace the piston. Measure the connecting-rod small-
end diameter. Standard connecting-
(5) Measure the end gap of piston. rod small-end diameter:
Push a piston ring into the cylinder ¶22.005~¶22.014Ǆ
with the piston to allow it to exceed
the bottom of piston ring travel a little, Connecting-rod
i.e., at a distance 110mm from the cyl- Group number
small-end hole
inder deck. A ¶22˄+0.005, +0.008˅
Measure the piston ring end gap with B ¶22˄+0.008, +0.011˅
a feeler. Top ring: 0.20~0.35mm. C ¶22˄+0.011, +0.014˅
Second ring: 0.30~0.45mm.
If the connecting-rod small-end diameter is
If the end gap is more than the maximum inconsistent with the specified value, replace
value, replace the piston ring. the connecting rod.
If after using a new piston ring, the end gap Subtract the measured piston-pin diameter
is still more than the maximum value, replace from the measured piston-pin hole diameter.
the cylinder block. Standard oil clearance:0.001~0.007mm.
(6) Check the piston-pin oil clearance. Maximum oil clearance: 0.010mm.
Measure the diameter of piston-pin If the measured oil clearance is more than the
hole. maximum value, replace the piston. If neces-
sary, replace the piston and piston pin set.
Standard piston-pin hole diameter:
Subtract the measured piston-pin
¶22.001~¶22.010Ǆ
diameter from the measured connect-
ing-rod small-end hole diameter. Stan-
dard oil clearance:0.005~0.011mm.
5-43
If the measured oil clearance is more than the completely.

maximum value, replace the connecting rod.
If necessary, replace the connecting rod and Calculation of main bearing shell group num-
piston pin set. ber: Bearing shell group number=3-Main
journal group number +Main bearing cap hole
2.6.24 Removal and inspection of crankshaft group number, see the attached Table B.1.
assembly
3) Measure the round run-out of main
1) Prize the crankshaft back and forth with journal.
a screwdriver. Measure the crankshaft
axial clearance with a feeler. Measure the crankshaft main journal with 2
V-shaped blocks and a micrometer.
Standard axial clearance:0.04~0.24mm.
Allowed maximum run-out:0.04 mm;
Maximum thrust clearance:0.30mm.
If the measured value exceeds this range, re-
If the measured clearance is more than the al- place the crankshaft.
lowed maximum valve, replace the thrust plate.
If after replacing the thrust plate, the measured 4) Measure the diameter of each main
clearance is still more than the allowed maxi- journal with a micrometer.
mum valve, replace the crankshaft. Range of diameter: 54.937~54.955mm.
2) Measure the oil clearance of main jour-
nal.
Note: Don’WURWDWHWKHFUDQNVKDIW
(1) Unscrew the 10 main bearing cap bolts

in several steps, and remove the 5
main bearing caps.
(2) Check the inner surface of main bear-

ing shell, main journal and crankshaft
for pitting and scratch, and then clean
them. 5) Check the roundness and cylindricity of
main journal. Allowed maximum round-
(3) Put a plastigauge on the main journal ness and cylindricity:0.005mm and
of each crankshaft. 0.0065mm, respectively.
(4) Put back the main bearing cap. Screw If the calculated result is more than the above-
in the 10 bolts in the order from the mentioned value, replace the crankshaft.
middle to both sides in several steps
with a tightening torque of 20 N·m , 40 6) Measure the diameter of each connect-
N·m, and then turn 90°. ing-rod journal with a micrometer. Stan-
dard diameter:47.940~47.955mm. If the
(5) Remove the main bearing cap. measured value exceeds this range, re-
place the crankshaft.
(6) Measure the widest point of oil clear-
ance with the plastigauge. 7) Check the roundness and cylindricity of
connecting-rod journal. Allowed maximum
Standard oil clearance:0.036~0.058 mm.
roundness and cylindricity:0.005mm and
Maximum oil clearance:0.060mm. 0.0065mm, respectively. If more than the
above-mentioned value, replace the crank-
If the oil clearance is more than the maximum shaft.
value, replace the main bearing shell. If nec-
essary, replace the crankshaft. After comple-
tion of measurement, remove the plastigauge
5-44
Filter screen
Shim
Screw
plug
3) Remove the oil cooling nozzle.

8) Check the crankshaft thrust plates. Remove the bolts and oil cooling nozzle with
the hexagon head wrench.
Measure the thickness of crankshaft
thrust plate with a micrometer. Standard
thickness:1.95~2mm.
If the measured result is inconsistent with the

above-mentioned value, replace the crank-
shaft thrust plate.
2.6.25 Removal and inspection of cylinder

block assembly
1) Remove the water-jacket outer wall of

cylinder block.
4) Remove the studs from the cylinder
Take out the water-jacket outer wall of cyl- block.
inder block with the needle-nose pliers. Re-
move the two plugs of water-jacket outer wall. 5) Check the cylinder block.
Note: If it is necessary to turn over the (1) Clean the joint surfaces of the cylinder
cylinder block, make sure to remove the block with the timing cover, cylinder
ZDWHUMDFNHWRXWHUZDOO¿UVWO\ head and cylinder block frame.
Note: When operating, be sure to wear

D SDLU RI SURWHFWLYH JODVVHV 0HDQZKLOH
make sure to avoid scratch to the cylinder
block surface, especially, the joint surfac-
es of the cylinder block with other compo-
QHQWV'RQ’t allow any impurity to fall into
WKHZDWHUMDFNHWRIF\OLQGHUEORFN
(2) Check the flatness of the upper face of

cylinder block.
2) Remove the strainer screen fitting of Maximum flatness value:0.05 mm.
filter.
If the measured flatness is more than this
Remove the screw plug and gasket with the value, replace the cylinder block.
hexagon wrench. Remove the strainer screen
of filter. Check the strainer screen for damage (3) Check the cylinder bore.
and clean it. Measure the cylinder bore diameter
with an inside micrometer.
At a distance 10mm, 70mm or 110mm
5-45
from the cylinder deck, measure the Front side Lower side
cylinder bore diameter once in the

horizontal and longitudinal directions,
respectively.
Standard diameter : ¶88.500 ~ ¶

Rear side
88.520mm.
Calculate the average of the measured

values of each cylinder. If the average
is more than the allowed maximum
Standard bulge
value, replace the cylinder block. Item Bulge
Pin A
Extruding
Pin B
height
Check the piston oil clearance. Pin C
Pin D
Subtract the measured piston diameter

from the measured cylinder bore diam-
eter.
Standard oil clearance:0.021~

0.041mm.
If the oil clearance is oversized, replace

the piston. If necessary, replace the cyl-
inder block.
Standard bulge
Extruding Item Bulge

27 Installation of engine assembly height Pin A
Pin B
2.7.1 Installation of cylinder block assembly
1) Clean the components of engine thor- 4) Install the double end studs of the cylin-
oughly. Make sure that there is no der block.
impurity in the oil passages or water
channels. Install the double end studs of the thermostat
cover, heater water-return pipe and water
2) Install the oil cooling nozzle. pump with a tightening torque: 5 N · m.
Before installation, lubricate the mounting 5) Install the oil filter cluster.
valve of the oil cooling nozzle. Screw in the 4
hexagon socket cap head screws (M6 × 12). Install the strainer screen fitting, gasket and
Tightening torque: 7 N.m screw plug of the filter in the main oil pas-
sage. Coat the screw plug with thread seal-
ant. Tightening torque: 30N.m.
Filter screen components
Front
engine(the
side with water
pump scroll
casing)
Gasket
Screw plug
3) Install the positioning cylindrical pin.
Install the positioning cylindrical pin in place 6) Assemble the main bearing shell.
at the position as shown in the figure. Install the main bearing shell (upper) with oil
5-46
groove. Meanwhile, coat the right amount of No interchangeable or wrong mounting

gasoline engine oil onto the friction surface of direction is permitted. Also, be sure to
the main bearing shell (upper). Before instal- allow the positioning rabbets of main
lation, check the friction surface of the main bearing shells to be located at the same
bearing shell. If any pitting or scratch is de- side. Before installation, check the fric-
tected, replace the main bearing shell. Select tion surface of the main bearing shell.
the main bearing shell according to the at- If any pitting or scratch is detected,
tached Table A.1. replace the main bearing shell. Select
the main bearing shell according to the
Note: Don’t install the upper and lower attached Table B.1.
EHDULQJVKHOOVUHYHUVHO\%HVXUHWRDYRLG
VFUDWFKWRWKHEHDULQJVKHOOVXUIDFH (2) Tighten the main bearing cap to the
specified torques in the order as shown
in the figure. Pre-tighten with a torque
of 20 N·m, and then tighten with a
torque of 40 N·m and turn 90°.
2.7.2 Installation of crankshaft cluster
1) Install the crankshaft.
When installing the crankshaft, make sure to Note: Before screwing in the bolts of main
allow the crankshaft main journal to be con- bearing cap, be sure to coat some oil onto
sistent with the main journal mounting pedes- WKHEROWWKUHDG
tal in the cylinder block. 4) After completion of assembly, rotate the
2) Install the crankshaft thrust plates. crankshaft. Make sure that the crank-
shaft can turn freely and smoothly.
After installing the crankshaft thrust plates, be
sure to paint the right amount of gasoline en- 5) Install the half-round key in the crank-
gine oil into their oil grooves. shaft.
Note: Make sure to enable the oil groove 2.7.3 Installation of piston and connecting-
surfaces of the two thrust plates to face rod assembly
WKHFUDQNDUP 1) Select new round wire snap rings for
3) Install the main bearing cap. hole. Install the round wire snap ring for
hole at the end of piston pin hole. Stag-
(1) Install the main bearing shell (lower) ger the end notch of the snap ring with
into the main bearing cap. Meanwhile, the notch portion of the piston pin hole.
coat the right amount of gasoline en-
gine oil onto the friction surface of the
main bearing shell. Assemble the main
bearing cap according to the number of
bearing seat. Make sure to enable the
arrow mark on the main bearing cap to
direct to the front end of cylinder block
(i.e., the end with water-pump volute).
5-47
Type mark faces up
2) Heat the piston up to 80~90°C. Make

sure to allow the front end marks on
the piston and connecting-rod to be at (3) Adjust the joint directions of the piston
the same side. Push into the piston pin rings, as shown in the figure.
quickly, and then install the snap ring at Bush ring open mouth
another end in place. 2nd compression Wiper ring
ring
Forward mark
Front engine Piston pin center
Round indentation
mark on the top of
piston
Wiper ring 1st

compression
ring
4) Install the connecting-rod bearing shell

(upper) in place. Coat the right amount
of gasoline engine oil onto the friction
Note: Both the forward mark on the pis-
surface of the connecting-rod bearing
ton crown and that on the connecting-rod
shell (upper). Allow the forward mark
VKRXOG IDFH WKH VDPH GLUHFWLRQ 'XULQJ
on the piston head to face towards the
installation, be sure to coat some gasoline
front end of engine. Install the piston
engine oil onto the piston pin and the pis-
into the cylinder with the special tool.
WRQ SLQ KROH$IWHU FRPSOHWLRQ RI DVVHP-
Before installation, check the friction
bly, make sure that the piston can swing
QDWXUDOO\ XQGHU LWV RZQ ZHLJKW 1R VWLFN-
shell. If any pitting or scratch is detect-
LQJLVSHUPLWWHG
ed, replace the connecting-rod bearing
3) Assembly of compression rings and shell. Select and match the connecting-
composite type oil ring rod bearing shell according to the at-
tached Table B.2.
(1) Install the composite type oil ring at
first.
Note: Make sure to make the expander

MRLQWEXWW1RRYHUODSSLQJLVSHUPLWWHG
(2) Install the top ring and second ring

into the piston ring grooves. Be sure to
make the factory mark on the notch of
ring side face towards the piston crown.
5-48
5) Install the connecting-rod bearing shell

(lower) in place. Coat the right amount
of gasoline engine oil onto the friction
shell (lower). Put back the connecting-
rod big-end cap. Coat a little oil onto the
connecting-rod bolt thread. Screw the
connecting-rod bolts into their mounting
holes with a tightening torque of 25 N·m,
and then turn 90°.
6) After completion of installation, try to ro-

tate the crankshaft freely and smoothly. Note: After completion of tightening, wipe
Make sure that the connecting-rod RIIWKHVXUSOXVVHDODQW
big-end axial clearance is between
0.160mm~0.362mm. No interference or 3) Coat thread sealant onto the NPT 3/8
sticking is permitted. plug, and screw it into its mounting hole
in the cylinder block frame with a torque
7) Turn the half-round key to the horizon- of 25 N·m.
tal position with the crank bolt cluster.
4) Select a new connecting threaded pipe
2.7.4 Installation of cylinder block frame for the oil filter. Coat thread sealant
onto the thread portion contacting with
1) Wipe the joint surfaces between the
the cylinder block. Screw the new con-
cylinder block frame and cylinder block
necting threaded pipe into its mounting
with alcohol. Coat plane sealant as
hole in the oil filter of the cylinder block
frame.
Note: No breakpoint is permitted when Oil filter connecting

threaded -pipe
FRDWLQJ SODQH VHDODQW %H VXUH WR LQVWDOO
WKHF\OLQGHUEORFNIUDPHZLWKLQPLQXWHV
DIWHU FRDWLQJ WKH VHDOLQJ PDWHULDOV ,W LV
recommended to start the engine 2 hours
after installing the cylinder block frame in 5) Press the rear oil seal of crankshaft into
SODFH the mounting hole formed by the cylin-
der block and the cylinder block frame.
2) Make sure that the positioning cylindri-
cal pin has been installed in the cyl- 2.7.5 Installation of water-jacket outer wall
inder block. According to the order as and cylinder-head gasket
shown in the figure, tighten the 11 bolts
with a tightening torque of 25 N·m. 1) Make sure to install the 2 plugs in place
before installation of water-jacket outer
wall. When installing the plugs, be sure
to lubricate them. Align the outer wall
with its mounting position and install it
into the cylinder block water-jacket.
5-49
(1) Measure the diameter of valve guide

hole in the cylinder head with the cal-
lipers.
Standard diameter:10.3~10.318mm.
Alignment
position (2) Shrink the valve guide with cold liq-
uid nitrogen before pressing it into the
Drain plug valve guide hole in the cylinder head.
Note: Be sure to distinguish intake valve

2) Install the two hollow cylindrical pins JXLGHV IURP H[KDXVW YDOYH JXLGHV 7KH
onto the cylinder deck. Install a new LQWDNHYDOYHJXLGHLVPPORQJDQGWKH
cylinder-head gasket by aligning with H[KDXVWYDOYHJXLGHLVPPORQJ
the positioning pins.
(3) Press the valve guide to the specified
standout height use the special tool.
Standout height:9.8mm~10.2mm.
Extruding
height
Note: Make sure to align the oil holes and

water holes of the cylinder-head gasket
ZLWKWKRVHRIWKHF\OLQGHUGHFN%HVXUHWR
(4) Ream the valve guide with a sharp
PDNHWKHLUPDUNVIDFHXSZDUGV1RUHYHU-
reamer of 5.5mm to enable the clear-
VDOLQVWDOODWLRQLVSHUPLWWHG
ance between the valve guide and
2.7.6 Installation of heater water-return pipe valve stem to reach the standard speci-
fied value. For intake valves, Speci-
1) Replace the gasket with a new one. fied clearance:0.030mm~0.065mm,
Install the heater water-return pipe and Maximum clearance: 0.08mm;
its gasket. Tighten the two nuts and one For exhaust valves, Specified
bolt with a tightening torque of 10 N·m. clearance:0.040mm~0.075mm, Maxi-
mum clearance: 0.1mm.
2) Replace the intake/exhaust valve oil

2.7.7 Installation of cylinder head assembly
seals with new ones. Coat lubricating
1) Installation of valve guide oil inside the oil seals. Press the valve
5-50
oil seal into the valve guide with the

special tool and be sure to make the oil
seal planish.
Note: The intake valve oil seal is green,

EXW WKH H[KDXVW YDOYH RLO VHDO LV EURZQ
The intake valve oil seal is not to be con-
IXVHGZLWKWKHH[KDXVWYDOYHRLOVHDO
Wrong
Correct
Note: When installing the cylinder-head

bolt washer, be sure to make the face with
a larger corner of the washer’s outer ring
upward in order to install the washer onto
WKH FRQFDYH RI WKH EROW KROH 1R LQFOLQD-
WLRQLVSHUPLWWHG
3) Coat gasoline engine oil onto the in-
take/exhaust valve stem before install- 8) Install the two cylinder-head plugs.
ing it into its valve guide hole. After Coat thread sealant onto the cylinder-
installation, try to move it up and down head plugs before screwing them into
to check whether it can slide smoothly. the mounting threaded hole, and then
tighten them to 86 N·m.
4) Install the valve spring seat (lower).
Make the valve spring seat (lower) level
with the screwdriver.
5) Install the valve spring, and then put

the valve collets in pair into the valve
spring seat (upper). Align the valve
spring seat (upper) with the valve stem
and install it into the valve spring with
the special tool.
6) Be sure to check and measure the

separately-installed cylinder-head as- 9) As shown in the figure, install the dou-
sembly through valve flapping with the ble end studs. Tighten the M6 studs to
leak testing instrument. 5 N· m and tighten the M8 studs to 10 N·
m.
7) Install the cylinder-head bolt washers.
Coat a little engine oil onto the cylinder- Front side
Upside
head bolt thread. Screw in the cylinder-

head bolts. According to the order as
shown in the figure, pre-tighten the
bolts to 30 N·m, and then tighten them Intake side Exhaust side
to 70 N·m and turn them to 90°.
5-51
2.7.8 Put the adjusted tappet into the cylin- 3) Coat a layer of engine oil onto the
der-head tappet hole in the specified camshaft journal, and install it onto the
order. cylinder head. Put back the camshaft
bearing caps in the specified order, and
2.7.9 Install the intake and exhaust cam- tighten them in the order as shown in
shafts separately. the figure. Bearing cap(first journal):30
1) Installation of intake VVT cluster N·m, others:9 N·m.
Put the camshaft timing gear together Intake

with the camshaft. Allow the straight
pin to misalign with the key groove, as
Straight pin
Key slot
Rotate the camshaft timing sprocket.

Meanwhile, push it to the camshaft
Intake
lightly. Press it further at the position
where the straight pin is inserted into
the key groove. 4) Tighten the intake/exhaust camshaft
sprocket bolts. Tightening torque (N ·m)
Note: Never turn the camshaft timing gear
LQWKHGHOD\GLUHFWLRQ ULJKWDQJOH 2.7.10 Inspection of intake/exhaust valve
clearance (see Section 2.3 in Chapter
Check the clearance between the
II)
sprocket and camshaft. Tighten the
timing sprocket bolts to 54N·m. 2.7.11 Installation and adjustment of timing
mechanism (see Section 2.4 in Chap-
Check whether the camshaft timing
ter II)
sprocket can be moved to the delay
angle side (right angle)and be locked 2.7.12 Installation of oil pump assembly (see
to the most delay position. Section 3.3 in Chapter III)
2) Install the camshaft bearing shell onto 2.7.13 Installation of front bracket cluster
the intake camshaft journal (first).
Align the front bracket cluster (including
double end studs) with the mounting holes
of the timing cover and cylinder head. Screw
in the bolts and tighten them to the specified
torques. 54 N·mǄ
5-52
2.7.14 Installation of water-pump assembly
1) Install the water pump assembly.
(1) Remove any sealing material on the

contact surfaces.
(2) As shown in the figure, coat seal- Note: After completion of installation of
ing materials within the continu - water pump, make sure that the water
ous coating line. Standard sealing pump can rotate smoothly without any ab-
diameter:2.2~2.5mm. QRUPDOQRLVH
Seal diameter 2) Mount the water pump pulley.
Install the water pump pulley with the assis-

tant tool T. Tighten the 4 bolts to the specified
torque in the crossed manner. Torqur: 26 N·m
Note
5HPRYH DQ\ RLO RQ WKH FRQWDFW VXUIDFHV

%HVXUHWRLQVWDOOWKHZDWHUSXPSZLWKLQ
PLQXWHV DIWHU FRDWLQJ VHDODQW 2WKHUZLVH
remove the newly-coated sealant thor-
RXJKO\DQGUHFRDWVHDODQW
2.7.15 Installation of oil pan assembly
(3) Install the water pump with the 4 bolts
and 2 nuts. According to the order as 1) Before installation of oil pan assem-
shown in the figure, tighten them to the bly, make sure that there is no oil or
specified torque. Torque: 9.0N·mǄ other impurity on the contact surface
between the oil pan and the cylinder
block frame. As shown in the figure,
coat plane sealant (with a diameter of
¶2.5mm~3.0mm) within the continu-
ous coating line of the oil pan group.
5-53
No breakpoint is permitted. Install the surface of the seal ring of the oil filter.
oil pan assembly within 3 minutes after
coating sealing materials. 3) Accordingly, screw in the connecting
threaded pipe to the end to the torque
of 13N·m. If the work environment is
not spacious enough to use a torque
Plane sealant
wrench, you can screw the oil filter
gently in the connecting threaded pipe
at first, until it adjoins the mounting sur-
face, and then screw in it to 3/4 ~1 turn
again.
2) As shown in the figure, install 2 guide

Special tool
pins at the corresponding points 7 and
13 of the cylinder block frame. Put
down the oil pan group along the guide
pins. Put the oil pan mounting bolts in
other 12 points and screw in the bolts
to 2~3 threads. Pull out the guide pins,
and put in two bolts and screw in them
to 2~3 threads.
2.7.17 Installation of tensioner cluster
3) As shown in the figure, tighten the 14
Install the tensioner cluster, tensioner cluster
bolts of the oil pan in sequence. Wipe
nuts, double end studs and tensioner cluster
off the surplus sealing materials extrud-
bracket retaining bolts.
ed with a clean cloth. Recommenda-
tion: Don’t start the engine until 2 hours Torque:
after installing the oil pan assembly in
place. 14 Tightening torque for the 14 Stud: 10 N.m
bolts: 9 N·m.
Nut:30 N·m.
Bolt:60 N·m.
2.7.16 Installation of oil filter assembly
1) Check and clean the mounting surface

of the oil filter. 2.7.18 Installation of crankshaft vibration-
damping pulley
2) Coat the right amount of oil onto the
5-54
1) First, as shown in the figure, coat plane Bolt A: 52 N.m

sealant onto the corresponding position
on the crankshaft vibration-damping Bolt B: 21 N.m.
pulley. And then align the key groove in
the crankshaft vibration-damping pulley
with the position of the half-round key
at the front end of the crankshaft be-
fore installing the crankshaft vibration-
damping pulley.
Plane sealant wire
2.7.21 Installation of multi-wedge belt
Put the sleeve on the hexagon head of the

2) Coat sealant onto the root of the crank- tensioner cluster. Compress the tensioner
shaft pulley bolt cluster, as shown in the cluster clockwise with the wrench, and then
figure. And then, install the crankshaft install the multi-wedge belt in place. Release
pulley bolt cluster onto the front end of the tensioner slowly to tension the belt, as
the crankshaft, and tighten the crank- shown in the figure. After completion of instal-
shaft pulley bolt cluster. Torque: 170 lation, check whether the multi-wedge belt
N.m can fit with each pulley. No multi-wedge belt
outside pulley groove is permitted.
Surround a round of plane

sealant wire on the back and
front of gasket
Hex head of
Tension mechanism
assembly
2.7.22 Installation of spark plugs

2.7.19 Installation of power steering pump
Install the spark plug into the spark plug hole.
Install the power steering pump. Make sure that the spark plug gap is between
1.0mm~1.1mm. Torque:25 N·m
2.7.20 Installation of engine assembly
2.7.23 Installation of cylinder-head cover
Install the alternator and two bolts. cluster
Torque: 1) As shown in the figure, coat the joint
surfaces of the cylinder head and tim-
5-55
ing cover with sealant. Make sure to al- 2.7.25 Installation of flywheel cluster
low the colloid diameter to be between
3mm~4mm. 1) Make sure that the surface of flywheel
cluster is clean. No oil dirt is permitted.
Note: Remove any oil on the contact sur- Before installation, make sure that the
IDFHV 0DNH VXUH WKDW WKHUH LV QR RLO RU flywheel positioning pins (M6 × 12) on
impurity on the contact surfaces of the the crankshaft have been installed in
cylinder head and timing cover before place.
FRDWLQJ VHDODQW RQ WKHP$IWHU FRDWLQJ
plane sealant, be sure to perform instal- 2) Put the flywheel cluster in place.
ODWLRQ ZLWKLQ PLQXWHV 2WKHUZLVH LW LV 3) Install the 8 bolts which have been pre-
proper to remove the used residue and recoated with the right amount of anaero-
FRDWVHDODQW$IWHULQVWDOOLQJWKHF\OLQGHU bic thread sealant into the flywheel. Fix
head cover, don’t add oil to the engine the crankshaft with the special assis-
XQWLOKRXUVODWHU tant tool. Tighten the bolts to the speci-
fied torque in the diagonal direction in
several steps with the cross method, as
shown in the figure. Torque: 98 N · m.
2) Align the cylinder-head cover with its

gasket well-installed with its positioning
studs, and then install the cylinder-head
cover in place. As shown in the figure,
install the cylinder-head cover bolts in
the order.
Torque:
Bolts 1 and 2: 14 N · m;
Nut 9, 12: 9 N.m
Nut 4, 6, 8, 10: 9 N.m 2.7.26 Installation of clutch plate assembly

and clutch cover assembly
Other bolts: 11 N.m
Before installation, check and make sure
that there is no oil dirt on the joint surfaces
of the flywheel and friction linings. Using the
special assistant tool, install the clutch plate
assembly and clutch cover assembly. When
installing the clutch cover assembly, align its
3 positioning pin holes with the 3 positioning
pins of the flywheel ring gear before installing
the hexagon socket cap head screws (M8 ×
2.7.24 Installation of ignition coil 25)separately. Tighten the screws diagonally
and evenly in several steps with the cross
Install the ignition coil assembly with the 4 method. Tightening torque: 40 N.m
bolts. Torque: 9.0 N·mǄ
5-56
Install the coolant temperature sensor with

the tool T. Tightening torque: 20 N.m
2.7.27 Installation of camshaft phase sensor

2.7.29 Installation of oil pressure switch
1) Coat the O-ring of sensor with a thin
layer of engine oil. 1) Coat the oil pressure switch with thread
sealant.
Note: Before installation, make sure that
WKH2ULQJLVSHUIHFWRUQRWH[WUXGHG
Tread seal
O - ring
2) Install the oil pressure switch with a
long socket wrench. Torque: 15 N · m.
Note: Don’t start the engine within 1 hour

2) Install the camshaft phase sensor with DIWHULQVWDOODWLRQ
the bolt. Tightening torque: 9 N.m
Engine oil
pressure switch
Coolant Temp Sensor
2.7.28 Installation of coolant temperature
sensor
5-57
2.7.30 Installation of knock sensor
1) Install the knock sensor with the double

end stud. Torque:10 N·m.
2) As shown in the figure, assemble the

knock sensor in place and tighten its Throttle valve
nut. Torque: 20 N · m.
Upper part
2.7.33 Installation of OCV valve

Front part 1) Coat the O-ring of the OCV valve with a
of engine
thin layer of engine oil.
Note: If there is any damage to the O-ring,

UHSODFHLW
2.7.31 Installation of intake manifold cluster

New O-ring
1) Install the intake pressure and temper-
ature sensors onto the intake manifold.
2) Install the 2 double end studs with a

torque of 10 N·m.
3) Align the intake manifold equipped with

its washer with the 2 studs on the cylin-
der head to install the intake manifold. 2) Install the OCV valve with the bolts.
According to the order as shown in the Torque: 9.0 N · m.
figure, tighten the 5 bolts and 2 nuts of
the intake manifold and ensure its air-
tightness. Torque:30 N· m.
2.7.34 Installation of PCV system
1) Install the seal ring of the PCV valve

into the cylinder-head cover.
2.7.32 Installation of throttle
2) Screw in the PCV valve slowly into its
1) After completion of installation of its
seal ring, and connect the intake mani-
washer, install the throttle to the posi-
fold with the PCV valve through the
tion as shown in the figure. Tighten the
PCV breather pipe fitting and clamp it
throttle bolts diagonally and ensure its
with the wire-type elastic hoop.
airtightness.
5-58
Transition joint Fuel distributor
2.7.37 Installation of thermostat assembly
1) Before installation of thermostat, in-

stall the two double end studs in place.
2.7.35 Installation of fuel evaporative emis-
Torque: 5 N · m.
sions control system assembly
2) Install the thermostat into its seat in the
1) Install the canister control valve bracket
cylinder block. As shown in the figure,
in place, as shown in the figure, and
make the ventilation valve upward.
tighten the bracket bolts. Tightening
It is recommended to set the ventila-
torque: 9 N.m
tion valve within a range at an angle of
Canister control
valve bracket
10°to both sides of the specified posi-
tion.
Upwards
Vent valve
2) Fit the canister control valve and its
mounting sleeve into the bracket. Con-
nect the canister control valve with the
intake manifold through the canister
connecting pipe, and clamp it with the
wire-type elastic hoop. 3) Install the thermostat cover and tighten
its nuts. As shown in the figure, be sure
3) Fit the vacuum booster bracket into the to make the thermostat cover’s bending
intake manifold cluster bracket, and angle downward. Torque:9 N·m.
tighten the bolts. Torque:9 N·m.
2.7.36 Installation of fuel distributor assembly
As shown in the figure, aligning to the posi-

tion of cylinder-head interface, install the 2
transition joints. Align the injector with the fuel
injection hole in the cylinder head and insert
it. Before insertion of injector, coat the injector
seal ring with a little grease, and tighten the
bolts. Tightening torque: 20 N.m
5-59
2.7.38 Installation of oil dipstick assembly
1) Coat the O-ring of the dipstick tube with

a little of lubricating oil before installing
the dipstick tube.
2) Insert the dipstick tube into its seat on

the cylinder block frame. Align the bolt
mounting holes of the tube bracket with
Oxygen sensor
the corresponding bolt holes of the mounting position
heater water-return pipe flange before
tightening the bracket bolts. Tightening
torque: 9 N.m
3) Coat the O-ring of the dipstick with a

little of lubricating oil. Insert the dipstick
into its tube and make sure that the 4) Install the exhaust manifold heat shield
dipstick can be pulled out and inserted I onto the exhaust manifold, and tighten
smoothly. the bolts. Tightening torque: 25 N.m
2.7.39 Installation of exhaust manifold and its 5) Install the two exhaust manifold
heat shield brackets(left and right) in place and
tighten the nuts and bolts. Tightening
1) Install the front oxygen sensor in place. torque: 44 N.m
Its mounting position is shown in the
figure. Tighten it to the specified torque. 2.7.40 Installation of starter and crankshaft
Torque: 44 N · m. position sensor Install the starter in the
position as shown in the figure with the
2) Install the exhaust manifold heat shield two bolts. Torque: 39 N · m.
II and three-way catalytic converter
heat shield onto the exhaust manifold,
and tighten the bolts.
3) When installing the exhaust manifold,

make sure that the 5 studs have been
installed in place. Align the new ex-
haust manifold gasket with the studs
and fit into it. Be sure to make the gas-
ket face with a mark outward. And then
install the exhaust manifold in place.
According to the order as shown in the
figure, tighten the nuts to ensure its air-
tightness. Torque: 37 N · m.
Install the crankshaft position sensor with one

bolt. Torque:9 N·m.
5-60
Section Lubricativng system ZLWKVRDSDQGZDWHULPPHGLDWHO\

To protect the environment, be sure
1 Checking engine oil level to put waste oil and filter in the
VSHFL¿HGSODFH
3.1.1 Make sure the car is parked on level
ground. Let the engine run for several 3.3.1 Lift the car levelly with a lifter or park
minutes. And then shut off the engine the car over the ditch.
to wait 5 minutes.
3.3.2 Remove the engine oil fill cap. Remove
3.1.2 Pull out the dipstick and look at the oil the oil drain bolt from the oil pan. Drain
level at the end of the dipstick. If it is the oil into an appropriate container.
between the A and B marks of the dip-
stick, the level is correct. If the level is 3.3.3 Put a new washer on the drain bolt with
at or below the lower mark, check for oil the flat side toward the engine, then
leakage. And then add oil to bring the reinstall the drain bolt. Tighten it to 40
level to the B mark. Nm.
Note: Don’WDGGRLOWRH[FHHGWKH%PDUN 3.3.4 Remove the oil filter with the special
tool.
Special tool
2 Checking engine oil quality

3.2.1 Check whether the engine oil is deterio- 3.3.5 Install a new oil filter.
rated, water polluted, thinning, discol-
ored or sour. If poor engine oil quality 1) Check and clean the mounting surface
is detected visually, replace the engine of the oil filter.
oil. 2) Coat the right amount of oil onto the
Oil grade: surface of the seal ring of the oil filter.
SJ grade and above 10W-30 (in spring, sum- 3) Accordingly, screw in the connecting
mer and autumn in the north and in each sea- threaded pipe to the end to the torque
son in the south) of 13N·m. If the work environment is
not spacious enough to use a torque
SJ grade and above 5W-30 ( used for North- wrench, you can screw the oil filter
ern regions in winter) gently in the connecting threaded pipe
at first, until it adjoins the mounting sur-
Replacement of the engine oil face, and then screw in it to 3/4 ~1 turn
again.
Note:
When the engine is hot, the oil tem- 4) Refill the engine with the recommended
perature is high, be sure to avoid oil.
VFDOGLQJ\RX
:DVWHRLOFDQEHFDUFLQRJHQLF$IWHU
replacement of oil, wash your skin
5-61
Engine oil change operating temperature. Adjust the en-

Item gine to the specified rotating speed.
capacity (L)
Replacing oil filter 4.3 And then measure the oil pressure to
170~550kPa˄3000r/min±50r/min˅.
Not replacing oil filter 4.1
Net refilling 5.0 Engine speed Oil 3ressure:
700±50r/min 80~170kPa
5) Reinstall the oil fill cap.
3000 r/min 170~550 kPa
6) Start the engine and check it for oil
leakage. 3.4.4 Install the oil pressure switch.
7) Check the engine oil level. If necessary, 1) Shut off the engine and let it cool down.
add oil to the engine.
2) Remove the oil pressure gauge and
Checking engine oil pressure commutator.
Note: When the engine is hot, its oil tem- 3) As shown in the figure, coat the oil
SHUDWXUH LV KLJK ZKLFK FDQ VFDOG \RX pressure switch thread with thread
Always shut off the engine and let it cool sealant.
GRZQEHIRUHSHUIRUPLQJRSHUDWLRQ
3.4.1 Remove the oil pressure switch.
4) Reinstall the oil pressure switch and

tighten it to 15N·m.
Note: After reinstalling the oil pressure

switch, don’t start the engine within 1
KRXU
3.4.2 Connect the oil pressure gauge with the
mounting hole of the oil pressure switch 5) Connect the oil pressure switch har-
through the special commutator. ness.
6) Start the engine and check it for oil

Oil pressure gauge
leakage.
5 Removal, inspection and installa-

tion of oil pump
3.5.1 Removal of oil pump
1) Removal of multi-wedge belt
2) Remove the oil fill cap and remove the

drain bolt from the oil pan, and drain
the oil into an appropriate container.
3.4.3 Run the engine until it reaches normal
5-62
3) Remove the alternator,tensioner clus-

ter, crankshaft vibration-damping pulley,
idler fitting and front bracket cluster.
4) Remove the ignition coil and remove

the PCV breather pipe fitting.
5) Remove the cylinder-head cover clus-

ter.
6) Remove the oil pan fitting.
7) Remove the chain tensioner.
8) Remove the timing cover.
(1) Remove the bolt(M6), 8 bolts(M8), 3

bolts(M10) and 2 nuts (M6) in the order
from outside to inside as well as from
both sides to the middle.
(3) Remove the plane sealant thoroughly

ing cover and the cylinder head or cyl-
inder block with a blade.
Note: Be sure to avoid scratch to the joint

surfaces of the cylinder block, cylinder
KHDG DQG WLPLQJ FRYHU :UDS WKH VFUHZ-
GULYHUZLWKDGKHVLYHWDSHEHIRUHXVLQJLW
9) Remove the seal ring from the cylinder

block frame.
10) Remove the front oil seal of crankshaft

from the timing cover.
Stud
11) Remove the oil strainer.
(2) Prize off the timing cover carefully by
12) Remove the oil pump cover.
applying the screwdriver to the joint
surfaces between the timing cover and 13) Remove the internal and external ro-
the cylinder head or the cylinder block. tors.
14) Remove the pressure-limiting-valve

spring seat, pressure-limiting-valve
spring and pressure limiting valve.
5-63
External
rotor
Internal
rotor
Engine oil
Front crankshaft
pump cover
oil seal
Relief
al e
Engine oil
collector
Relief valve
Timing spring
cover body
Pressure-limiting
valve spring seat
3.5.2 Inspection of oil pump
1) Check the clearance of the internal/

external rotor. The standard clearance
is between 0.13~0.18mm and the maxi-
mum clearance is 0.25mm.
3) Check the axial fit clearance between
If the measured clearance exceeds the maxi- the rotor and the oil pump body.
mum value, replace the rotor. The standard clearance is between
0.018~0.056 mm.
Maximum clearance:0.1mm.
If the measured clearance exceeds the maxi-

mum value, replace the rotor. If necessary,
replace the oil pump.
2) Check the radial fit clearance between 4) As for inspection of pressure limiting
the external rotor and the oil pump valve spring, apply a certain pressure
body. The standard clearance is be- to the spring and check the spring
tween 0.160~0.236 mm. height. If necessary, replace the pres-
Maximum clearance:0.32mm. sure limiting valve spring.
If the measured clearance exceeds the maxi- Pressure: 58.6N ± 4.7N;

mum value, replace the rotor. Spring height: 51.1mm;
Pressure: 133N ± 10.7N;
Spring height: 43mm.
5) Inspection of pressure limiting valve
Coat the pressure limiting valve with a layer

of engine oil. Check whether it can slide
smoothly in the valve hole. If not, replace
5-64
the valve. If necessary, replace the oil pump

cover.
3.5.3 Assembly of oil pump
1) Install the pressure limiting valve and its

spring into the oil pump cover in turn.
Coat the spring seat thread with the
thread sealant and screw in the pres-
sure limiting valve into the threaded
hole in the oil pump cover, and tighten
it to 45N·m.
4) Press the front oil seal of crankshaft

into the timing cover from the front end
of the timing cover. To avoid damage to
the oil seal lip, coat the oil seal lip with
Relief a little of grease.
valve
5) According to the direction as shown in
Relief valve
the figure, install the oil strainer clus-
spring ter as well as two hexagon socket cap
head screws and small washers. Tight-
ening torque:10N·m.
Pressure-limiting
valve spring seat Hexagon Oil collector components
socket cap
head
screw
2) Make sure that the studs of the chain

tensioner on the timing cover have
been installed in place.
3) Install the external and internal ro-

tors coated with gasoline engine oil Small
gasket
into the timing cover in turn. Be sure
to make the marks on the rotors face
outwards. And then, put back the
oil pump cover. Install the oil pump
cover and tighten its bolts according 6) Wipe the joint surfaces between the
to the order as shown in the figure timing cover and cylinder head or cyl-
below. After completion of installation, inder block with alcohol. No oil dirt or
make sure that the rotors can rotate impurity is permitted. Make sure that
smoothly. the two positioning cylindrical pins on
the cylinder block and the oil hole seal
rings on the cylinder block frame have
5-65
Cylindrical
location pin
Nut Nut
Oil hole seal

ring
7) As shown in the figure, coat the timing

cover with plane sealant.
Seal diameter
Stud
Seal diameter
Seal
diameter
Seal diameter Note: Be sure to install the oil pump assem-

EO\ZLWKLQPLQXWHVDIWHUFRDWLQJVHDODQW
Seal diameter
Tighten the mounting bolts of the oil pump
assembly securely within 15 minutes after
Seal
diameter Seal
FRDWLQJVHDODQW'RQ’t start the engine within
diameter
KRXUVDIWHUFRDWLQJVHDODQW
Seal diameter
10) Install the chain tensioner assembly.
Seal diameter
units
(1) Be sure to ensure that the 2 studs on
the timing cover have been installed
in place before installing the chain
8) As shown in the figure, coat the joint
tensioner. Lubricate the plunger of the
surfaces between the cylinder block
chain tensioner before installation.
and the cylinder head as well as be-
tween the cylinder block and its frame (2) Loosen the limit stop, and push into the
with sealant. Make sure to allow plunger completely and use the hasp
the sealant diameter to be between to hook the hanger pin to enable the
4.0~4.5mm. plunger to stay at the position as shown
in the figure.
Seal material Seal material
Lift
Clipper
Seal material
Seal material
Hook
Pin
9) According to the order as shown in the

figure, tighten the bolts securely. Tight-
en the 8 bolts (M8) to 25 N·m, one bolt (3) Install the chain tensioner and new
(M6) to 9N·m, 3 bolts (M10) to 55 N·m shim with the 2 nuts. Pay attention to
and 2 nuts (M6) to 10N·m. the direction of the shim. Be sure to
make its sharp angle towards the rear
end of the engine.
5-66
Section Cooling System

1 Inspection of cooling system
Note:
Turn the air conditioning switch to
WKH2))SRVLWLRQEHIRUHLQVSHFWLRQ
Always let the engine and radiator
cool down before removing the ra-
GLDWRU FDS$YRLG VFDOGLQJ FDXVHG
by high pressure and temperature
HQJLQHFRRODQWRUYDSRU
4.1.1 Checking coolant for leakage
Front part of
engine 1) Refill the radiator with coolant, and con-
nect the radiator cap tester.
(4) Insert the flat-tip screwdriver into the 2) Run the engine until it reaches normal
middle of the timing cover from the up- operating temperature.
per end of the cylinder head. Use the
tip of the flat-tip screwdriver to press 3) Using the radiator cap tester, increase
the chain tensioner plate to release the the radiator pressure to 118KPa, and
hasp of the chain tensioner and allow check the pressure for reduction. If
the chain tensioner’s plunger to pop up. so, check the hose, radiator and water
pump for leakage. If no external leak-
(5) Use the flat-tip screwdriver to press the age is detected, check the heater core,
chain tensioner while checking whether cylinder block and cylinder head.
the chain tensioner’s plunger is moving.
Make sure that the chain tensioner has
4.1.2 Checking the engine coolant level in

the reserve tank
Let the engine cool down and check whether

the engine coolant level is between the LOW
and FULL lines. If the level is at or below the
LOW line, check for coolant leakage, and add
coolant to bring it up to the FULL line.
4.1.3 Checking the engine coolant quality
1) Remove the radiator cap.
Note: Make sure the engine and radiator
5-67
DUHFRROEHIRUHUHPRYLQJWKHUDGLDWRUFDS Recommendations:
Avoid scalding caused by high pressure
DQGWHPSHUDWXUHHQJLQHFRRODQWRUYDSRU 3XW WKH XVHG FRRODQW LQ DQ DSSURSULDWH
container and dispose of it according to
2) Check whether there is excessive rust WKHORFDOUHJXODWLRQV
or scale deposit around the radiator cap
and the radiator filler opening. Mean- 4.2.2 Adding engine coolant
while, no oil in coolant is permitted. If 1) Screw in the drain plug of the radiator
there is excessive dirt, clean the cool- and reinstall the two drain bolts of the
ant passage and replace the coolant. cylinder block.
3) Reinstall the radiator cap. 2) Pour coolant into the radiator slowly up
2 Replacement and refilling of to the FULL line.
coolant Note: Don’W XVH ZDWHU LQVWHDG RI FRRODQW
5H¿OOLQJLPSURSHUFRRODQWFDQFDXVHGDP-
Note: DJHWRWKHHQJLQHFRROLQJV\VWHP
When the engine is running, cool-
ing system shall have enough cool- 3) Push down the inlet and outlet of radia-
ant to ensure the engine works nor- tor hose several times by hand, and
PDOO\ 2WKHUZLVH WKH YHKLFOH ZLOO check the coolant level. If the level is at
become “boiling” or below the LOW line, add coolant to
bring it up to the FULL line.
If the engine is overheated, service
OLIH RI WKH HQJLQH ZLOO EH DIIHFWHG 4) Reinstall the radiator cap subassembly
6HULRXVO\VFXI¿QJRIF\OLQGHUERUH and the reserve tank cap.
PD\RFFXU
To avoid scalding, don’t remove the 5) Start the engine to enable the fan to
UDGLDWRUFDSZKHQWKHHQJLQHLVKRW work.
4.2.1 Draining engine coolant When the engine is hot, set the air condition-
ing according to the following requirements:
1) Remove the radiator cap subassembly Air conditioning air-supply speed setting: Ar-
from the radiator assembly. bitrary setting except closing air supply.
2) Loosen the drain plug on the bottom of Temperature setting: Heating.
the radiator and remove the drain bolts
from the cylinder block to drain the Air conditioning switch: OFF.
coolant. 6) Shut off the engine and let the engine
coolant cool down.
Radiator cover
7) Check the level in the radiator, add

coolant if needed. Repeating the
above-mentioned steps, fill the reserve
tank to the FULL line.
Cylinder exhaust
Notices for replacing and adding the en-
stopcock JLQHFRRODQW:KHQUH¿OOLQJDGGLQJRUUH-
Radiator exhaust
stopcock placing the coolant, make sure that the car
LVSDUNHGRQOHYHOJURXQG
Thermostat
4.3.1 Removal of thermostat
1) Disconnect the cable from the negative
5-68
battery terminal.
2) Drain the engine coolant
3) Disconnect the outlet hose from the ra-

diator.
4) Remove the water inlet. As shown in the

figure, loosen the nut on the thermostat
cap, and remove the thermostat cap and 3) Perform the following checks on the
then remove the thermostat. thermostat:
Opening temperature (°C) 82

Fully-open temperature (°C) 95
Fully-open stroke (mm) 8
Fully-closed temperature (°C) 77
If not, replace the thermostat.
4.3.2 Inspection of thermostat
1) Checking the thermostat visually:

With the opening temperature mark
Valve lift
on the thermostat, replace the ther-
mostat if its mark is inconsistent with
the requirements of this engine model.
Opening temperature of this engine 4.3.3 Installation of thermostat
model:(82±2˅°C.
1) Install the thermostat into its seat hole
to make the ventilation valve hole up-
ward, as shown in the figure.
Upwards
Vent valve
2) Dip the thermostat into water and heat

the water slowly.
2) Install the thermostat cap and screw
in two bolts to fix the thermostat cap.
Tightening torque: 9Nm.
5-69
5) Removing water-pump pulley
3) Connect the radiator outlet hose.
4) Add the engine coolant. 6) Remove the water pump.
5) Check the coolant for leakage. (1) Remove the 4 bolts and 2 nuts.
Water pump

4.4.1 Removal of water pump
1) Disconnection of cable from negative

battery terminal
2) Drain the engine coolant.
3) Remove the V-shaped multi-wedge

belt.
4) Remove the alternator assembly.
(1) Disconnect the alternator connector.
(2) Remove the nut from the terminal and

disconnect the harness. (2) Apply the screwdriver between the wa-
(3) Remove the bolts and the bracket of ter pump and the cylinder block to prize
harness clamp. and then remove the water pump.
(4) Remove the harness clamp. Note: Be careful not to cause damage to
the contact surfaces between the water
(5) Remove the 2 bolts and the alternator SXPS DQG WKH F\OLQGHU EORFN :UDS WKH
assembly. screwdriver tip with adhesive tape before
XVLQJWKHVFUHZGULYHU
5-70
4.4.2 Inspection of water pump Seal diameter
1) Check the drain hole and bleed hole

visually for coolant leakage. If any leak-
age, replace the water pump assembly.
Air hole
Exhaust hole
4) Install the water pump with the 4 bolts

and 2 nuts. Tighten them securely to
9.0N·m.
2) Rotate the pulley and check whether

the water pump bearing can turn
smoothly without clicking. If not, replace
the water-pump assembly.
5) Mount the water pump pulley.
Fix the water pump pulley with the tool T. In-

stall the 4 bolts of the water pump pulley and
tighten them to 26 N·m.
4.4.3 Installation of water pump
1) Install the water pump.
2) Remove any sealing material on the

contact surfaces.
3) As shown in the figure, coat seal-

ing materials within the continu -
ous coating line. Standard sealing 6) Installation of engine assembly
diameter:2.2~2.5mm.
Butt the main hanging angle of the alternator
Note: Remove any oil on the contact sur- against the cylinder block, and put the bolts in
IDFHV 0DNH VXUH WR LQVWDOO WKHVH SDUWV place. Rotate the alternator to allow its aux-
ZLWKLQPLQXWHVDIWHUFRDWLQJVHDOLQJPD- iliary hanging angle to butt against the cylin-
WHULDOV2WKHUZLVHUHPRYHWKHQHZO\FRDW- der block, and tighten the two bolts securely.
HGVHDODQWWKRURXJKO\DQGUHFRDWVHDODQW Torques: Tighten bolt A to 52 N·m, and tighten
bolt B to 21 N·m.
5-71
7) Install the V-shaped multi-wedge belt.
8) Connect the cable to the negative bat-

tery terminal.
9) Add the engine coolant.
10) Check the coolant for leakage.
5-72

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BYD S6, S6A, S6K Service Manual

BYD S6, S6A, S6K

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Technical Service Department BYD Auto Sales Co., Ltd.

Zip code: 518118

Please fill the following information in the Quality Report in contact:

 Name of Sales and Service Store

 Telephone and fax numbers of Sales and Service Store

 Description of your concerns

 Other necessary information (such as sample or marked page number)

 Any applicable electronic information (such as parts identification number)

 Forward your questions to the relevant repair motorer

 Consult the relevant repair motorer

 Provide you with answers to your questions within 10 working days

To Manager of Technical Service Department

Name of Manual Publication Date

Dealer Name Reporter name

Section 1 Technical 3erformance and 3arameters of Finished Automobile1-1

1. This manual description (4) Removal steps are exactly reverse as

Ĺ Final inspection Ĺ Descriptive text focuses on how

ķ Using a jack or a lifter 5. Definition of terms

Ĺ Visual inspection Special notes indicate that it may dam-

(1) Provide composition diagram in each

(2) Specify non-reusable parts, lubricated

(3) Focus on tightening torque, lubricated

Section 1 Technical 3erformance and 3arameters of Finished Automobile

Content Design parameter

Product model S6, S6A,S6K

Basic type Integral body constructure, 5-door, 2-compartment, 1-cover

Drive type Front-mounted engine, front wheel drive

Axle distance (mm) 2720

Front overhang(mm) 1010

Rear overhang(mm) 1080

Minimum ground clearance (mm)  190

Model S6 S6A S6K

12 Engine performance parameter:

Item Unit Type and parameters

Model BYD483QB BYD488QA

Displacement L 1.991 2.362

Compression ratio 9.6 : 1 9.8 ĩ 1

Rated power kW/rpm 95/5800 118/5800

Maximum torque Nm /rpm 172/4750 229/4000

Fuel feed type Electronic fuel injection

Ignition type Spark ignition type

1 Engine accessory and chassis assembly type and parameter:

Assembly Structure parameter

Exhaust system Two-stage muffler, with three-way catalyst device

Intake system Intake pipe, air resonant cavity, air filter

Drive shaft Type Breaking type

Front suspension Mcpherson independent suspension

Tyre type Tubeless radial tire

Steering gear type Pinion-and-rack, hydraulic power steering

Front wheel camber -0º40´±45´

Front wheel toe-in 0±1 mm

Rear wheel camber -0º45´±45´

Rear wheel toe-in 1.5±1 mm

Rear brake Solid disc brake, clearance automatic adjustment

1 Body structure type

Name of Sales and Service Store

Telephone and fax numbers of Sales and Service Store

Description of your concerns

Other necessary information (such as sample or marked page number)

Any applicable electronic information (such as parts identification number)

Forward your questions to the relevant repair motorer

Consult the relevant repair motorer

Provide you with answers to your questions within 10 working days

Section 1 Technical 3erformance and 3arameters of Finished Automobile1-1

Minimum ground clearance (mm) 190

12 Engine performance parameter:

1 Engine accessory and chassis assembly type and parameter:

1 Body structure type

15 Body accessory

16 A/C system structure and parameter

17 Electric System Structure and 3arameters

1 Lubricating oil and fuel, and capacity

22 Warning note label position: Section Maintenance rule

3. Special remarks definition 2 Instructions:

Do not place tools and parts on the

Avoid metal or hard objects from be-

When two persons or above work to-

Keep enough distance between ve- When maintaining high temperature,

When jacking up the vehicle, safety production.

Before dismantling parts, check the

If the assembly is very complicated,

If necessary, clean dismantled parts If necessary, apply sealant on the washer to